Conveyor component with flexible hub and conveyor assembly

Abstract

A conveyor component for use in a conveyor includes a hub for mounting a shaft and a continuous rim connected to the flexible hub for contacting a conveyor belt. The hub includes a flexible finger including a locking tab that engages a groove on the shaft to lock the conveyor component to the shaft. A tool disengages the locking tab from the groove to unlock the conveyor component from the shaft.

Description

[0001] Conveyor Component with Flexible Hub and Conveyor Assembly

[0002] Related Applications

[0003] The present application claims priority to US Provisional Patent Application No. 63 / 533,216, filed 8 / 17 / 2023 and US Provisional Patent Application No. 63 / 575,964 filed April 8, 2024, both entitled "Conveyor Component with Flexible Hub and Conveyor Assembly" and incorporated herein by reference.

[0004] Field of the Invention

[0005] The present application relates to power-driven conveyors. More particular, the present invention relates conveyor components, such as rollers and sprockets used to support and— or drive a conveyor belt in a returnway, infeed or another location.

[0006] Background of the Invention

[0007] Conveyor belts are used in many industries to convey products from a first location to a second location. Conveyor belts generally form an endless belt loop that is trained around drive and idler sprockets or rollers at each end of a conveying path. Each sprocket is mounted on a shaft received by a bore extending axially through the sprocket. Articles conveyed atop the conveyor belt are supported along an upper carryway. The conveyor belt returns along a lower returnway. To minimize the maximum sag of the conveyor belt in the returnway, return shoes or rollers are often used. Return rollers typically extend across the width of the conveyor belt at selected positions along the returnway. Rollers may also be used to support a conveyor belt at the infeed end of the endless conveyor belt circuit and— or another location. Mounting rollers, sprockets and other components on a shaft in a conveyor can be difficult and cumbersome. In addition, separate locking components are often required to secure the component in a fixed axial position along the shaft.

[0008] Summary of the Invention

[0009] A conveyor component for use in a conveyor includes a flexible hub with a locking tab on a flexible finger for selectively locking the conveyor component to a shaft. The shaft includes a groove for receiving the locking tab. The flexible finger can be lifted to disengage the locking tab from the groove and allow the conveyor component to slide axially along the shaft for removal and— or repositioning.

[0010] According to one aspect, a component for a conveyor comprises a hub for receiving a shaft, the hub including a flexible finger with a locking tab for engaging a recess on the shaft and a rim connected to the flexible hub, the rim having a continuous periphery for contacting a conveyor belt.

[0011] According to another aspect, a conveyor assembly comprises an axially-extending shaft, the shaft including a peripheral recess in a first face and a component mounted to the shaft, the component including a hub for receiving a shaft, the hub including a flexible finger with a locking tab for engaging the peripheral recess on the shaft and a rim connected to the flexible hub, the rim having a continuous periphery for contacting a conveyor belt.

[0012] Brief Description of the Drawings

[0013] FIG. 1 is an isometric view of a sprocket assembly including sprockets with flexible hubs according to an embodiment;

[0014] FIG. 2 is an end view of the sprocket assembly of FIG. 1;

[0015] FIG. 3 is a front view of a sprocket including a flexible hub in a locked position according to an embodiment;

[0016] FIG. 4 is a detailed view of the flexible portion of the flexible hub of the sprocket of FIG. 3;

[0017] FIG. 5 is an isometric view of a sprocket with a flexible hub at the beginning of an unlocking of the sprocket using a tool;

[0018] FIG. 6 is an isometric view of the sprocket of FIG. 5 during flexing of the flexible hub with a tool to unlock the sprocket from the shaft;

[0019] FIG. 7 is a front view of the sprocket of FIG. 5 during flexing of the flexible hub;

[0020] FIG. 8 is a detailed front view of the flexible portion of the flexible hub of FIG. 7 during flexing;

[0021] FIG. 9 is an isometric view of a sprocket with a flexible hub according to another embodiment;

[0022] FIG. 10 is a front view of the sprocket of FIG. 9;

[0023] FIG. 11 is an isometric view of the sprocket of FIGS. 9 and 10 mounted on a shaft; FIG. 12 shows the assembly of FIG. 11 during unlocking of the sprocket using a tool;

[0024] FIG. 13A is a detailed front view of the hub of the sprocket of FIG. 9;

[0025] FIG. 13B is a cross-sectional view through lines A-A of the hub of FIG. 13A;

[0026] FIG. 14A is a detailed front view of a hub of a conveyor component according to another embodiment;

[0027] FIG. 14B is a cross-sectional view through lines A-A of the hub of FIG. 14A.

[0028] FIG. 15 is an isometric view of a sprocket assembly including sprockets with flexible hubs according to another embodiment;

[0029] FIG. 16 is a front view of the assembly of FIG. 15;

[0030] FIG. 17 is a top view of a portion of the assembly of FIG. 15;

[0031] FIG. 18 is a cross-sectional view of the assembly of FIG. 17 through lines A-A;

[0032] FIG. 19 is a front view of a sprocket of the assembly of FIG. 15;

[0033] FIG 20 is an isometric view of the sprocket of FIG. 19;

[0034] FIG. 21 is another view of the sprocket of FIG. 19;

[0035] FIG. 22 is a bottom isometric view of the sprocket of FIG. 19;

[0036] FIG. 23 is a detailed front view of a locking tab of the sprocket of FIG. 19;

[0037] FIG. 24 is a bottom isometric view of the locking tab of FIG. 23;

[0038] FIG. 25 is a front view of the sprocket of FIG. 19 during unlatching using a pair of pliers;

[0039] FIG. 26 is an isometric top view of the sprocket of FIG. 25;

[0040] FIG. 27 is an isometric top view of the sprocket of FIG. 19 during unlatching using a screwdriver;

[0041] FIG. 28 is a front view of the sprocket of FIG. 27;

[0042] FIG. 29 is a front view of a sprocket with a flexible hub portion according to another embodiment;

[0043] FIG. 30 is an isometric top view of the sprocket of FIG. 29;

[0044] FIG. 31 is an isometric bottom view of the sprocket of FIG. 29;

[0045] FIG. 32 is a top view of the sprocket of FIG. 29;

[0046] FIG. 33 is a cross-sectional view through line B-B of the sprocket of FIG. 32;

[0047] FIG. 34 is a detailed view of a locking tab of the sprocket of FIG. 29; FIG. 35 is a front view of a sprocket with a flexible hub according to another embodiment;

[0048] FIG. 36 is a side view of the sprocket of FIG. 35;

[0049] FIG. 37 is an isometric view of the sprocket of FIG. 35; and

[0050] FIG. 38 is a front view of a sprocket with a flexible hub according to another embodiment.

[0051] Detailed Description

[0052] A conveyor component includes a hub with a flexible portion and a peripheral rim connected to the hub. The conveyor component can be a roller, sprocket or any suitable shaft-mounted conveyor component. The invention will be described below relative to certain illustrative embodiments, though those skilled in the art will recognize that the invention is not limited to the described embodiments.

[0053] Referring to FIGS. 1—2, a conveyor sprocket assembly 10 comprises a series of conveyor sprockets 100 mounted on a mounting shaft 12 in a conveyor. The illustrative series of conveyor sprockets 100 are evenly spaced along the axial length of the mounting shaft, but the invention is not so limited, and any number conveyor sprockets 100 can be mounted in any suitable location, configuration and— or pattern. In the illustrative assembly, a first sprocket 100a is mounting in a floating position on the shaft: fixed rotationally, while enabling the sprocket to shift axially a certain degree along the shaft 12. A second sprocket 100b is fixed both axially and rotationally to the shaft 12.

[0054] The sprockets 100 may comprise flexible hubs 120 to facilitate mounting and dismounting of the respective sprocket on the mounting shaft 12 and to provide axial location and containment of the sprockets. As described below, sets of grooves in the peripheral surface of the mounting shaft 12 in mounting regions engage movable locking tabs on the flexible hubs 120 to prevent or limit migration of the sprockets along the axial length of the mounting shaft 12. Each flexible hub is connected to the periphery 150 of the sprocket 100 by a connector, shown as spokes 140. The connector can be a webbing, solid portion or any suitable connector. The illustrative spokes 140 radiate from the corners of the flexible hub 120, but can have a different orientation, size, number and— or pattern. The illustrative periphery 150 includes drive structure 151 for driving a conveyor belt, but can alternatively be smooth or have another design. The illustrative periphery is 150 is continuous and forms a closed rim for the sprocket.

[0055] Different sized shaft grooves control the amount of axial float and— or the locking location of the sprockets. A first set of grooves 16 may be sized to fix an associated sprocket and prevent axial movement of an associated sprocket along the shaft 12, while a second set of grooves 18 may be elongated to allow a certain amount of floating of the associated sprocket along the mounting shaft 12. The grooves 16, 18 may be machined or otherwise formed in desired locations on the shaft 12.

[0056] The flexible hub 120 forms a shaft opening for receiving the mounting shaft 12. The flexible hub includes a flexible latching portion for locking the sprocket to the shaft, as well as non-flexing portions. The flexible latching portion can be moved to release the sprocket from the shaft.

[0057] Referring to FIGS. 3 and 4, the illustrative flexible hub 120 of the sprocket 100 includes a plurality of shaft-engaging walls. The illustrative hub is configured to receive a square shaft 12 with four perpendicular faces and therefore includes four shaft-engaging walls 131, 132, 133, 134. The shaft-engaging walls transmit torque from the shaft to the peripheral teeth. The flexible hub 120 can be designed to engage any suitable size and shape shaft. Wall 134 forms a flexible portion for axially containing the sprocket on the shaft 12. The illustrative flexible wall 134 includes a pair of opposing flexible fingers on each axial end of the hub. A first flexible finger 135 extends laterally across a first axial end of the hub over a shaft face and a second flexible finger 136 extends laterally on a second axial end of the hub in an opposite direction from the first flexible finger 135 over the shaft face.

[0058] Each flexible finger 135, 136 is separated from a non-flexible portion of the wall 134 by side and tip gaps and connects to the non-flexible portion of the wall 134 at a base. Each flexible finger 135, 136 includes a radially inwards facing locking tab 137 at the tip end and a central lifting recess 138 in a central portion. The central lifting recesses 138 are aligned with each other. A flexing recess 139 at the base facilitates flexing of the flexible finger.

[0059] In a locked position, the walls 131, 132, 133, 134 engage the shaft. The flexible fingers naturally rest against a corresponding face of the shaft and the locking tabs 137 engage corresponding recesses 16 or 18 to lock the sprocket to the shaft. Recesses 16 lock the axial position of the sprocket, while recesses 18 restrain the axial position, allowing a limited amount of axial float of the sprocket along the shaft 12.

[0060] As shown in FIGS. 5—8, the flexible fingers 135, 136 can be selectively disengaged from the shaft using a tool 200 to release the sprocket 100 from the shaft. The tool 200 comprises a handle 201, a lifting member 202 extending perpendicular to the handle. The lifting member 202 terminates in a tapering tip 203. The lifting member 202 has a semicircular cross-section, with a flat bottom and rounded side and tops.

[0061] To release the sprocket 100 from the shaft 12, the tool 200 slides over the shaft 12, with the flat bottom of the lifting member 202 sliding over a corresponding face of the shaft 12. The lifting member 202 enters the lifting recesses 138 of both flexible fingers 135, 136 to lift the locking tabs 137 out of engagement with the shaft recess 16. Then the sprocket 100 can be repositioned or removed from the shaft by sliding the sprocket off of the shaft. Other suitable tools for disengaging the flexible member from the shaft can be used.

[0062] The illustrative sprocket may be an injection-molded, unitary structure, but the invention is not so limited.

[0063] FIGS. 9 and 10 illustrate another embodiment of a conveyor component, shown as a sprocket 300, with a flexible hub to facilitate mounting and adjustment of the component relative on a shaft 312. The sprocket 300 includes a shaft-receiving hub 330 with a flexible portion, spokes 340 radiating from the flexible hub and a closed periphery 350 with drive elements connected to the hub 330 via the spokes or another connector.

[0064] The illustrative shaft-receiving hub includes four shaft-engaging walls 331, 332, 333, 334. The shaft-engaging walls transmit torque from the shaft to the peripheral drive elements. Wall 334 includes a central flexible portion for axially containing the sprocket on the shaft 312. The central flexible portion includes an axially-extending flexible finger that can flex up and down. The flexible finger includes a flexible neck 339 extending from wall 334 and terminating in a locking tab 337 that radially inwards from the flexible finger end of the flexible neck. The flexible neck 339 connects the locking tab 337 to the non-flexible portion of the hub wall 334. The flexible finger forms a lifting tab 336 above the locking tab 337 at the tip of the finger. The lifting tab 336 may protrude axially outward of the locking tab 337 to facilitate access, but the invention is not so limited. A sheath 338 surrounds the flexible portion and provides clearance for vertical movement of the flexible finger. In a locked position, shown in FIG. 11, the locking tab 337 is received in a groove 316 on the shaft. The sprocket 300 naturally assumes the locked position. The groove 316 is sized and dimensioned to allow axial float or limit axial movement of the sprocket. The groove 316 can extend along the entire width of the shaft 312 or be a single, smaller centered pocket.

[0065] Referring to FIG. 12, a tool, shown as a pliers tool 400, may be used to release the sprocket from the locked position. The flexible finger may be raised by squeezing the lifting tab 336 and sheath 338 with the pliers, lifting the locking tab 337 out of the groove. Then, the sprocket 300 can easily slide along the length of the shaft for removal or repositioning. The lifting tab 336 may also be lifted manually or using another type of tool.

[0066] Referring to FIGS. 13A and 13B, the flexible finger can be a single member extending through the hub, symmetrical about the axial center of the sprocket 300. Alternatively, the flexible portion of the hub 330 can comprise multiple axially-extending flexible fingers and— or locking tabs 337.

[0067] In another embodiment, shown in FIGS. 14A and 14B, a flexible shaft-receiving hub 430 of a conveyor component, such as a sprocket or roller, can include a flexible finger 436 with a locking tab 437 in which the flexible finger is attached to the top wall of a sheath 438 by a neck 439. In the embodiment of FIGS. 14A and 14B, the flexible finger 436 extends axially along the shaft, with the locking tab 437 in the axial center of the hub 430. The flexible finger 436 can be raised to release the locking tab 437 from engagement with a groove or other feature of a shaft.

[0068] FIGS. 15 — 18 show another embodiment of a sprocket assembly 510 including a plurality of sprockets 500 with flexible hubs mounted on a shaft 512. The shaft has a series of surface recesses 516 for receiving a locking tab of a flexible hub of a sprocket 500. As shown, in FIG. 15, a plurality of sprockets 500 can be arranged along the axial length of the shaft 512, each in a mounting region defined by a recess 516. Each illustrative recess 516 is longer than the depth of a sprocket from a first face to a second face along the axial direction of the shaft and spans the majority of the face of the shaft, as shown in FIG. 17, but the invention is not so limited.

[0069] Each flexible hub includes non-flexing, shaft-engaging portions and a flexible finger 535 forming a shaped locking tab 537 that overlies a surface of the recess 516 in a latched position, as shown in FIG. 18. The shaped locking tab 537 has a flat bottom surface, as described below, to overlie against the recess 516.

[0070] Referring to FIGS. 19—22, each sprocket 500 includes a hub 520 forming an axially- extending opening for seating the shaft 512, a peripheral portion 550, which may include drive elements 551, and a connecting portion 540 between the flexible hub 520 and peripheral portion 550. The illustrative connecting portion 540 is solid, but can comprise spokes or another suitable structure. The flexible hub 520 includes three fixed walls for containing three sides of the shaft 512 and a fourth wall formed by a flexible finger 535 extending laterally from a corner region. The shaft-containing walls may include cleaning recesses and reliefs in corners. The flexible finger 535 includes a shaped body 536 extending from a fixed portion and terminating in a shaped locking tab 537 extending toward the center of the hub 520. A shaped lifting handle 541 extend away from the shaped locking tab 537. A relief area 519 is formed above the flexible finger 535 to allow the flexible finger to flex up and down. The flexible hub 520 forms a space 521 between the lifting handle 541 and wall 522 extending away from a shaft-engaging wall 523. The walls 522 and 523 may be fixed. The bottom surface 539 of the flexible finger 535 curves concavely towards the base of the locking tab 537.

[0071] The sprocket 500 further includes a shaped sheath 538 surrounding the top corners of the flexible hub 520 and flexible finger 535 to strengthen the sprocket in that area and provide clearance for the flexible finger 535. The sprocket 500 also includes shaped mounds 525 around the bottom two corners of the flexible hub 520 to strengthen the sprocket. The shaped sheath 538 and mounds 525 protrude past of the faces of the connecting portion 540 to thicken the sprocket in the hub region.

[0072] A grasping ledge 542 is formed in the sheath 538 above the shaped lifting handle 541 and protrudes outward from the sheath 538.

[0073] As shown in FIGS. 23 and 24, the illustrative shaped locking tab 537 flares from the tip of the shaped body 536 to form a flat, rectangular-shaped bottom surface 559 that extends through the axial width of the hub. The shaped locking tab 537 includes flat front and rear surfaces 558, a first angled side wall 552 extending at an angled from the end of the shaped body 536 and a second curving side wall 553 that flares from the shaped body 536. The shaped lifting handle 541 extends forward of the front surface 558, projecting outwards. The grasping ledge 542 also protrudes from the sheath 538, so as to align with the shaped lifting handle 541.

[0074] Referring to FIGS. 25 and 26, a tool, shown as a pair of pliers 580 may be used to release the locking tab 537 from engagement with the recess 516 of a shaft 512 received in the flexible hub 520. The locking tab 537 may be lifted by squeezing the lifting handle 541 and grasping ledge 542 together between the jaws of the pliers 580. With the locking tab 537 disengaged, the sprocket 500 can slide along the shaft 512 for repositioning or removal.

[0075] Any suitable tool may be used to disengage the locking tab 537. For example, in another embodiment, shown in FIGS. 27 and 28, a screwdriver 590 may be used to lift the locking tab 537 with a prying action. The tip of the shaft of the screwdriver 590 may be inserted into the space 521 between the lifting handle 541 and wall 522 and rotated or otherwise manipulated to push up on the lifting handle 541 to disengage the locking tab 537.

[0076] FIGS. 29—34 show another embodiment of a sprocket including a flexible finger to facilitate mounting and dismounting of the sprocket on a shaft. The sprocket 600 includes an axially-extending flexible finger 636 including a locking tab 637 extending radially inwards. The illustrative locking tab 637 has a flat bottom surface 639, which may be rectangular in shape, as shown in FIG. 34, but the invention is not so limited.

[0077] The flexible finger 636 extends from a base 640 over a side of a hub 620 forming an opening for seating a shaft. The base 640 extends outwards from a first face of the sprocket, but the invention is not so limited. A lateral channel 632 in the tip of the flexible finger 636 forms a lifting tab above the locking tab 637. In one embodiment, the top surface 638 of the flexible finger angles inwards toward the center of the sprocket as it extends from the base 640, as shown in FIG. 33. As also shown in FIG. 33, the tip of the finger 636 may be recessed from the second face of the sprocket, so that the locking tab 637 and lifting tab are contained within the body of the sprocket.

[0078] The sprocket 600 may also include a grasping ledge 642 formed in a sheath portion 682 above the locking tab 637 and lifting tab to facilitate use of a gripping tool to lift the locking tab 637 out of engagement with a feature, such as a recess or groove, on a shaft received in the hub 620.

[0079] In another embodiment, shown in FIGS. 35—37, a sprocket 700 may include opposing flexible fingers to latch the sprocket 700 to a shaft. Each flexible finger 736, 746 is similar in structure to the flexible finger 636 of FIGS. 29—34. The first flexible finger 736 is formed at a first side of a shaft-receiving hub 720 and extends in a first axial direction. The second flexible finger 746 is formed at a second side of the hub 720 opposite the first side and extends in a second, opposite direction. A shaft configured to be received in the hub can have recesses configured to engage the flexible fingers, as described above.

[0080] Referring to FIG. 38, in another embodiment, a sprocket 800 including a flexible retaining finger 835 with a shaped locking tab 837 and shaped lifting handle 841 may further include a stopping projection 880 in a shaped sheath portion 838 to prevent overflexing of the flexible retaining finger 835. The invention is not limited to the illustrative conveyor roller, sprocket and— or mounting shaft, and encompasses variations and alterations of these embodiments. For example, the illustrative flexible hubs may be implemented in any shaft-mounted conveyor component, not limited to rollers and sprockets.

Claims

What is claimed is:

1. A component for a conveyor, comprising: a hub for receiving a shaft, the hub including a flexible finger with a locking tab for engaging a recess on the shaft; and a rim connected to the flexible hub, the rim having a continuous periphery for contacting a conveyor belt.

2. The component of claim 1, wherein the flexible hub includes a pair of opposing flexible fingers on each axial end of the hub, each flexible finger extending laterally extending across a face of the shaft.

3. The component of claim 1, wherein the flexible finger includes a lifting recess for receiving a lifting tool in a middle portion of the flexible finger.

4. The component of claim 1, wherein the flexible finger includes a flexing recess at a base portion connecting the flexible finger to non-flexible portions of the hub.

5. The component of claim 1, wherein the locking tab is formed at a tip of the flexible finger.

6. The component of claim 1, wherein the flexible finger extends axially within the hub.

7. The component of claim 1, further comprising a sheath surrounding the flexible finger and providing clearance to allow vertical movement of the flexible finger.

8. The component of claim 7, further comprising a stopping protrusion extending from the sheath to limit overflexing of the flexible finger.

9. The component of claim 1, further comprising a lifting handle extending away from the locking tab at the tip of the flexible finger.

10. The component of claim 9, further comprising a grasping ledge spaced from the lifting handle for engaging a tool.

11. The component of claim 1, wherein the flexible finger extends axially from a base that protrudes from a face of the component.

12. The component of claim 1, wherein the locking tab flares from a tip of the flexible finger.

13. The component of claim 12, wherein the locking tab includes a flat, rectangularshaped bottom surface, flat front and rear surfaces, a first angled side wall extending at an angled from the tip of the flexible finger and a second curving side wall that flares from the flexible finger.

14. A conveyor assembly comprising: an axially-extending shaft, the shaft including a peripheral recess in a first face; and a component mounted to the shaft, the component including a hub for receiving a shaft, the hub including a flexible finger with a locking tab for engaging the peripheral recess on the shaft and a rim connected to the flexible hub, the rim having a continuous periphery for contacting a conveyor belt.

15. The conveyor assembly of claim 14, wherein the flexible finger extends laterally across a face of the hub, with the locking tab flaring inwards from a tip of the flexible finger.

16. The conveyor assembly of claim 15, wherein the flexible finger further includes a shaped handle extending outwards from the tip of the flexible finger for lifting the locking tab out of engagement with the peripheral recess.

17. The conveyor assembly of claim 16, further comprising a sheath surrounding the flexible finger and providing clearance to allow vertical movement of the flexible finger.

18. The conveyor assembly of claim 17, wherein the sheath forms a grasping ledge aligned with the shaped handle.

19. The conveyor assembly of claim 18, further comprising a tool for squeezing together the grasping ledge and the shaped handle to lift the locking tab out of engagement with the peripheral recess.

20. The conveyor assembly of claim 14, wherein the axially-extending shaft includes a plurality of peripheral recesses in the first face.

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