Carrier-belt conveyor with passive article diverter

Abstract

A modular-belt conveyor for translating articles along the width of the conveyor atop passive carriers on the belt. The carriers have an upper article-supporting slat at the top of a belt module as well as a peg and rib extending below the upper article-supporting slat for allowing the carrier to freely slide relative to the belt module body under the influence of a diverting force that is above and—or external to the conveyor belt.

Description

[0001] CARRIER-BELT CONVEYOR WITH PASSIVE ARTICLE DIVERTER

[0002] RELATED APPLICATIONS

[0003] The present application claims priority to US Provisional Patent Application No. 63 / 719,842, filed November 13, 2024 and entitled "Carrier-Belt Conveyor with Passive Article Diverter", the contents of which are herein incorporated by reference.

[0004] BACKGROUND

[0005] The invention relates generally to power-driven conveyors and in particular to conveyors having modular belts with article-supporting carriers to selectively translate articles across the belts.

[0006] Article diverters, such as shoe sorters, are used to translate articles across the width of a conveyor as the conveyor transports the articles in a conveying direction. Typical shoe sorters include article-pushing elements, referred to as shoes, that are actively driven laterally across the conveyor to push articles off one or both sides of the conveyor or to position articles across the width of the conveyor. Slat conveyors and modular conveyor belts are used as platforms for the shoes, which ride in tracks extending across the width of the slat or belt conveyors. Typical shoes are block- or peg-shaped with depending structural elements that keep the shoes in the tracks and extend below the bottom of the belt or slat to engage carryway guide rails that control the lateral position of the shoes. The guide rails must be activated to cause the shoes to slide. Pushing shoes work well with many articles. But some articles require gentler handling on their sides. Soft articles, such as bread loaves, can be dented by pushers. And packages that enter the conveyor wide-side-leading are difficult for pusher shoes to orient because of the short package length presented to the pushers.

[0007] SUMMARY

[0008] One version of a conveyor embodying features of the invention comprises a conveyor belt suitable for advancing along a carryway in a direction of belt travel. The conveyor belt is constructed of a series of belt rows of one or more belt modules hingedly joined end to end at hinge joints. Each of the belt rows extends in width from a first side to a second side and in thickness from a top to a bottom. At least some of the belt rows include a slidable carrier having an article-bearing slat and a peg that extends from the slat through a slot in the belt module body. A rib also extends from the slat and slides through a groove in the belt module. The slidable carrier is passively activated to selectively divert a conveyed article to a side of the belt.

[0009] According to another aspect, a conveyor belt module comprises a belt module body and a carrier slidably coupled to the belt module body. The belt module body extends in width from a first side to a second side and in thickness from a top surface to a bottom surface. The belt module body includes a slot extending through the thickness of the belt module body in a lateral direction and a groove extending laterally across the top surface of the belt module body. The carrier has a peg extending through the slot and having an enlarged end that engages the bottom of the belt module body, a slat attached to the peg and forming an upper article-supporting surface and a bottom side and a rib extending down from the slat for slidably engaging the groove, such that the carrier can slide freely relative to the body.

[0010] BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an isometric view of a conveyor including a passive article diverter according to an embodiment;

[0011] FIG. 2 is an isometric view of the conveyor of FIG. 1 in a diverted state;

[0012] FIG. 3 is an exploded bottom view of a conveyor belt module used in the conveyor of FIG. 1;

[0013] FIG. 4 is an isometric view of a portion of the conveyor belt module of FIG. 3;

[0014] FIG. 5 is a cross-sectional view of the conveyor belt module of FIG. 3;

[0015] FIG. 6 is an isometric view of a conveyor including a passive article diverter according to another embodiment;

[0016] FIG. 7 is an isometric view of the conveyor of FIG. 6 in a diverting state;

[0017] FIG. 8 is an isometric view of a conveyor including a passive article diverter according to another embodiment;

[0018] FIG. 9 is an isometric view of the conveyor of FIG. 8 in a diverting state;

[0019] FIG. 10 is an isometric view of a conveyor including a passive article diverter according to another embodiment; FIG. 11 is an isometric view of the conveyor of FIG. 6 in a diverting state;

[0020] FIG. 12 shows the conveyor of FIG. 11 in the diverting state;

[0021] FIG. 13 shows the conveyor of FIG. 12 after diverting an article;

[0022] FIG. 14 is a bottom view of the conveyor of FIG. 1;

[0023] FIGS. 15A— 15C show the process of realigning diverted carriers using the centering mechanism shown in FIG. 14.

[0024] DETAILED DESCRIPTION

[0025] A diverting conveyor 10 embodying features of the invention is shown in FIGS. 1 and 2. The diverting conveyor 10 comprises a frame 12 extending longitudinally from a first end to a second end and forming a carryway extending laterally from a first side to a second side. A diverting conveyor belt 20 travels longitudinally in an endless loop over the frame in a conveying direction 14, which can be reversible. The diverting conveyor belt 20 can selectively divert a conveyed article 16 to a side of the conveyor using passive means, rather than active means below the conveyor belt. The diverting conveyor belt 20 comprises a series of hingedly connected modules 120, at least some of the modules including a freely slidable carrier 122 for selectively translating a conveyed article 16 to a side of the conveyor. A diverter 40 selectively pushes article-bearing carriers 122 to one side as needed to divert a conveyed article 16. The diverter 40 actuates the carrier 122 from above or external to the carry way to divert the conveyed article 16. The illustrative diverter 40 comprises a pushing blade 42 and a pushing actuator 44. The actuator 44 selectively extends the blade 42 laterally across the conveyor belt to push against a conveyed product supported by carriers, causing the product and underlying carriers to slide to the side of the conveyor, as shown in FIG. 2.

[0026] Referring to FIGS. 3— 5, a carrier module 120 comprises a module body 130 including a first set of hinge elements 132 extending from a first end and a second set of hinge elements 133 extending from a second end. The first hinge elements 132 of a belt row are interleaved with the second hinge elements 133 of an adjacent belt row and joined by hinge rods or pins (not shown) at hinge joints to form an endless modular conveyor belt 20. The module body 130 extends from a top surface 136 to a bottom surface 138 and from a first side to a second side. The module body may span the width of the conveyor belt, or the conveyor belt may include multiple modules in a row. The illustrative bottom surface 138 includes a drive tooth 139, but the invention is not so limited and other means for driving the conveyor belt may be used. A laterally-extending slot 142 extends through the thickness of the module body 130 from the top surface 136 to the bottom surface 138 at the lateral center of the module body and offset from the longitudinal center, such that the slot 142 opens up to the bottom surface 138 adjacent the drive tooth 139. The length of the slot defines the range of motion for the carrier. A laterally-extending groove 144 is formed in the top surface 136 spaced from and parallel to the slot 142 above the drive tooth 139. The groove 144 is longer than the slot 142 and also defines the range of motion for the carrier.

[0027] A carrier 150 is slidably mounted to the module body 130. The carrier 150 includes an upper slat 152 for supporting and conveying an article. The illustrative upper slat 152 is roughly rectangular in a plan view with a long dimension and a short dimension. In the short dimension, the upper slat 152 extends longitudinally from the first set of hinge elements 132 to the second set of hinge elements 134. In the long dimension, the upper slat 152 extends laterally about 1 / 3 of the width of the module body 130, but the invention is not so limited. The slat size can vary depending on the size of the product and desired range of motion of the product.

[0028] A peg 154 extends down from the bottom surface of the upper slat 152. The peg 154 is laterally centered, but offset in the longitudinal direction from the center of the carrier 150. The peg is configured to be received by and freely slide along the slot 142. As shown in FIG.

[0029] 5, the peg 154 includes an enlarged end 158 that interferes with and engages the bottom surface 138 of the module body and abuts the edge of the drive tooth 139 to retain the slat on the module body. The enlarged end 158 is recessed from the drive tooth 139 and hinge elements 132, 133 and does not protrude below the belt module body.

[0030] A rib 168 extends down from the bottom surface of the upper slat 152. The rib 168 is shallower but longer than the peg 154 and is configured to slide in the groove 144.

[0031] The carrier 150 also includes side flanges 159 extending down from the long edges of the upper slat 152 for elevating the upper slat above the top surface 136 of the module body.

[0032] The carrier 150 can thus passively slide over the module body between a first position in which a first short edge of the slat 152 aligns with a first side edge of the module body and a second position in which a second short edge of the slat 152 aligns with a second side edge of the module body. During conveyance, the carrier 150 may be centered between the two side edges of the module body, as shown in FIG. 1. In another embodiment, a diverter for causing one or more article-carrying carriers on a conveyor belt module to slide to a side can comprise a carryway filter. For example, as shown in FIGS. 6 and 7, a liftable conveyor 200 can comprise a frame having a top portion 220 hingedly connected to a bottom portion 221 via connectors 223 on one side. A hingedly-connected conveyor belt 20 including freely-slidable carriers 122, as described above, is trained around reversing elements in the top frame portion 222 A lifting arm 241, external to the carryway 200, selectively lifts one side of the top frame portion 222 to tilt the carryway, as shown in FIG. 7. As the side of the conveyor belt 20 lifts, the force of gravity on the product 16 and associated carriers 122 pushes the article-carrying carriers 122 and product 16 to the lower side of the conveyor, as shown in FIG. 7.

[0033] The passive carriers 122 can be translated through any suitable means external to the conveyor belt 20. For example, as shown in FIGS. 8 and 9, an operator 300 positioned to the side of, or otherwise external to, the carry way can push or pull a product 16 conveyed on one or more slidable carriers 122 in a conveyor belt 20, as described above, to a side of a conveyor. The configuration of the slidable carriers and belt modules enables passive sliding.

[0034] FIGS. 10 — 13 show another embodiment of a diverter for sliding a product and underlying carrier to a side of a conveyor without requiring activating components below the conveyor belt. The illustrative diverter 340 comprises a raisable and lowerable transversely-extending paddle 341 that is positioned above the carryway and conveyor belt 20. In a raised position, shown in FIG. 10, the conveyor belt 20 conveys an article in the conveying direction 14, with the carriers 122 centered on the belt. When the paddle 341 is lowered, as shown in FIG. 11, the paddle 341 pushes the article 16 and associated slidable carriers 122 to the side of the conveyor, as shown in FIG. 12 until the product 16 reaches the side of the conveyor, as shown in FIG. 13.

[0035] Referring to FIGS. 14— 15C, a conveyor 10 including passively translatable carriers 122 can include a centering mechanism for returning translated carriers to a lateral center of the conveyor belt 20. An illustrative centering mechanism comprises a pair of guides 400 coupled to each side of the conveyor frame 12 in the returnway. The guides 400 include an angled edge 401 in an upper portion, closer to the drive end of the conveyor. The angled edges 401 push the displaced carriers to the lateral middle of the conveyor belt 20, as shown in FIG. 15B. The guides then transition to a straight, longitudinally-extending edge 402 to maintain the carriers in an aligned, central position before transitioning back to the carry way, as shown in FIG. 15C.

[0036] Although the features of the invention have been described with respect to exemplary versions, other versions are possible and the invention is not limited to the illustrative embodiments.

Claims

What is claimed is:

1. A conveyor comprising:a carryway;a conveyor belt suitable for advancing along the carryway in a direction of belt travel, the conveyor belt comprising:a series of belt rows of one or more belt modules hingedly joined end to end at hinge joints and at least some of the belt rows comprising:a belt module body that extends in width from a first side to a second side and in thickness from a top surface to a bottom surface, the belt module body includinga slot extending through the thickness of the belt module body in a lateral direction;a groove extending laterally across the top surface of the belt module body; andat least one carrier slidably coupled to the belt module body, the carrier having:a peg extending through the slot and having an enlarged end that engages the bottom of the belt module body;a slat attached to the peg and forming an upper article-supporting surface and a bottom side;a rib extending down from the slat for slidably engaging the groove, such that the carrier can slide freely relative to the body; and a diverter for pushing an article-supporting carrier from a middle of the carryway to a side of the carryway.

2. The conveyor of claim 1, wherein the diverter comprises an extendable arm and a blade coupled to the extendable arm.

3. The conveyor of claim 1, wherein the diverter comprises a lifter for lifting a first side of the carryway relative to a second side of the carryway.

4. The conveyor of claim 3, wherein the carry ay comprises a frame having a top portion hingedly connected to a bottom portion via connectors on the second side.

5. The conveyor of claim 1, wherein the diverter comprises a raisable, transversely-extending paddle.

6. The conveyor of claim 1, further comprising an alignment mechanism for realigning diverted carriers.

7. The conveyor of claim 6, wherein the alignment mechanism comprises guides in a returnway below the carryway, each guide including an angled edge for pushing a diverted carrier to an aligned position on the conveyor belt and a straight edge for maintaining the carriers in the aligned position.

8. The conveyor of claim 1, wherein the belt module body further comprises a drive tooth on the bottom.

9. The conveyor of claim 8, wherein the drive tooth is adjacent to the slot.

10. The conveyor of claim 8, wherein the enlarged end of the peg abuts an edge of the drive tooth to retain the slat on the belt module body.

11. The conveyor of claim 1, wherein the slot is offset from the longitudinal center of the belt module body.

12. The conveyor of claim 1, wherein the rib is shallower than the peg.

13. The conveyor of claim 1, wherein the carrier also includes side flanges extending down from the long edges of the upper slat for elevating the upper slat above the top surface of the module body.

14. A conveyor belt module, comprising:a belt module body that extends in width from a first side to a second side and in thickness from a top surface to a bottom surface, the belt module body includinga slot extending through the thickness of the belt module body in a lateral direction;a groove extending laterally across the top surface of the belt module body; anda carrier slidably coupled to the belt module body, the carrier having:a peg extending through the slot and having an enlarged end that engages the bottom of the belt module body;a slat attached to the peg and forming an upper article-supporting surface and a bottom side;a rib extending down from the slat for slidably engaging the groove, such that the carrier can slide freely relative to the body.

15. The conveyor belt module of claim 14, wherein the carrier also includes side flanges extending down from the long edges of the upper slat for elevating the upper slat above the top surface of the module body.

16. The conveyor belt module of claim 14, wherein the belt module body further comprises a drive tooth on the bottom, wherein the enlarged end of the peg abuts an edge of the drive tooth to retain the slat on the belt module body.

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