Transfer unit for a conveyor

Abstract

A transfer unit for transitioning a conveyor belt at an end of a carryway comprises opposing cross members mounted between side plates. Each cross member mounts a nosebar for guiding a conveyor belt. Each cross member comprises a top plate upon which a nosebar is mounted, a first stiffening beam, a second stiffening beam oriented perpendicular to the first stiffening beam and a shaped sheath covering the stiffening beams. Vertical strengthening ribs intersect the stiffening beams at intersections spaced across the width of the sheath.

Description

[0001] Transfer Unit for a Conveyor

[0002] Related Applications

[0003] The present invention claims priority to US Provisional Patent Application No. 63 / 729,618, filed December 9, 2024 and entitled " Transfer Unit for a Conveyor", the contents of which are herein incorporated by reference.

[0004] Field of the Invention

[0005] The present application relates to power-driven conveyors. More particularly, the present invention relates to a transfer unit for transferring product from a first conveyor belt to a second conveyor belt and transitioning the conveyor belts between a carryway and a returnway.

[0006] Background of the Invention

[0007] Conveyor belts are widely used in various industries to convey products. Endless conveyor belts are generally trained around reversing elements, such as sprockets, pulleys, nosebars or noserollers, to form an endless circuit having a carry ay and returnway.

[0008] In a conveyor system, transfer units including nosebars can be used to support a conveyor belt at an end of a carry way to enable transfer of small products and — or minimize a gap between an offloading conveyor and an onloading conveyor. The transfer of product through a transfer unit may cause jostling and -or tipping of the product.

[0009] Summary of the Invention

[0010] A robust transfer unit for a conveyor includes opposing cross members mounted between side plates. Each cross member mounts a nosebar for guiding a conveyor belt. Each cross member comprises a top plate upon which a nosebar is mounted, a first stiffening beam, a second stiffening beam oriented perpendicular to the first stiffening beam and a shaped sheath covering the stiffening beams. Vertical strengthening ribs intersect the stiffening beams at intersections spaced across the width of the sheath.

[0011] According to one aspect, a transfer unit for a conveyor belt comprises a first side plate, a second side plate spaced from the second side plate and a first cross member extending between the first side plate and the second side plate. The cross member comprises a top plate, a first stiffening beam, a second stiffening beam oriented perpendicular to the first stiffening beam and a sheath housing the first stiffening beam and the second stiffening beam and connected at first and second ends to the top plate.

[0012] Brief Description of the

[0013]

[0014] These features and aspects of the invention, as well as its advantages, are better understood by referring to the following description, appended claims, and accompanying drawings, in which:

[0015] FIG. 1 is an isometric view of a transfer portion of a conveyor according to an embodiment;

[0016] FIG. 2 is a rear view of the transfer portion of FIG. 1;

[0017] FIG. 3 is a cross-sectional side view of the transfer portion of FIG. 1 through the line A — A of FIG. 2;

[0018] FIG. 4 is an isometric view of a transfer unit in the transfer portion of FIG. 1;

[0019] FIG. 5 is an isometric view of the transfer unit of FIG 4 with nosebars removed; FIG. 6 is an isometric view of a cross member of the transfer unit of FIG. 4;

[0020] FIG. 7 is another view of the cross member of FIG; 6;

[0021] FIG. 8 is a bottom view of the cross member of FIG. 6;

[0022] FIG. 9 is an isometric view of the cross member of FIG. 6 with a sheath portion removed;

[0023] FIG. 10 is a rear view of the cross member of FIG. 6 with the sheath portion removed; FIG. 11 is a cross-sectional view of the cross-member through lines A — A of FIG. 10; FIG. 12 is an isometric view of a modular transfer unit according to another embodiment;

[0024] FIG. 13 is a front view of the modular transfer unit of FIG. 12;

[0025] FIG. 14 is an isometric view of a cross member module used to form the modular transfer unit of FIG. 12;

[0026] FIG. 15 is an isometric view of a portion of a modular transfer unit including strengthening gussets according to another embodiment;

[0027] FIG. 16 is a cross-sectional view of the modular transfer unit of FIG. 15; FIG. 17 is an isometric view of a portion of a modular transfer unit including tubular cross members according to another embodiment;

[0028] FIG. 18 shows the modular transfer unit of FIG. 17 with side plates removed to show the shape of the tubular cross members;

[0029] FIG. 19 is a cross-sectional view of the modular transfer unit of FIG. 17;

[0030] FIG. 20 is an isometric view of a portion of a modular transfer unit including leaf springs according to another embodiment;

[0031] FIG. 21 is a front view of the modular transfer unit of FIG. 20;

[0032] FIG. 22 is a bottom view of the modular transfer unit of FIG. 20;

[0033] FIG. 23 is an isometric view of a modular transfer unit including multi-piece side plates according to another embodiment;

[0034] FIG. 24 is a side view of the modular transfer unit of FIG. 23;

[0035] FIG. 25 is an isometric view of a two-piece side plate for a modular transfer unit according to another embodiment;

[0036] FIG. 26 is an isometric view of a nosebar with cutouts for interfacing with wearstrips according to another embodiment of a transfer unit for a conveyor;

[0037] FIG. 27 is a top view of the nosebar and wearstrips of FIG. 26;

[0038] FIG. 28 is an isometric view of a transfer unit for a conveyor that accommodates multiple lanes of conveyor belts according to another embodiment;

[0039] FIG. 29 is an isometric view of a transfer unit for a conveyor including a bearing for an underslung sprocket according to another embodiment;

[0040] FIG. 30 is a front view of the transfer unit of FIG. 29.

[0041] Detailed Description of the Invention

[0042] A transfer unit for a conveyor facilitates transitioning of a conveyor belt between a carryway and a returnway and smoothly transfers conveyed items from a first conveyor belt to a second conveyor belt. 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.

[0043] FIGS. 1 —3 shows a transfer portion 10 of a conveyor system including nosebars for transitioning conveyor belts between a carryway and a returnway according to an embodiment. At the transfer portion 10, product is transferred from a first conveyor belt 20 to a second conveyor belt 30 over a relatively small gap 12. The transfer portion 10 includes a transfer unit 100 comprising a frame 101 mounting a pair of confronting nosebars or noserollers forming transition points for each conveyor belt. A first nosebar 110a guides the first conveyor belt 20 from a carryway to a returnway to discharge product over the gap 12 and a second nosebar 110b guides the second conveyor belt 30 from a return way to a carryway to receive product from the first conveyor belt 20.

[0044] FIG. 4 shows the transfer unit 100 without the conveyor belts and FIG. 5 shows the frame 101 of the transfer unit 100 with the nosebars 110a, 110b removed. The frame of the transfer unit comprises a pair of spaced-apart side plates 120 and a pair of cross members 130 extending between the side plates 120. Each cross member 130 mounts a corresponding nosebar, and is configured to withstand strong forces applied by the conveyor belts, while ensuring sanitation. The cross members 130 face each other to mount the nosebars 110a, 110b in a suitable position, forming a gap 12 for passing the conveyor belts 20, 30 therethrough.

[0045] Referring to FIGS. 6 — 8, a cross member 130 for a conveyor transfer unit 100 includes a top plate 132 upon which the nosebar is mounted. The illustrative top plate 132 includes a plurality of openings 133 to reduce the overall weight of the top plate 132 without compromising strength, but the invention is not so limited. The top plate 132 can have any suitable size, shape, configuration and— or suitable pattern of openings, if any.

[0046] The inner edge 134 of the top plate 132 (adjacent the gap 12) is longer than the outer edge 135 of the top plate 132 to form tabs 136 for mounting the cross member to the side plates 120. The side plates 120 includes recesses that receive the tabs 136. The inset portion 137 of the top plate side edge abuts the inner surface of the associated side plate 120 when the associated tab 136 inserted in a side plate recess to mount the cross member between the side plates 120. Any suitable means for mounting the cross member 130 between the side plates 120 can be used.

[0047] In one embodiment, each side plate 120 can comprise multiple components pieced together. As described below.

[0048] A sheath 140 extends below the top plate 132 from below the inner edge 134 to below the outer edge 135 to house stiffening beams 150, 160, as described below. The illustrative sheath 134 and resulting cross-member 130 has a wing-like structure to maximize strength while minimizing weight. The illustrative sheath 140 indudes an inwardly angled front wall 141 extending from a top vertical portion 142, a flat bottom wall 143 and a vertical back wall 144. Rounded corners connect the flat bottom wall 143 to the front and back walls 142, 144.

[0049] As shown in FIGS. 9 — 11, the cross member 130 further includes strengthening ribs 170 spaced sequentially across the width of the sheath. Each strengthening rib 170 comprises a vertical plate that extends from the top plate 132 to the bottom wall 140 and from the front wall 141 to the back wall 143, with cutouts for the stiffening beams 150, 160. Each strengthening rip further includes curved recesses 171 at the bottom corners. Tabs extending from a top edge can be received in opening in the top plate 132 to mount and place each strengthening rib 170. Other suitable means for mounting and placing the strengthening ribs within the sheath 140 can be used.

[0050] The stiffening beams 150, 160 are arranged adjacent and perpendicular to each other in orientation. A first stiffening beam 160 is located in the longitudinal center of the sheath 140 and extends up from the bottom wall 140. The first stiffening beam has a rectangular cross-section, with the short edge adjacent to the bottom wall 140 and the long edge extending vertically. The second stiffening beam 150, also rectangular in cross-section, has a long edge abutting the bottom wall 140 and a short edge abutting the first stiffening beam 160. The stiffening beams 150, 160 can be welded to the strengthening ribs 170, the sheath, and each other at their intersections.

[0051] The second stiffening beam 150 is longer than the first stiffening beam 160 so as to project farther from the outer strengthening ribs 170. Recesses in the side plates 120 can receive the protruding portions of the longer stiffening beam 150 when mounting the cross member 130 to the side plates 120.

[0052] The hollow configuration of the cross member 130 provides a robust, cleanable and lightweight structure with an efficient space to ensure sufficient stiffness for operation.

[0053] Referring to FIGS. 12—14, in another embodiment, a transfer unit 200 for a conveyor includes modular cross members 230 that are strong yet lightweight. Each cross member 230, used to mount a nosebar, as described above, comprises a series of connected cross member modules 240 connected together. The modular cross members 230 extend between side plates 220. Each cross member module 240, shown in FIG. 14, includes a top plate 241, a bottom plate 243 and central strengthening beams 244. The cross member modules are designed to overlap each other, as shown in FIGS. 12 and 13. Fastener openings 252 are formed in the overlapping portions and receive fasteners 254 to fasten the modules 240 together to form the cross member 230.

[0054] Referring to FIGS. 15—16, in another embodiment, a transfer unit 300 for a conveyor can include gussets 331 attached to an intermediate wall 332 and a top wall 333 of I-shaped cross members 330 to reinforce the assembly. Each I-shaped cross member 330 also includes a bottom wall 335. The gussets 331 can have any suitable number, orientation and spacing. Similar to the embodiments above, the cross members extend between side plates 320 and support nosebars 310.

[0055] In another embodiment, shown in FIGS. 17—19, cross members 430 in a transfer unit 400 for a conveyor can comprise tubing. The tubing forming the cross members 430 can extend between side plates 420 for supporting a nosebar 410. Each cross member 430 can comprise a single tube or a combination of different shapes and sizes. "The tubing may include additional support beams within the hollow interior.

[0056] In another embodiment, shown in FIGS. 20—22, a transfer unit 500 for a conveyor includes cross members 530 supporting a nosebar 510 extending between side plates 520 and including a laterally extending leaf spring 535 below the cross member 530 to reinforce the assembly.

[0057] In another embodiment, shown in FIGS. 23 — 24, a side plate 620 mounting cross members 630 supporting nosebars 610 in a transfer unit 600 can comprise multiple pieces 621, 622 joined together. An illustrative first piece 621 includes a shaped protrusion configured to be received in a shaped recess in the second piece 622 so that the piece mate together in a puzzle-like manner.

[0058] In another embodiment, shown in FIG. 25, a side plate 720 comprises a first piece 721 having pointed protrusions configured to be received in tapering recesses in a second piece 722. Any suitable type of locating feature for ensuring proper positioning of multiple side plate pieces can be used.

[0059] Referring to FIGS. 26 and 27, in another embodiment, a nosebar 810 in a transfer unit can include recesses 811 in an inside edge 812 that seat the ends of the wearstrips 840 forming a carryway. The recesses 811 allow the wearstrips 840 and nosebars 810 to overlap to reduce vibrations in the system.

[0060] In still another embodiment, shown in FIG. 28, a transfer unit 910 including robust cross members 930 for a conveyor can have a multi-lane setup to allow two or more conveyor belts 902, 903 to run on the same frame. A longitudinally-extending divider 920 may be used and mounted on the transfer unit 910 to separate the edges of adjacent conveyor belts. The longitudinally-extending divider 920 can be mounted to one or both cross members 930.

[0061] In another embodiment, shown in FIGS. 29 and 30, a transfer unit 1000 for a conveyor includes an underslung sprocket assembly 1080 to drive a conveyor belt. The underslung sprocket assembly 1080 comprises a series of sprocket modules 1081 mounted on a shaft 1082 that is rotatably mounted between mounting plates 1090 using bearings 1091. The mounting plates 1090 are mounted to side plates 1020 mounting confronting cross members 1030 upon which nosebars are mounted. The transfer unit 1000 includes a mounting arm 1085 extending down from a cross member 1030. The mounting arm 1085 includes a bearing 1092 for the sprocket shaft 1082 to facilitate positioning and operation of the sprocket assembly 1080.

[0062] According to another embodiment, a transfer unit for a conveyor can have two different sized nosebars to accommodate different belt sizes.

[0063] The invention has been described relative to certain illustrative embodiments, but the scope of protection is not limited to these illustrative embodiments.

Claims

What is claimed is:

1. A transfer unit for a conveyor belt, comprising:a first side plate;a second side plate spaced from the second side plate; anda first cross member extending between the first side plate and the second side plate, the cross member comprising a top plate, a first stiffening beam, a second stiffening beam oriented perpendicular to the first stiffening beam and a sheath housing the first stiffening beam and the second stiffening beam and connected at first and second ends to the top plate.

2. The transfer unit of claim 1, further comprising a second cross member opposing the first cross member and extending between the first side plate and the second side plate.

3. The transfer unit of claim 2, further comprising a first nosebar mounted to the first cross member and a second nosebar mounted to the second cross member.

4. The transfer unit of claim 3, wherein the nosebars include recesses in a back surface for seating ends of wearstrips supporting the conveyor belt in a carryway.

5. The transfer unit of claim 1, further comprising a plurality of vertical strengthening ribs intersecting the first stiffening beam and the second stiffening beam.

6. The transfer unit of claim 5, wherein the vertical strengthening ribs are welded to the first and second stiffening beams at intersection points.

7. The transfer unit of claim 1, wherein the top plate includes tabs that are received in recesses in the side plates to mount the first cross member between the first and second side plates.

8. The transfer unit of claim 1, wherein the second stiffening beam protrudes beyond the first stiffening beam.

9. The transfer unit of claim 8, wherein the first side plate and second side plate include recesses to receive protruding ends of the second stiffening beam.

10. The transfer unit of claim 1, wherein the sheath includes an inwardly angled front wall extending from a top vertical portion, a flat bottom wall and a vertical back wall.

11. The transfer unit of claim 10, further comprising rounded corners connecting the flat bottom wall to the front and back walls.

12. The transfer unit of claim 1, wherein the first cross member comprises a plurality of modules fastened together.

13. The transfer unit of claim 1, further comprising a mounting arm extending down from the cross member for mounting a bearing for a sprocket assembly mounted below the transfer unit.

14. The transfer unit of claim 1, wherein the first side plate and second side plate each comprise multiple pieces coupled together.

15. The transfer unit of claim 1, further comprising a longitudinally-extending divider mounted on first cross member to separate the edges of adjacent conveyor belts.

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