Conveyor belt modules suitable for long belt conveyors

Abstract

Conveyor belts having a high density of article-diverting rollers supported by divider bars and lacking significant voids in the tension-bearing bars to make the belts suitable for long conveyor runs. Voids are avoided by adding drive lugs or lateral drive recesses on the bottoms of the bars instead of drive pockets. Thus, the bars' tension capacity and the belt's pull strength are increased. Other features, such as drivable belt rollers and firmly affixed roller axles, also strengthen the belt for use in long runs.

Description

[0001] CONVEYOR BELT MODULES SUITABLE FOR LONG BELT CONVEYORS

[0002] TECHNICAL FIELD

[0003] The invention relates generally to power-driven conveyors. In particular it relates to long modular-belt conveyors, especially those having rollers that can be actuated to divert articles laterally.

[0004] BACKGROUND

[0005] The INTRALOX® Series 7000 modular conveyor belt with actuatable articlesupporting rollers is used in many package-handling applications, such as in switches and sorters. The belt rollers are arranged to rotate on axes parallel to the direction of belt travel. When the belt rollers ride over actuating rollers in the carryway, the belt rollers rotate on their axes. Changing the orientation of the actuating rollers changes the direction of rotation of the belt rollers to divert articles atop the belt rollers to the left or the right, including perpendicular to the direction of belt travel.

[0006] As shown in FIGS. 1-4, the belt-roller density of the INTRALOX® Series 7000 belt is high to accommodate small packages and to provide sufficient diverting forces to large packages. The belt 20 is constructed of a series of rows 22 of one or more side-by-side belt modules 24 joined at hinge joints 26 by hinge rods 27. Bars 28 between consecutive cavities 30 for the rollers 31 in each module 24 carry the belt's tensile load while it's running. For most applications, the bars 28 suffice to carry that load. But some of the bars 28 include drive pockets 32 opening onto the bottom to receive the teeth of drive sprockets. The resulting drive-pocket voids in the bars 28 decrease the cross-sectional area of the bars at the pockets and, consequently, the bars' load-bearing capacity. Because the belt tension to be borne by the bars 28 increases with the length of the belt, the Series 7000 belt 20 with drive pockets 32 along the centerline 34 of the bars 28 can't be used in long belt conveyors.

[0007] SUMMARY

[0008] One version of a conveyor belt module comprises a module body that extends longitudinally from a first end to a second end, laterally from a first side to a second side, and in thickness from a top to a bottom. The module body includes first hinge elements spaced apart laterally along the first end and second hinge elements spaced apart laterally along the second end. Longitudinally elongated cavities, spaced apart laterally between thefirst and second sides, open onto the top and bottom of the module body. Longitudinally elongated bars, having a top face and a bottom face, extend between the first and second ends of the module body. Each of the bars forms a wall bounding laterally consecutive cavities. Rollers mounted in the cavities rotate on longitudinal axes of rotation and protrude outward of the cavities. No lateral cross section of any of the bars has a void midway between consecutive cavities.

[0009] Another version of a conveyor belt module comprises a module body that extends longitudinally from a first end to a second end, laterally from a first side to a second side, and in thickness from a top to a bottom. The module body includes first hinge elements spaced apart laterally along the first end and second hinge elements spaced apart laterally along the second end. Longitudinally elongated cavities, spaced apart laterally between the first and second sides, open onto the top and bottom of the module body. Longitudinally elongated bars, having a top face and a bottom face, extend between the first and second ends of the module body. Each of the bars forms a wall bounding laterally consecutive cavities. One or more of the bars each include a lug protruding from the bottom face.

[0010] One version of a conveyor comprises a conveyor belt comprising a series of rows of one or more conveyor belt modules extending in width from a first outer belt side to a second outer belt side. At least some of the conveyor belt modules include a module body that extends longitudinally from a first end to a second end, laterally from a first side to a second side, and in thickness from a top to a bottom. The module bodies include

[0011] first hinge elements spaced apart laterally along the first end and second hinge elements spaced apart laterally along the second end. Longitudinally elongated cavities, spaced apart laterally between the first and second sides, open onto the top and bottom of the module body. Longitudinally elongated bars, having a top face and a bottom face, extend between the first and second ends of the module body. Each of the bars forms opposite walls bounding laterally consecutive cavities. Rollers mounted in the cavities rotate on longitudinal axes of rotation and protrude outward of the cavities. No lateral cross section of any of the bars has a void midway between consecutive cavities. The first hinge elements of each row interleave with the second hinge elements of an adjacent row. Hinge rods through the interleaved first and second hinge elements link the rows together at hinge joints to formthe conveyor belt. One or more sprockets are configured to engage the conveyor belt to drive the conveyor belt in a direction of belt travel.

[0012] Another version of a conveyor comprises a conveyor belt comprising a series of rows of one or more conveyor belt modules extending in width from a first outer belt side to a second outer belt side. At least some of the conveyor belt modules include a module body that extends longitudinally from a first end to a second end, laterally from a first side to a second side, and in thickness from a top to a bottom. The module bodies include

[0013] first hinge elements spaced apart laterally along the first end and second hinge elements spaced apart laterally along the second end. Longitudinally elongated cavities, spaced apart laterally between the first and second sides, open onto the top and bottom of the module body. Longitudinally elongated bars, having a top face and a bottom face, extend between the first and second ends of the module body. One or more of the bars each include a lug protruding from the bottom face. The first hinge elements of each row interleave with the second hinge elements of an adjacent row. Hinge rods through the interleaved first and second hinge elements link the rows together at hinge joints to form the conveyor belt. One or more sprockets have a periphery with notches spaced apart to receive the lugs and drive the conveyor belt.

[0014] BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an isometric view of a portion of a prior-art modular conveyor belt.

[0015] FIG. 2 is a top axonometric view of one of the modules of the conveyor belt of FIG. 1. FIG. 3 is a bottom axonometric view of the module of FIG. 2 without rollers.

[0016] FIG. 4 is a cutaway view of the module of FIG. 3 cut along lines IV-IV.

[0017] FIG. 5 is a bottom axonometric view of one version of a belt module suitable for use in long belt conveyors.

[0018] FIG. 6 is a cutaway view of the module of FIG. 5 cut along lines VI-VI.

[0019] FIG. 7 is a side elevation view of a portion of a belt conveyor showing two consecutive modules as in FIG. 5 driven by a drive sprocket.

[0020] FIG. 8 is a bottom axonometric view of a second version of a belt module suitable for use in long belt conveyors.

[0021] FIG. 9 is a cutaway view of the module of FIG. 8 cut along lines IX-IX.FIG. 10 is an axonometric view of a portion of a belt conveyor showing two belt modules as in FIG. 8 driven by a mating sprocket.

[0022] FIG. 11 is an enlarged view of the tooth region of the sprocket of FIG. 10.

[0023] FIG. 12 is a top axonometric view of a third version of a belt module suitable for use in long belt conveyors.

[0024] FIG. 13 is a cutaway view of the module of FIG. 12 cut along lines XIII— XIII.

[0025] FIG. 14 is a side elevation view of a portion of a belt conveyor showing two belt modules as in FIG. 12 engaged with a mating sprocket.

[0026] FIG. 15 is an axonometric view of a belt module with a first version of a scrubbing roller.

[0027] FIG. 16 is a side elevation view of the belt module of FIG. 15.

[0028] FIG. 17 is an axonometric view of a belt module with a second version of a scrubbing roller.

[0029] FIG. 18 is a side elevation view of the belt module of FIG. 17.

[0030] FIGS. 19A and 19B are side elevation and bottom plan views of a portion of a fourth version of a belt module suitable for use on long belt conveyors.

[0031] FIG. 20 is an isometric view of a portion of a conveyor belt constructed of a belt modules like the belt module of FIG. 19 engaged by mating sprockets.

[0032] FIG. 21 is an isometric view as in FIG. 19 with the addition of polygonal rollers supporting the outside edges of the conveyor belt.

[0033] DETAILED DESCRIPTION

[0034] One version of a roller-conveyor belt module usable in a long conveyor is shown in FIG. 5 without rollers. The module 40 includes a module body 41 that extends longitudinally from a first end 42 to a second end 43, laterally from a first side 44 to a second side 45, and in thickness from a top 46 to a bottom 47. First hinge elements 48 are spaced apart laterally along the first end 42. Second hinge elements 49 are spaced apart laterally along the second end 43. Longitudinally elongated bars 50, 51 that extend between the first and second ends 42, 43 of the module body 41 are laterally spaced apart across cavities 52. The bars 50, 51 form walls 54, 55 bounding the cavities 52. Rollers (not shown) mount on axles 56 that extend longitudinally along the cavities 52. The axles 56 define the axis of rotation 58 of the rollers. The axes of rotation 58 are parallel to the lengths of the bars 50, 51.The bars 50, 51 have bottom faces 60, 61 and top faces. A lug 62 protrudes outward from the bottom faces 60 of some of the bars 50. In this example, the lugs 62 extend from the bottom faces 60 of the narrower bars 50. But the lugs could be formed on the wide bars 51 as well or instead. The lugs 62 in this version extend outward of the bottom faces 60 between the first and second ends 42, 43 of the module body 41. The lugs 62 in this version are at the middle of the bars 50 but could be offset. As shown in FIG. 6, there are no voids in the bars 50, 51 as there are in the bars 28 of FIG. 3. Thus, the bars 50, 51 in FIG. 5 can bear greater tension as is needed in long belts. Half lugs 62' on half bars 50' at the sides 44, 45 of the module body 41 form split full lugs and full bars with identical half lugs and half bars on adjacent modules 40.

[0035] FIG. 7 shows the driving engagement of a drive sprocket 64 with a belt 66 constructed of the belt modules 40 of FIG. 5. The belt rows 68 are joined at hinge joints 70 by hinge rods 72. Belt rollers 74 protrude from the cavities 52 (FIG. 5) past the tops 46 of the modules 40 to support conveyed articles. Notches 75 in the periphery of the sprocket 64 receive the lugs 62 extending from the bottoms 47 of the modules 40. Trailing faces 76 of the notches 75 drive against the lugs 62 to drive the belt 66 as indicated by the arrow 78.

[0036] Another version of a roller-conveyor belt module usable in a long conveyor belt is shown in FIG. 8 without rollers. The module 80 differs from the module 40 of FIG. 5 in that some of the bars 81 have side recesses 82 in walls 84 bounding the cavities 86 instead of lugs 62. The recesses 82 open onto the module bottom 83. Although the cross-sectional area of the bars 81 is decreased by the side recesses 82, the separating web 86 along the bars' centerlines 88 provides the bars 81 with more strength than the bars 28 of FIG. 3 with the pockets 32 along the centerlines 34. The recesses 82, which are aligned laterally across the web 86 from each other, may be formed on one or more of the wide bars 81 or on the narrow bars 83.

[0037] The recesses 82 receive the complementary tooth pairs 90 on the periphery 92 of a sprocket 94 as shown in FIGS. 10 and 11. The tooth pairs 90 are separated by an intervening gap 96 sized to admit the modules' webs 86. The tooth pairs 90 drive against drive surfaces 98 (FIG. 8) bounding the recesses 82. The modules 80 on consecutive belt rows are linked together end to end at hinge joints by hinge rods 100 to form a conveyor belt 102.A third version of a belt module suitable for use in a long conveyor belt is shown in FIG. 12 with some of the rollers in place. In this version the module 106 has bars 107 whose lateral cross sections are constant along the bars' lengths without voids as shown in FIG. 13. Instead, belt rollers 108 have reduced-diameter portions 110. The reduced-diameter portions 110 of the rollers 108 admit the teeth 111 of a sprocket 112 as in FIG. 14. The teeth 111 mesh with the rollers 108 and drive against the rear of their leading halves 114.

[0038] Unlike the belt module of FIG. 4, none of the belt modules shown in FIGS. 6, 9, and 13 has a void in any lateral cross section of the bars.

[0039] FIGS. 15-18 show similar belt modules with scrubbing belt rollers to remove from the roller cavities debris that could interfere with the rotation of the rollers. The conveyor belt module 120 in FIGS. 15 and 16 has belt rollers 122 with grooves 124 extending longitudinally along the outer surfaces 126. The grooves 124 are parallel to the rollers' axes of rotation 58. As the rollers rotate, the edges of the grooves 124 scrape debris from the roller cavities 128.

[0040] The belt module 130 shown in FIGS. 17 and 18 has grooves 132 in the rollers 134 that encircle the outer surfaces 136. The grooves 132 direct top-side debris away from conveyed articles as the rollers 134 rotate. The scrubbing feature of the rollers 122, 134 of FIGS. 15-18 may be used with any of the module versions described in this application.

[0041] Another way to strengthen conveyor belts to make them suitable for use in long conveyors is explained in reference to FIG. 5. Belt pull strength is increased by having the roller axles 56 bear the belt tension. This is achieved by firmly affixing both ends of the axles 56 in the belt body. Metal axles, especially, are able to handle heavy tension loads and lessen the loads that would otherwise have to be borne by the bars 50, 51. Firm affixation of the axle ends can be achieved by knurling the axle ends for a secure fit, gluing the axle ends to the module, or molding the module around the axle and installing a two-piece roller on the molded-in axle. Firmly affixed axles may be used with any of the versions described in this application.

[0042] Another version of a conveyor belt module suitable for use in a long conveyor belt is shown in FIGS. 19A and 19B without belt rollers in cavities. But the conveyor belt can include rollers in the cavities. The belt module 140 is similar to the belt module of FIG. 3 and the belt module of FIG. 5. Like the belt module of FIG. 5, the belt module 140 has a lug 142extending downward from the bottom 144 of a bar 146. The lug 142 has a ramped leading face 148 and a trailing drive face 149. Aft of the drive face 149 is a shallow pocket 150, which is not so deep as the pocket 32 of FIG. 3 and enables the bar 146 to bear greater belt tension.

[0043] FIG. 20 shows a portion of a conveyor belt 160 constructed of a plurality of belt modules 140 as in FIGS. 19A and 19B engaged by a set of sprockets 152 mounted on a shaft 153. Only one side of the belt is shown. The other side of a full- width conveyor belt would typically be the same as the side shown. The sprockets 152 receive the belt lugs 142 in notches 154 in the sprocket's periphery and engage the belt lugs' drive faces 149 with sprocket teeth 156 received in the shallow pockets 150.

[0044] FIG. 21 is the same as FIG. 20, except with the addition of a toothless polygonal roller 164 supporting an edge portion 162 of the conveyor belt 160. Because the edge portion 162 lacks drive pockets that would admit the teeth 156 of sprockets 152, support for the edge portion while articulating about sprockets is limited. Polygonal rollers 164 flanking the standard toothed sprockets 152 support both side edges of the belt 160 as it articulates about the sprockets. The polygonal periphery of the polygonal rollers 164 matches the polygonal periphery of the sprockets 152. The sprockets 152 and the rollers 164 are mounted on a common shaft 153 with their polygonal peripheries in phase. The side-edge support provided by the polygonal rollers 164 enables the belt 160 to be used in long runs.

[0045] Like the polygonal rollers 164, the sprockets 152 have polygonal peripheries to fully contact the belt underside for better support of the belt as it articulates about the sprockets. And sprockets with polygonal peripheries are preferred, but not essential, in all the conveyors described.

Claims

What is claimed is:

1. A conveyor belt module comprising:a module body extending longitudinally from a first end to a second end, laterally from a first side to a second side, and in thickness from a top to a bottom and including: first hinge elements spaced apart laterally along the first end and second hinge elements spaced apart laterally along the second end;cavities longitudinally elongated, spaced apart laterally between the first and second sides, and opening onto the top and bottom of the module body;bars longitudinally elongated, having a top face and a bottom face, and extending between the first and second ends of the module body, wherein each of the bars forms a wall bounding laterally consecutive cavities;rollers mounted in the cavities to rotate on longitudinal axes of rotation and protruding outward of the cavities;wherein no lateral cross section of any of the bars has a void midway between consecutive cavities.

2. The conveyor belt module as claimed in claim 1 wherein one or more of the bars each include a lug protruding from the bottom face.

3. The conveyor belt module as claimed in claim 1 wherein one or more of the bars each include recesses in the walls opening onto the bottom face.

4. The conveyor belt module as claimed in claim 1 wherein one or more of the rollers has a reduced-diameter portion between the first and second ends of the module body, wherein the reduced-diameter portion does not protrude outward of the cavities.

5. The conveyor belt module as claimed in claim 1 wherein the rollers have outer surfaces with grooves.

6. The conveyor belt module as claimed in claim 5 wherein the grooves extend on the outer surface parallel to the axis of rotation.

7. The conveyor belt module as claimed in claim 5 wherein the grooves encircle the outer surface.

8. The conveyor belt module as claimed in claim 1 comprising axles affixed securely at opposite ends in the module body in each of the cavities and wherein the rollers have bores receiving the axles, which define the axes of rotation.

9. A conveyor belt module comprising:a module body extending longitudinally from a first end to a second end, laterally from a first side to a second side, and in thickness from a top to a bottom and including: first hinge elements spaced apart laterally along the first end and second hinge elements spaced apart laterally along the second end;cavities longitudinally elongated, spaced apart laterally between the first and second sides, and opening onto the top and bottom of the module body;bars longitudinally elongated, having a top face and a bottom face, and extending between the first and second ends of the module body, wherein each of the bars forms a wall bounding laterally consecutive cavities;wherein one or more of the bars each include a lug protruding from the bottom face.

10. The conveyor belt module as claimed in claim 9 including a pocket in the bottom face of the bar adjacent to the lug.

11. The conveyor belt module as claimed in claim 9 comprising rollers mounted in the cavities to rotate on longitudinal axes of rotation and protruding outward of the cavities.

12. The conveyor belt module as claimed in claim 11 wherein the rollers have outer surfaces with grooves parallel to the axes of rotation or encircling the outer surfaces.

13. The conveyor belt module as claimed in claim 11 comprising axles affixed securely at opposite ends in the module body in each of the cavities to bear belt tension and wherein the rollers have bores receiving the axles, which define the axes of rotation.

14. A conveyor comprising:a conveyor belt comprising a series of rows of one or more conveyor belt modules extending in width from a first outer belt side to a second outer belt side, at least some of the conveyor belt modules including:a module body extending longitudinally from a first end to a second end, laterally from a first side to a second side, and in thickness from a top to a bottom and including:first hinge elements spaced apart laterally along the first end and second hinge elements spaced apart laterally along the second end;cavities longitudinally elongated, spaced apart laterally between the first and second sides, and opening onto the top and bottom of the module body;bars longitudinally elongated, having a top face and a bottom face, and extending between the first and second ends of the module body, wherein each of the bars forms opposite walls bounding laterally consecutive cavities; rollers mounted in the cavities to rotate on longitudinal axes of rotation and protruding outward of the cavities;wherein the bars have lateral cross sections without voids midway between consecutive cavities and are configured to bear greater belt tension suitable for long conveyor belts;wherein the first hinge elements of each row interleave with the second hinge elements of an adjacent row and wherein hinge rods through the interleaved first and second hinge elements link the rows together at hinge joints to form the conveyor belt;one or more sprockets configured to engage the conveyor belt to drive the conveyor belt in a direction of belt travel.

15. The conveyor as claimed in claim 14 wherein one or more of the bars each include a lug protruding from the bottom face and wherein the one or more sprockets have a periphery with notches spaced apart to receive the lugs and drive the conveyor belt.

16. The conveyor as claimed in claim 14 wherein one or more of the rollers has a reduced- diameter portion between the first and second ends of the module body, wherein the reduced-diameter portion does not protrude outward of the cavities, and wherein the one or more sprockets have a periphery with teeth spaced apart to mesh with the reduced-diameter portion of the rollers to drive the conveyor belt.

17. The conveyor as claimed in claim 14 wherein the wherein the rollers have outer surfaces with grooves parallel to the axes of rotation or encircling the outer surfaces to scrape debris from the walls.

18. The conveyor as claimed in claim 14 wherein one or more of the bars each include recesses in the opposite walls opening onto the bottom face and wherein the one or more sprockets have a periphery with pairs of teeth arranged to fit into the opposite walls to drive the conveyor belt.

19. The conveyor as claimed in claim 14 comprising first and second polygonal wheels supporting the bottom of the conveyor belt at the first and second outer belt sides.

20. A conveyor comprising:a conveyor belt comprising a series of rows of one or more conveyor belt modules extending in width from a first outer belt side to a second outer belt side, at least some of the conveyor belt modules including:a module body extending longitudinally from a first end to a second end, laterally from a first side to a second side, and in thickness from a top to a bottom and including:first hinge elements spaced apart laterally along the first end and second hinge elements spaced apart laterally along the second end;cavities longitudinally elongated, spaced apart laterally between the first and second sides, and opening onto the top and bottom of the module body; bars longitudinally elongated, having a top face and a bottom face, and extending between the first and second ends of the module body, wherein each of the bars forms opposite walls bounding laterally consecutive cavities; wherein one or more of the bars each include a lug protruding from the bottom face;wherein the first hinge elements of each row interleave with the second hinge elements of an adjacent row and wherein hinge rods through the interleaved first and second hinge elements link the rows together at hinge joints to form the conveyor belt;one or more sprockets having a periphery with notches spaced apart to receive the lugs and drive the conveyor belt.

21. The conveyor as claimed in claim 20 wherein one or more of the bars each have a pocket in the bottom face adjacent to the lug and wherein the one or more sprockets have teeth adjacent to the notches arranged to fit into the pockets.

22. The conveyor as claimed in claim 20 comprising rollers mounted in the cavities to rotate on longitudinal axes of rotation and protruding outward of the cavities.

23. The conveyor as claimed in claim 20 comprising first and second polygonal wheels supporting the bottom of the conveyor belt at the first and second outer belt sides.

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