Note: Descriptions are shown in the official language in which they were submitted.
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CA 02642915 2008-10-31
1 "APPARATUS, SYSTEM AND METHOD FOR MOVING A VEHICLE FROM
2 DUAL BELT CONVEYOR TO DUAL BELT CONVEYOR"
3
4 FIELD OF THE INVENTION
Embodiments of the invention are directed to apparatus, systems
6 and methods for transferring a vehicle from one dual belt conveyor to
another
7 dual belt conveyor and more particularly from at least a dual belt entrance
8 conveyor of a car wash to a dual belt wash conveyor in the car wash wherein
the
9 vehicle may be in a variety of states including but not limited to park,
neutral, foot
brake engaged or emergency brake engaged.
11 BACKGROUND OF THE INVENTION
12 Conveyance systems are well known for moving vehicles along a
13 direction of travel, such as along an assembly line in an automotive
assembly
14 plant or through a car wash tunnel.
One type of conveyor utilized particularly in conventional car
16 washes is a chain conveyor having spaced, large, upwardly extending lugs
17 which positively engage a wheel of the vehicle and act to drag the vehicle
18 through the car wash tunnel. The vehicle's transmission is placed in
neutral to
19 permit the wheels of the vehicle to rotate on the floor of the carwash
tunnel as
the vehicle is dragged by the lug. The engaged wheel is guided throughout the
21 car wash tunnel by tracks which align the wheels and prevent skewing of the
22 vehicle. Should the wheels of the vehicle be prevented from rotating, such
as by
23 placing the drivetrain in Park or one or more of the footbrake or the
emergency
24 brake being engaged, the vehicle may be damaged when engaged with the lug.
1
CA 02642915 2008-10-31
1 It is known in the automotive industry, particularly in the assembly
2 thereof, to utilize endless belt conveyors to support and carry a vehicle on
the
3 belt(s) along the direction bf travel. The conveyor may comprise a single
belt or
4 dual, spaced apart, substantially parallel belts. A surface of the belts may
or may
not be cleated. Where two or more end-to-end conveyors are utilized to move
6 the vehicle the desired distance, the vehicle must be transitioned across a
gap
7 formed therebetween. One common transition used in belt-to-belt transfer is
a
8 plate positioned across the gap between the belts. Another common transition
is
9 one or more rollers positioned in the gap.
Vehicles carried on belt conveyors typically have the wheels locked
11 and therefore non-rotatable, such as when the drivetrain is in Park or when
12 brakes, including the emergency brake, are applied. In the locked state,
the
13 wheels of the vehicle are carried by the conveyor surface and movement of
the
14 conveyor supplies sufficient momentum to overcome any force encountered by
the wheels at the conventional transition. If however the vehicle's drivetrain
is
16 placed in neutral and the wheels are rotatable, the momentum caused by the
17 conveyor would merely cause the wheels engaged in the gap to rotate and the
18 vehicle would riot be advanced over the gap or the conventional transition.
Thus,
19 conventional belt conveyor systems either require that the wheels be in a
locked
state to permit transition from belt to belt.
21 US Patent 7,278,533 to Horn teaches two, dual, endless belt
22 conveyors oriented end-to-end for use in a carwash. Horn requires that the
23 vehicle's drivetrain be placed in Park once the vehicle has been driven
onto the
24 entrance conveyor to lock the wheels against rotation. The locked wheels
are
2
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.... .. .. . . .
CA 02642915 2008-10-31
1 thereafter pushed by the momentum of the conveyor over a single transfer
roller
2 fit within the gap between the entrance conveyor and the wash conveyor.
3 Despite warnings to the contrary, it is known that operators may
4 place the vehicle in the locked state or the freewheeling state. This
becomes
particularly problematic in unmanned car washes which utilize belt conveyors
6 and the vehicle's operator places the vehicle in neutral. The wheels are
therefore
7 freewheeling and can hang up in gaps at the transitions between belts, the
8 vehicle potentially becoming stalled at the transition. Further, the vehicle
may
9 skew if passed over the transition, particularly if the rotatable wheels are
not
aligned with the direction of travel.
11 As a further complication in belt conveyors, Applicant believes that
12 should the wheels be placed in the locked state and the vehicle
successfully
13 reach an end of the conveyor, the vehicle may be damaged as the front
wheels
14 of the vehicle exit from the final conveyor onto a surface outside the
carwash
while the rear wheels remain on the moving conveyor.
16 As well safety concerns are well known in the industry whenever
17 there is a gap or nip formed between rollers or belts. It is possible that
should the
18 gap be large enough, personnel may engage with the gap, such as with their
feet
19 and severe injury is known to result.
Thus, there is an interest, particularly in the car wash industry, for a
21 conveyance system for vehicles which provides safe and reliable movement of
a
22 vehicle, regardless the rotational state of the wheels of the vehicle,
permits
23 unimpeded and aligned transfer of the vehicle from belt to belt in a multi-
3
CA 02642915 2008-10-31
1 conveyor system and minimizes any gap between conveyors and transitions
2 therebetween to prevent personnel injury.
3
4 SUMMARY OF THE INVENTION
Embodiments of the invention facilitate transfer of a vehicle from
6 one dual belt conveyor to another dual belt conveyor, particularly when the
7 wheels of the vehicle are freewheeling such as when the drivetrain is placed
in
8 neutral. Transitions between the belts of one conveyor and the belts of
another
9 end-to-end oriented conveyor are offset along a direction of travel. The
offset
transitions result in only one wheel of the vehicle crossing a transition at
any one
11 time minimizing resistance acting against the vehicle during the transfer
from
12 conveyor to conveyor. Thus, the vehicle is transferred substantially
without
13 impedance from one conveyor to another conveyor.
14 In one broad aspect of the invention, a system for transferring a
vehicle along a direction of travel from discharge ends of a first pair of
belts to
16 intake ends of a second pair of belts oriented as end-to-end belts, the
vehicle
17 having freewheeling wheels, comprises: a pair of passive transitions
positioned
18 between the first and second pairs of belts, the transitions being offset
along the
19 direction of travel so that only one transitioning, freewheeling wheel is
supported
on one of the pair of passive transitions at a time and imposes a resistance
force
21 at a first resistance threshold thereon; a plurality of cleats spaced along
at least
22 one belt of the first pair of belts and; a plurality of cleats spaced along
on at least
23 one belt of the second pair of belts, wherein a cleat of the plurality of
cleats
24 engages and imposes at least a minimum transitioning force on at least one
4
CA 02642915 2008-10-31
1 freewheeling wheel, the at least a minimum transitioning force being greater
than
2 the first resistance threshold, for moving each transitioning wheel across
the
3 transitions and moving the vehicle between the first and second pairs of
belts.
4 In another broad aspect of the invention, a method for carrying a
vehicle, having freewheeling wheels, along a direction of travel from a first
dual
6 belt conveyor to a second dual belt conveyor, the vehicle having a first
front
7 wheel, a second front wheel, a first rear wheel, and a second rear wheel,
8 comprising: providing a first transition positioned in a gap between a first
side
9 belt of the first dual belt conveyor and a first side belt of the second
dual belt
conveyor, and a second transition positioned in a gap between a second side
11 belt of the first dual belt conveyor and a second side belt of the second
dual belt
12 conveyor; offsetting the first transition from the second transition along
the
13 direction of travel so that, when one of the first front wheel, second
front wheel,
14 first rear wheel or second rear wheel engages either of the first or second
transition, all the remaining front and rear wheels are supported on either or
both
16 of the first and second dual belt conveyors; moving the first and second
side
17 belts of each of the first and second dual belt conveyors in the direction
of travel
18 for carrying the vehicle supported thereon; engaging at least one of a
front wheel
19 or rear wheel with a pushing cleat of a plurality of spaced cleats on at
least one
of the first side belt or second side belt of the first dual belt conveyor;
pushing
21 the engaged wheel with the pushing cleat until at least one of the front or
rear
22 wheels crosses the first or second transition; engaging at least a pulling
cleat of
23 a plurality of spaced cleats on at least one of the first side belt or
second side
5
CA 02642915 2008-10-31
1 belt of the second dual belt conveyor; and pulling at least a last rear
wheel of the
2 first or second rear wheel over the remaining second or first transition.
3 In embodiments of the invention, a first plurality of spaced cleats
4 are formed on the first side belt of the first conveyor and a second
plurality of
cleats are formed on the second side belt of the second conveyor.
Alternatively,
6 either the first and second plurality of cleats are formed on each of the
first side
7 belts of the first and second conveyor or on each of the second side belts
of the
8 first and second conveyor or are formed on all of the belts of the first and
second
9 conveyors. A cleat engaging a wheel on the first conveyor acts to push on
the
cleat for pushing the vehicle. A cleat engaging a wheel on the second conveyor
11 acts to push on the cleat for pulling the vehicle.
12 While embodiments of the invention are particularly suitable for
13 transferring a vehicle having freewheeling wheels, the transfer however is
also
14 accomplished if at least some of the wheels of the vehicle are in a locked
state.
In another broad aspect of the invention, a transition for
16 transferring a freewheeling wheel of a vehicle between end-to-end belts of
an
17 endless belt conveyor system and in a direction of travel, comprises: a
loop of
18 recirculation rollers adapted to be positioned in a gap between the end-to-
end
19 belts, the loop of rollers being passively rotatable in the direction of
travel; a fixed
intake roller adapted to be supported in a gap between a discharge end of a
first
21 belt of the end-to-end belts and the loop of recirculation rollers; and a
fixed
22 discharge roller adapted to be supported in a gap between the loop of
23 recirculation rollers and an intake end of a second belt of the end-to-end
belts;
24 wherein the fixed intake and discharge rollers are adapted to be spaced
6
_ . ,
CA 02642915 2008-10-31
1 sufficiently from the discharge and intake ends of the end-to-end belts to
permit
2 unimpeded passage of the end-to-end belts thereby.
3
4 BRIEF DESCRIPTION OF THE DRAWINGS
Figure 1 is a partial plan view of an embodiment of the invention
6 illustrating a first pair of substantially parallel spaced first and second
endless
7 belts forming a first conveyor and a second pair of substantially parallel
spaced
8 first and second endless belts forming a second conveyor, the first and
second
9 conveyors oriented end to end and having offset transitions positioned
between
end-to-end first side belts and end-to-end second side belts, portions of a
central
11 area between the belts having been removed for clarity;
12 Figure 2 is a partial perspective view according to Fig. 1, portions
13 of upper sections of the belts and coverings over a central area between
the
14 belts having been removed for clarity;
Figure 3 is a perspective view of a transition for use between belts
16 of conveyors oriented end-to-end for use in embodiments of the invention;
17 Figure 4 is a plan view of the transition according to Fig. 3;
18 Figure 5 is a front view of the transition according to Fig. 3;
19 Figure 6 is a side view of the transition according to Fig. 3;
Figure 7 is a side view of the transition according to Fig, 6, a cover
21 removed for viewing fixed and recirculation rollers therein;
22 Figures 8A - 8F are a series of schematic side views of the
23 embodiment of Fig. 1 illustrating passage of a cleat formed on an outer
surface
24 of one of the belts past a fixed intake roller of the transition of Fig. 3;
7
CA 02642915 2008-10-31
1 Figures 9A - 9G are a series of schematic side views of first and
2 second side belts of the embodiment of Fig. 1 illustrating passage of first
and
3 second side wheels of a vehicle along the belts and over the offset
transitions
4 between the end-to-end oriented first and second side belts of the first and
second pairs of belts;
6 Figures 10A - 10G are perspective views according to Figs. 9A-9G
7 respectively;
8 Figures 11A1 - 11D5 are schematic plan views illustrating the
9 effect of engaging different of the wheels with cleats on opposing belts of
the first
and second pairs of belts;
11 Figures 12A1 - 12E5 are schematic plan views illustrating the
12 effect of engaging different of the wheels with cleats on same side belts
of the
13 first and second pairs of belts;
14 Figures 13 is a side view of a belt of a conveyor, a return portion of
the belt being supported by return rollers; and
16 Figure 14 is a schematic plan view of a car wash having three dual
17 belt conveyors according to an embodiment of the invention.
18
19 DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In embodiments of the invention, shown in Figs. 1-7, a conveyor
21 system 1 carries a vehicle in a direction of travel T. The system 1 is
particularly
22 suited for use when a vehicle's wheels 2 are in the rotational or
freewheeling
23 state. The system 1 comprises a first pair 4 of substantially parallel
first 6a and
24 second 6b spaced apart endless belts and a second pair 10 of substantially
8
CA 02642915 2008-10-31
1 parallel spaced apart first 8a and second 8b endless belts. The first pair
of belts
2 4 forms a first dual belt conveyor 12 and the second pair of belts 10 forms
a
3 second dual belt conveyor 14. Corresponding of the belts 6a,6b,8a,8b of the
first
4 and second dual belt conveyors 12,14 are oriented end-to-end as end-to-end
belts.
6 A first side transition 20 is positioned in a gap 22 between a
7 discharge end 23 of the first side belt 6a of the first pair of belts 4 and
an intake
8 end 25 of the first side belt 8a of the second pair of belts 10. A second
side
9 transition 24 is positioned in a gap 26 between the discharge end 27 of the
second side belt 8a of the first pair of belts 4 and an intake end 28 of the
second
11 side belt 8b of the second pair of belts 10. The transitions 20,24 are
passive as
12 the transitions 20,24 do not act to drive the wheels 2 of the vehicle but
merely
13 act rollably to support the wheels 2 to transition from conveyor 12 to
conveyor
14 14. Suitable transitions 20,24 could include a roller or rollers.
Cleats 30 are provided to engage the wheels 2 of the vehicle. A
16 plurality of cleats 30 are spaced along at least one belt of the first pair
of belts 4
17 and a plurality of cleats 30 spaced along on at least one belt of the
second pair
18 of belts 10. The cleats 30 project from an outer surface 32 of at least one
of the
19 first or second side belts 6a, 6b of the first pair of belts 4. The cleats
30 engage
at least one wheel 2 of the vehicle to push the wheel 2 of the vehicle. By
pushing
21 a wheel 2, a pushing cleat advances the vehicle as the remaining wheels 2
22 sequentially reach the first or second transition 20, 24. Thus the vehicle
is
23 transferred, one wheel 2 at a time over the transitions 20,24 from the
first
24 conveyor 12 to the second conveyor 14. As an exception, a last
transitioning
9
CA 02642915 2008-10-31
1 wheel 2L is pulled over a remaining transition 20,24 by a pulling cleat 30
on the
2 second conveyor 14 pushing on a wheel 2 which has crossed the transitions
3 20,24. Thus, the action of the cleats 30, pushing on the wheels 2 of the
vehicle,
4 causes a push or pull on the vehicle resulting in substantially unimpeded
transfer
of the wheels 2 across the passive first and second transitions 20, 24 between
6 the conveyors 12, 14.
7 Further, the first transition 20 is offset relative to the second
8 transition 24 sufficiently such that only one wheel 2 of the vehicle, a
transitioning
9 wheel 2t, is crossing either the first or second transition 20, 24 at any
one time.
The remaining front and rear wheels 2 are supported on either or both of the
first
11 and second pairs of belts 4,10 of the first and second conveyors 12, 14. In
other
12 words, when any one of the vehicle's wheels 2t is on one of the first or
second
13 transition 20,24, there remains three points of contact between the vehicle
and
14 the belts 6a,6b,8a,8b of one or both of the conveyors 12, 14. Thus, the
only
resistance to movement of the vehicle is caused by one wheel 2 at the
16 transitions 20,24.
17 Gaps 22,26 are found between discharge ends 23,27 and intake
18 ends 25,28 of the belts 6a,6b,8a,8b of the conveyors 12,14. Resistance to
19 movement of the wheels 2 across the transition is at least in part a
function of a
width of the gap 22,26. At least a portion of the wheel 2 will fall into the
gap
21 22,26 and thereafter must climb out of the gap 22,26 in order to move in
the
22 direction of travel T. A wider gap 22,26 will permit a greater portion of
the wheel
23 2 to drop into the gap 22,26 and imposes a higher resistance force against
24 further motion of the wheel 2 in the direction of travel T. A narrower gap
22,26
CA 02642915 2008-10-31
1 will engage a lesser portion of the wheel 2 and thus will result in less
resistance
2 force against the wheel 2. Additionally, there may be other resistance
forces
3 such as a result of the action of the wash brushes against the vehicle
creating a
4 cumulative resistance force.
Thus, in embodiments of the invention, the first and second
6 transitions 20,24 are designed to minimize the size of the gap 22,26 while
still
7 providing a minimum tolerance for permitting the belts 6a,6b,8a,8b and
cleats 30
8 thereon unimpeded passage by the transitions 20,24. A cleat height is
9 sufficiently high so as to provide at least a minimal cleat or transitioning
force to
a freewheeling wheel 2 to overcome at least the resistance force when a
vehicle
11 encounters a first resistance threshold R1 of one wheel 2 crossing either
the first
12 or second transition 20, 24 at any one time.
13 Having reference again to Figs. 1-7, and in embodiments of the
14 invention, the transition 20, 24 extends across a length of the gap 22,26
being
substantially a width of each of the belts 6a,6b,8a,8b.
16 Having reference as well to Figs. 8A - 8F, the offset first and
17 second transitions 20,24 comprise a fixed intake roller 44 adjacent the
discharge
18 ends 23,27 of each of the belts 6a,6b of the first conveyor 12 and a fixed
19 discharge roller 48 supported in gap 22,26, adjacent the intake ends 25,28
of
each of the belts 8a,8b of the second conveyor 14. The fixed intake roller 44
and
21 the fixed discharge roller 48 are spaced from the discharge ends 23,27 and
the
22 intake ends 25,28 of the belts 6a,6b,8a,8b sufficient so as to permit
passage of
23 the belts 6a,6b,8a,8b and cleats 30 thereby.
11
CA 02642915 2008-10-31
1 In an embodiment of the invention, the fixed intake and fixed
2 discharge rollers 44,48 are ultra high-molecular weight polyethylene
(UHMWPE)
3 rollers so as to be sufficiently strong to support the weight of vehicles
thereon
4 and to withstand repeated use. The UHMWPE rollers are mounted on stainless
steel shafts, the UHMWPE acting as a bearing on the shafts.
6 In embodiments of the invention, a plurality of the cleats 30 are
7 spaced along at least one of the first side belts 6a,8a or second side belts
6b,8b
8 of each of the first pair of belts 4 and the second pair of belts 10. The
cleats 30
9 engage and push at least one of the freewheeling wheels 2 of the vehicle for
pushing or pulling the vehicle over the first and second transitions 20,24.
Where
11 at least one wheel 2 of the vehicle is engaged by a cleat 30 on the first
conveyor
12 12, the vehicle is pushed over the. transition 20,24. Where at least a
second
13 wheel 2 is engaged by a cleat 30 on the second conveyor 14, the vehicle is
14 pulled over the first and second transitions 20,24.
Each cleat 30, of the plurality of cleats 30, projects upwardly from
16 the belts 6a,6b,8a,8b sufficient to engage and push the wheel 2 with at
least
17 minimal cleat or transitioning force required for pushing, pulling, or
pushing and
18 pulling the vehicle to overcome at least the first resistance threshold R1
formed
19 when a transitioning wheel 2t engages one of either the first or second
transition
20,24.
21 If the cleat height is too low, the resistance force exceeds the
22 transitioning force and the cleat 30 will pass beneath a freewheeling wheel
2 in
23 lockstep with the wheel 2, lifting the wheel 2 and rotating the wheel 2
backwards
24 causing the vehicle to cease moving forward. In order for this to occur,
the
12
CA 02642915 2008-10-31
1 resistance force must also be greater than the total of a force vector
necessary
2 to lift a normal force of the vehicle supported by the wheel 2. Once lifted,
the
3 wheel 2 can then roll backward down a lee side of the cleat 30.
4 The cleat height is- therefore designed to be equal to or greater
than the first resistance threshold R1. The minimal cleat or transitioning
force is
6 minimally greater than a normal resistance force or first resistance
threshold R1
7 at a transition 20,24 to permit the cleat 30 to typically engage and push a
wheel
8 2 thereover. As a result of using only the minimal transitioning force, the
cleat 30
9 can pass beneath the wheel 2 in the case where there may be a temporary
spike
in the resistance force, and the wheel 2 can then be engaged by a subsequent
11 spaced cleat 30 for pushing the wheel 2 across the transition 20,24 when
the
12 resistance force returns to design levels.
13 Further, the cleats 30 extend upwardly therefrom sufficiently to
14 permit passage of the cleats 30 beneath at least some of the wheels 2 of
the
vehicle when remaining of the wheels 2 of the vehicle encounter the first
16 resistance threshold R1. For example the cleats 30 extend upwardly
therefrom a
17 sufficient height such that the cleats 30 are safely able to pass under the
rear
18 wheels 2R when at least one of the wheels 2 of the vehicle encounters a
higher
19 second resistance threshold R2. The higher second resistance threshold R2
might occur when front wheels 2F, in a locked state, exit the second conveyor
14
21 onto a fixed surface and freewheeling rear wheels 2R remain on the driven
22 second conveyor 14.
23 Additionally, the cleats 30 extend upwardly therefrom only a
24 sufficient height such that the cleats 30 are caused to pass under the rear
13
CA 02642915 2008-10-31
1 wheels 2R when at least one of the wheels 2 of the vehicle encounters a even
2 higher third resistance threshold R3. The even higher third resistance
threshold
3 R3 might occur when front wheels 2F, in a locked state, exit the second
4 conveyor 14 onto a fixed surface and locked rear wheels 2R remain on the
moving, second conveyor 14.
6 In the case of a vehicle where the wheels 2 are in a locked state,
7 the resistance force must exceed the total of the force vector and a
frictional
8 resistance force to drag the cleat 30 across the locked wheel's surface.
9 The second and third resistance thresholds R2, R3 are established
so that damage to the vehicle is avoided.
11 While the description provided thus far has been restricted to the
12 discussion of first and second pairs of belts 4,10 forming the first and
second
13 dual belt conveyors 12,14, one of skill in the art would appreciate that
14 embodiments of the invention are not limited to only two conveyors. It is
within
the scope of the invention to provide an infinite number of conveyors oriented
16 end-to-end and having transitions supported therebetween.
17 In operation, as shown in Figs. 9A-9G, 10A-10G, 11A1-11D5 and
18 12A1-12E5, an operator drives a vehicle onto the first dual belt conveyor
12. The
19 state of the vehicle can be non-rotational or locked, including placing the
drivetrain in Park or engaging the foot brake or emergency brake or can be
21 rotational or freewheeling, such as placing the drivetrain in Neutral.
22 In an embodiment of the invention, a first plurality of spaced cleats
23 30 are formed on the first side belt 6a of the first dual belt conveyor 12
and a
14
CA 02642915 2008-10-31
1 second plurality of spaced cleats 30 are formed on the second side belt 8b
of the
2 second dual belt conveyor 14.
3 In this embodiment, the first and second conveyors 12,14 are
4 driven for carrying the vehicle in the direction of travel T. A cleat 30 on
the first
side belt 6a is caused to engage at least one of a first front wheel 2F1 or a
first
6 rear wheel 2R1 on a first side of the vehicle. The cleat 30, having a design
height
7 as previously described, acts to push the engaged first front or first rear
wheel
8 2E as remaining wheels 2 sequentially encounter resistance force at the
9 transitions 20,24 and acts with at least the minimal transition force to
overcome
the resistance force so as to move the transitioning wheel 2t of the vehicle
over
11 the transitions 20,24.
12 If the cleat 30 on the first side belt 6a of the first conveyor 12
13 engages the first front wheel 2F1 (Fig. 11A1), the cleat 30 pushes a second
front
14 wheel 2F2 on the second side belt 6b, now the transitioning wheel 2t, over
the
second transition 24 (Fig. 11A2), after which the second front wheel 2F2 is
16 engaged by a cleat 30 on the second side belt 8b (Fig. 11A3) for
sequentially
17 pulling the remaining wheels 2, being the first front wheel 2F1 (Fig. 11A3)
and
18 both of a second rear wheel 2R2 and a first rear wheel 2R1, being the last
wheel
19 2L (Figs. 11 A4 and 11 A5), over the first and second transitions 20,24.
As shown in Figs. 11 B1-11 B5, if the cleat 30 on the first side belt
21 6a of the first conveyor 12 engages the first rear wheel 2R1 on the first
side of
22 the vehicle (Fig. 11131), the cleat 30 acts to sequentially push the second
front
23 wheel 2F2 (Fig. 11132), the first front wheel 2F1 (Fig. 11133) and the
first rear
24 wheel 2R1 (Fig. 11 B4) over the second and first transitions 20,24,
respectively.
CA 02642915 2008-10-31
1 Either the second front wheel 2F2 (Fig, 11 B5) or possibly the second rear
wheel
2 (not shown) thereafter engages a cleat 30 on the second side, cleated belt
8b of
3 the second conveyor 14 for pulling the first rear wheel 2R1, over the first
4 transition 20.
Alternatively, as shown in Figs. 11 C1-11 C5, if the cleat 30 on the
6 first side belt 6a of the first conveyor 12 engages the first rear wheel 2R1
on the
7 first side of the vehicle (Fig. 11 Cl), the cleat 30 acts to push the second
front
8 wheel 2F2 (Fig. 11 C2) over the second transition 24. The second front wheel
9 2F2 (Fig, 11 B5) may thereafter engage a cleat 30 on the second side cleated
belt 8b of the second conveyor 14 for sequentially pulling the first front
wheel
11 2F1 over the first transition 20, the second rear wheel 2R2 over the second
12 transition 24 and the first rear wheel 2R1 over the first transition 20.
13 Alternatively as shown in Figs. 11 D1-11 D5, if the cleat 30 on the
14 first side belt 6a of the first conveyor 12 engages the first rear wheel
2R1 (Fig.
11 D1) for pushing the second front wheel 2F2 over the second transition 24
(Fig.
16 11 D2) as previously described, the first rear wheel 2R1 may remain engaged
17 with the cleat 30 on the first side belt 6a when the second front wheel 2F2
18 engages a cleat 30 on the second side belt 8b of the second conveyor 14
(Fig.
19 11 D3), the two engaged wheels 2R1,2F2 thereafter act together to push and
pull
the first front wheel 2F1 (Fig. 11 D3) and the second rear wheel 2R2 (Fig. 11
D4)
21 over the first and second transitions 20,24, respectively, Once the first
rear
22 wheel 2R1 reaches the first transition 20, only the second front wheel 2F2
23 remains engaged with the cleat 30 on the second side belt 8b of the second
16
CA 02642915 2008-10-31
1 conveyor 14 and it acts to pull the remaining first rear wheel 2R1 over the
first
2 transition 20 (Fig. 11 D5).
3 In an embodiment of the invention shown in Figs. 12A1-12E5, a
4 plurality of spaced cleats 30 are formed on either of the first or second
side belt
6a,6b of the first conveyor 12 and on the same side, being the first or second
6 side belt 8a,8b on the second conveyor 14. Thus only wheels 2 on one side of
7 the vehicle are engaged by the cleats 30 for pushing and pulling the vehicle
over
8 the transitions 20,24.
9 If the cleat 30 on the first side belt 6a of the first conveyor 12
engages the first front wheel 2F1 (Fig. 12A1), the cleat 30 pushes the second
11 front wheel 2F2 on the second side belt 6b over the second transition 24
(Fig.
12 12A2). When the first front wheel 2F1 engages the first transition 20 (Fig.
12A3),
13 the first rear wheel 2R1 is engaged by a cleat 30 on the first side belt 6a
for
14 pushing the first front wheel 2F1 over the first transition 20. The first
rear wheel
2R1 remains engaged with the cleat 30 for pushing the second rear wheel 2R2
16 over the second transition 24 (Fig. 12A4) after which the first front wheel
2F1
17 engages a cleat 30 on the first side belt 8a of the second conveyor 14
(Fig.
18 12A5) for pulling the first rear wheel 2R1, being the last wheel 2L (Figs.
11A4
19 and 11A5), over the first transition 20.
Alternatively, as shown in Figs.12B1-12B5, if the cleat 30 on the
21 first side belt 6a of the first conveyor 12 engages the first front wheel
2F1 (Fig.
22 12B1), the cleat 30 pushes the second front wheel 2F2 on the second side
belt
23 6b over the second transition 24 (Fig. 12B2). When the first front wheel
2F1
24 engages the first transition 20 (Fig. 12B3), the first rear wheel 2R1 is
engaged by
17
_ _ ,
CA 02642915 2008-10-31
1 a cleat 30 on the first side belt 6a for pushing the first front wheel 2F1
over the
2 first transition 20. The front wheel 2F1 thereafter engages with the cleat
30 on
3 the first side belt 8a of the second conveyor 14 for pulling the second rear
wheel
4 2R2 (Fig.12B4) over the second transition 24 and the first rear wheel 2R1,
being
the last wheel 2L (Fig. 12155), over the first transition 20.
6 As shown in Figs. 12C1-12C5, if the cleat 30 on the first side belt
7 6a of the first conveyor 12 engages the first rear wheel 2R1 on the first
side of
8 the vehicle (Fig. 12C1), the cleat 30 acts to sequentially push the second
front
9 wheel 2F2 (Fig. 12C2), the first front wheel 2F1 (Fig. 12C3) and the first
rear
wheel 2R1 (Fig. 12C4) over the second and first transitions 20,24,
respectively.
11 Thereafter, the first front wheel 2F1 (Fig, 11 B5) engages a cleat 30 on
the first
12 side belt 8a of the second conveyor 14 for pulling the first rear wheel
2R1, over
13 the first transition 20.
14 Alternatively, as shown in Figs. 12D1-12D5, if the cleat 30 on the
first side belt 6a of the first conveyor 12 engages the first front wheel 2F1
on the
16 first side of the vehicle (Fig. 12D1), the cleat 30 acts to push the second
front
17 wheel 2F2 (Fig. 12D2) over the second transition 24. When the first rear
wheel
18 2R1 engages the first transition 20, the first rear wheel 2R1 engages a
cleat 30
19 on the first side belt 6a of the first conveyor for pushing the first front
wheel 2F1
over the first transition 20. Thereafter, the first front wheel 2F1 may engage
a
21 cleat on the first side belt 8a of the second conveyor 14, the first rear
wheel 2R1
22 remaining engaged with a cleat 30 and thus the second rear wheel 2R2 is
both
23 pushed and pulled over the second transition 24. As soon as the first rear
wheel
18
CA 02642915 2008-10-31
1 2R1 reaches the first transition, it releases the cleat 30 and the first
rear wheel
2 2R1 is pulled over the first transition 20.
3 Alternatively, as shown in Figs. 12E1-12E5, if the cleat 30 on the
4 first side belt 6a of the first conveyor 12 engages the first rear wheel 2R1
(Fig.
12E1) for pushing the second front wheel 2F2 over the second transition 24
(Fig.
6 12E2) and the first front wheel 2F1 over the first transition 20 (Fig.
12E3), as
7 previously described, the first rear wheel 2R1 may remain engaged with the
cleat
8 30 on the first side belt 6a when the first front wheel 2F1 engages a cleat
30 on
9 the first side belt 8a of the second conveyor 14 (Fig. 12E4). The two
engaged
wheels 2R1,2F1 thereafter act together to push and pull the second rear wheel
11 2R2 (Fig. 112E4) over the first and second transitions 20,24, respectively,
Once
12 the first rear wheel 2R1 reaches the first transition 20 (Fig. 12E5), only
the first
13 front wheel 2F1 remains engaged with the cleat 30 on the first side belt 8a
of the
14 second conveyor 14 and it acts to pull the remaining first rear wheel 2R1
over
the first transition 20 (Fig. 12E5).
16 In the case where the plurality of spaced cleats 30 are formed on
17 all of the belts 6a,6b,8a,8b, the spacing of the cleats 30 between the
first side
18 belt 6a,8a and the second side belt 6b,8b of the first and the second
conveyors
19 12,14 are preferably synchronized. Any number or all of the wheels 2 of the
vehicle may be engaged by a cleat 30 on any of the cleated belts 6a,6b,8a,8b
for
21 pushing the wheels 2. Depending upon which of the wheels are engaged and
22 with which cleats 30, the wheels 2 of the vehicle are pushed and pulled
over the
23 transitions 20, 24, the last transitioning wheel 2L being pulled over the
second
24 transition 24.
19
CA 02642915 2008-10-31
1 In embodiments of the invention particularly suited for cold
2 climates, best seen in Figs. 3-7 and 8A-8F, each of the first and second
3 transitions 20,24 further comprises a loop 40 of recirculation rollers 42
positioned
4 in the gap 22,26 between the first conveyor 12 and the second conveyor 14
and
extending across a width of the transition 20, 24. The loop 40 is positioned
6 between the fixed intake roller 44 and the fixed discharge roller. The loop
40 is
7 oriented so that the loop 40 is passively rotatable in the direction of
travel T,
8 each of the rollers 42 therein also being rotatable so as to break up any
ice
9 which tends to form thereon.
In embodiments of the invention the rollers 42 are made of
11 stainless steel, such as recirculation rollers 42 available from Hillman
Rollers,
12 Marlboro, N.J., 07746, USA.
13 The fixed intake roller 44 forms a discharge gap 46 between the
14 discharge ends 23,27 of each of the first and second side belts 6a, 6b of
the first
dual belt conveyor 12 and the loop 40 of recirculation rollers 42 of the first
and
16 second transitions 20, 24, respectively. The fixed discharge roller 48
forms an
17 intake gap 50 between the loop 40 of recirculation rollers 42 of the first
and
18 second transitions 20, 24 and the intake ends 25,28 of each of the first
and
19 second side belts 8a, 8b of the second dual belt conveyor 14. The fixed
intake
and fixed discharge rollers 44,48 are sized so as to substantially fill the
21 discharge gap 49 and the intake gap 50 while leaving sufficient space
therein to
22 permit unimpeded passage of the endless belts 6a,6b,8a,8b and the cleats 30
23 thereby.
_ _ ,
CA 02642915 2008-10-31
1 In an embodiment of the invention, the fixed intake roller 44, the
2 loop 40 of recirculation rollers 42 and the discharge roller 48 form a set
of
3 transition rollers 52 having a limited length dictated by the load the set
of
4 transition rollers 52 can support. A plurality of sets of transition rollers
52 are
positioned substantially parallel and side-by-side across the length of the
gap
6 22,26 for forming the transition 20,24 to extend across a width of each
belt. A
7 width of each of the plurality of recirculation rollers 42 and the plurality
of fixed
8 intake and fixed discharge rollers 44,48 is selected such that each wheel 2
on
9 the vehicle contacts at least a portion of each of two recirculation rollers
42,42,
two fixed intake rollers 44,44 and two fixed discharge rollers 48,48 as the
wheel
11 2 crosses the transition 20,24, regardless the positioning of the wheel 2
across
12 the length of the transition 20,24.
13
14 EXAMPLE A
In one example, as shown in Figs. 1-7, embodiments of the
16 invention are used in a car wash to move a vehicle into and through a wash
17 tunnel 70. The first pair 4 of substantially parallel endless first 6a and
second 6b
18 side belts form an entrance conveyor 12 which extends from external the
wash
19 tunnel 70 and into an entrance 72 of the wash tunnel 70 and onto which the
operator drives the vehicle.
21 Once inside the entrance 72 of the wash tunnel 70, a second pair
22 10 of substantially parallel endless first 8a and second 8b side belts
forms a
23 wash conveyor 14 which is oriented end-to-end with the entrance conveyor
12.
24 First and second transitions 20,24 according to an embodiment of the
invention
21
, . .
CA 02642915 2008-10-31
1 are supported between the first side belt 6a of the entrance conveyor 12 and
the
2 first side belt 8a of the wash conveyor 14 and the second side belt 6b of
the
3 entrance conveyor 12 and the second side belt 8b of the wash conveyor 14.
The
4 vehicle is transferred from the entrance conveyor 12, over the transitions
20,24
and onto the wash conveyor 14, by the motion of the conveyors 12,14 in the
6 direction of travel T and by the action of the cleats 30 to provide at least
a
7 minimal transitioning force to overcome at least a resistance force
encountered
8 as each of the wheels 2 of the vehicle sequentially reach and engage the
first
9 and second transitions 20,24.
The vehicle can be placed in neutral (freewheeling state) or in park
11 or the foot brakes or emergency brake can be applied (locked state) without
12 affecting the operation of the car wash's conveyors 12,14 to move the
vehicle
13 through the car wash.
14 The height to which the cleats 30 project upwardly from the belts
6a,6b,8a,8b of the conveyors 12,14 is finely balanced to provide the at least
the
16 minimal transitioning force to overcome the resistance force while
minimizing the
17 49,50 required between the transitions' fixed intake rollers 44 and fixed
18 discharge rollers 48 and the cleats 30 for permitting passage of the cleats
30 and
19 belts 6a,6b,8a,8b thereby. If the cleat 30 does not extend high enough, the
resistance force may permit the wheel 2 to roll backward over the cleat 30 as
the
21 wheel 2 engages the transition as previously described. If however, the
cleat is
22 higher to increase the transitioning force, causing the gaps 49,50 to be
much
23 larger, the resistance force may become too great and the transition force
of the
22
CA 02642915 2008-10-31
1 higher cleat is insufficient to overcome the greater resistance force as
previously
2 discussed.
3 Should there be additional, instantaneous resistance at the
4 moment a wheel 2 reaches a transition 20,24, the engaged cleat 30E may not
be
able to provide sufficient transition force to overcome the instantaneous
6 resistance force. The cleat would therefore be unable to push the wheel 2
onto
7 and over the transition 20,24. In this case, the engaged cleat 30E may be
8 caused to slip under the wheel 2. The wheel 2 is then engaged up by a
following
9 cleat 30 which, provided the resistance force has returned to a design
magnitude, will cause the wheel 2 to be moved onto and over the transition
11 20,24.
12 The transition force caused by the cleats 30 pushing on a wheel 2
13 acts as either a vehicle pushing force or a vehicle pulling force depending
upon
14 which of the cleats 30 on which of the belts 6a,6b,8a,8b engages at least
one
wheel 2 of the vehicle.
16 The first and second side belts 6a,6b,8a,8b of the entrance and
17 wash conveyors 12,14, referred to as "the belts" for the purposes of the
following
18 discussion, are supported above a floor 74 of the car wash tunnel by a
support
19 frame system 76 such as is understood by one of skill in the art. Each of
the
belts 6a,6b,8a,8b is about 896 mm (about 35 inches) in width. The belts
21 6a,6b,8a,8b of each of the entrance and wash conveyors 12,14 are spaced
22 about 710 mm (about 28 inches) apart. Thus, each conveyor 12,14 is capable
of
23 supporting thereon a wide range of vehicles having from a minimum to a
24 maximum known wheel base. Further, if the driver does not center the
vehicle on
23
CA 02642915 2008-10-31
1 the belt 6a,6b,8a,8b, regardless how far to one edge or the other of the
belts
2 6a,6b,8a,8b the vehicle is positioned, the wheels 2 will be engaged by both
of
3 the belts 6a,6b,8a,8b regardless a width of the vehicle from wheel 2F1,2R1
to
4 wheel 2F2, 2R2.
The first and second transitions 20,24 are offset from each other
6 along the direction of travel by about 520 mm (about 20 inches) such that,
even
7 when a vehicle has a short wheel base, only one wheel 2 of the vehicle will
8 engage and cross one transition 20,24 at any one time. The remaining wheels
2
9 provide at least three points of contact between the vehicle and the belts
6a,6b,8a,8b for maintaining vehicle positioning on the belts 6a,6b,8a,8b and
11 reduce the resistance force encountered by the vehicle at the transitions
20,24.
12 Particularly advantageous in a car wash embodiment, the action of
13 the recirculation rollers 42 acts to break up and prevent ice build up at
the
14 transitions 20,24 when used in climates which are susceptible to freezing
temperatures.
16 In an embodiment of the invention, the support frame system 76 is
17 positioned within a trench in the wash tunnel 70. A plurality of cleats 30
are
18 spaced about 320mm (about 13 inches) 63.5 mm (2.5 inches) apart along a
19 length of the first side belt 6a of the first conveyor 12 and the opposing
second
side belt 8b of the second conveyor 14. The cleats 30 in cross-section are
21 arcuate in profile to assist the cleat to pass under the wheels 2 of the
vehicle
22 should it be necessary to do so. The cleats 30 project upwardly about 12.5
mm
23 (about 0.49 inch) to engage the wheels 2 of the vehicle and prevent the
vehicle
24 when placed in neutral, from rolling backward on the entrance conveyor 12,
24
_ , ,
CA 02642915 2008-10-31
1 particularly when the entrance conveyor 12 is put into motion. Further, the
cleats
2 30 extend transversely across substantially an entirety of the width of the
belt
3 6a,6b,8a,8b.
4 In one embodiment of the invention, the cleats 30 and at least
portions of the belts 6a,6b,8a,8b may be perforated to permit drainage of wash
6 fluids therethrough. The endless belts 6a,6b,8a,8b are modular plastic belts
7 formed using a plurality of interconnected links upon which the cleats 30
are
8 formed or otherwise attached thereto.
9 The entrance and wash conveyors 12,14 are generally sloped
about 12mm (0.49 inches) to about 19mm (0.75 inches) over the length of the
11 entrance and wash conveyors, being about 25 m (82 feet), to encourage
12 drainage and aid in ensuring forward momentum of the vehicle.
13 Having reference to Fig. 13, a plurality of return rollers 80 extend
14 transversely beneath a lower, return portion 82 of each of the endless
belts
6a,6b,8a,8b for supporting the return portion 82 thereon. The plurality of
return
16 rollers 80 are variably spaced along a length of each of the belts
6a,6b,8a,8b so
17 as to minimize harmonics which can occur such as when the plurality of
return
18 rollers 80 are spaced evenly therealong. Typically, there is a certain
amount of
19 slack tolerated in the return portion of the belts 6a,6b,8a,8b as a result
of belt
elasticity, expansion and contraction, resulting from changes in temperature,
21 wear conditions and the like. The variably spaced return rollers 80 support
the
22 return portion 82 of the belts 6a,6b,8a,8b thereon so as to minimize the
23 harmonic effects in the return portion 82 between the plurality of variably
spaced
24 return rollers 80 for maximizing smooth operation of the belts 6a,6b,8a,8b.
CA 02642915 2008-10-31
1 In the embodiment of the invention shown in Fig. 13, the plurality of
2 return rollers 80 are variably spaced along the length of the belt's return
portion
3 82 as shown in Table A.
4
Table A
Return portion belt Spacing between return Spacing between return
segment rollers (inches) rollers (m)
a 43.6 1.107
b 78.5 1.994
c 35.5 0.902
d 36.5 0.927
e 35.5 0.902
f 36.2 0.919
36.0 0.914
h 36.0 0.914
i 35.5 0.902
36.5 0.927
k 35.5 0.902
1 36.5 0.927
m 36.0 0.914
n 32.5 0.826
0 35.0 0.889
45.0 1.143
35.0 0.889
r 30.0 0.762
s 22.2 0.564
6
7 Further, a diameter of the return rollers 80 is larger than
8 conventionally used so as to permit the cleats 30 on the outer surface 32 of
the
9 belts 6a,6b,8a,8b to climb the return rollers 80 with minimal impedance of
the
motion of the belts 6a,6b,8a,8b thereover.
11 In an embodiment of the invention shown in Fig. 14, it is
12 contemplated to use three dual belt conveyors, such as the entrance
conveyor
13 12, the wash conveyor 14 and a discharge conveyor 90. The discharge
conveyor
26
CA 02642915 2008-10-31
1 90 is a dual belt conveyor comprising a third pair 91 of first side and
second side
2 belts 9a,9b oriented end-to-end to the first and second side belts 8a,8b of
the
3 wash conveyor 14. A third transition 92 and a fourth transition 94 are
positioned
4 between the first side belt 8a of the wash conveyor 12 and the first side
belt 9a
of the discharge conveyor 90 and the second side belt 8b of the wash conveyor
6 12 and the second side belt 9b of the discharge conveyor 90, respectively. A
7 discharge end 96 of the discharge conveyor 90 causes the vehicle to be
8 discharged onto a fixed surface located outside an exit 98 of the wash
tunnel 70.
9
EXAMPLE B
11 Design of an optimum cleat height, as previously described, finely
12 balances the height of the cleat so as to provide at least a minimum
transitioning
13 force to push against a wheel of the vehicle to overcome at least a first
minimum
14 resistance threshold acting against another wheel of the vehicle at either
of the
first or second transition.
16 A worst case scenario for design of the cleat height is a vehicle
17 having small wheels, where more of the wheel is engaged by the gaps and
18 therefore the resistance is greater to the forward movement of the wheel
over
19 the transitions.
In one embodiment of the invention, an optimum cleat height was
21 determined for a 1989 Pontiac Firefly having a tire size of 33 cm (13
inches).
22 As Table B illustrates, increasing the cleat height to attempt to
23 achieve a greater pushing or transitioning force requires an increase in
the
24 discharge and intake gaps so as to permit the higher cleat to pass thereby.
The
27
CA 02642915 2008-10-31
1 increase in the gap size required to accommodate the higher cleat results in
an
2 increased resistance force acting against the wheels of the vehicle.
3
4 Table B
Cleat Height Gap mm Resistance Transitioning
Force Force
mm *Roller/Cleat *Roller/Belt lbs lbs
0 3.5 3.5 15-20 0
2.5 3.5 6 15-20 5
3.5 8.5 15-20 10
7.5 3.5 11 20-25 15
3.5 13.5 25-30 25
12.5 3.5 16 30-40 40
3.5 18.5 40-60 55
17.5 3.5 21 60-90 75
5
6 * "Roller" refers to the fixed intake or discharge rollers
7
8
9 As one of skill would appreciate, an optimum height of 12.5 mm is
10 minimally sufficient to overcome the resistance force during normal
operations.
11 Cleat heights of less than 12.5 mm do not provide sufficient transitioning
force to
12 overcome the resistance force. Increasing the cleat height above 12.5mm
results
13 in a transitioning force which may be insufficient over the complete range
of the
14 resistance force and therefore is unreliable to transition a wheel of the
vehicle
15 during operation.
28
