Note: Descriptions are shown in the official language in which they were submitted.
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CONVEYOR ASSEMBLY
FIELD
[0001] The present disclosure relates to the field of conveyor systems
for
transporting wheeled structures, and in particular to a conveyor system
incorporating a heater to provide heat to at least a portion thereof.
BACKGROUND
[0002] Conveyor systems have long been used to assist in the transport
of
materials from one location to another, in particular with respect to heavy
and
cumbersome items. The use of conveyor systems in assembly lines is well
documented, with perhaps Henry Ford being the most famous proponent of the
technology of the 20th century.
[0003] Conveyors come in a variety of configurations, suiting a wide
array of
implementations. Belt conveyors in particular have been widely adopted due to
their wide versatility and adaptability. For example, belt conveyors are
commonly
used in the warehousing, manufacturing, and mining sectors. More recently,
belt
conveyors have found application in the automotive industry, in particular
with
respect to automated car wash stations.
[0004] A recent advancement in automated car washes is the synchronous
dual-belt conveyor system for moving the vehicle through the wash tunnel. The
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dual-belt system is especially suited for modern vehicles as the previous
roller
conveyor system with alignment rails has the potential to interfere with low
profile
rims and lower underbody clearance. The older roller conveyor system also
required more alignment precision when entering the wash tunnel, resulting in
many car owners turning to alternate cleaning options.
[0005] With the introduction of the dual-belt car wash conveyor
system, and
the adoption of this technology in an increasing number of car wash stations,
new challenges are faced, in particular with respect to cold weather
installations.
During winter months in regions of colder temperatures, the wash tunnels may
experience freeze events in which water freezes upon the belt and underlying
substructure. The shear loads placed upon the conveyor drive mechanisms can
be considerable, leading to damage and servicing down-time.
[0006] It is recognized that a need still exists to provide a
conveyor system
capable of operating in regions of colder temperature with lower risks
associated
with freeze events.
SUMMARY
[0007] According to an aspect of an embodiment, a conveyor
system for use
in moving a wheeled structure through a service line is provided. The conveyor
system comprises at least one endless belt mounted in a longitudinal direction
through the service line. The endless belt has an upper transport portion
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adapted to move the vehicle through the service line, and a lower return
portion.
A support deck is positioned below the upper transport portion of the endless
belt
to support the endless belt. A debris deflector is mounted between the upper
transport portion and the lower return portion of the endless belt to protect
the
lower return portion from debris falling through the support deck. A heater is
mounted between the debris deflector and the support deck along at least a
portion of a longitudinal length of the service line. The debris deflector and
the
support deck define a region of higher heat concentration relative to an area
below the debris deflector, within which heat emitted from the heating means
is
directed towards the support deck.
BRIEF DESCRIPTION OF FIGURES
[0008]
The foregoing and other features and advantages of the disclosure will
be apparent from the following description of embodiments hereof as
illustrated
in the accompanying drawing. The
accompanying drawings, which are
incorporated herein and form a part of the specification, further serve to
explain
the principles of the disclosure and to enable a person skilled in the
pertinent art
to make and use the disclosure. The drawings are not to scale.
[0009]
Fig. 1 is a plan view of the conveyor system according to an
embodiment hereof.
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_
[0010] Fig. 2a is a partial side sectional view of the
conveyor system
according to the embodiment of Fig. 1.
[0011] Fig. 2b is a partial side sectional view of the
conveyor system with
reference to line 2b-2b of Fig. 2a.
[0012] Fig. 2c is a partial side sectional view of the conveyor system with
reference to line 2c-2c of Fig. 2a.
[0013] Fig. 3a is a partial isometric view of the conveyor
system according to
the embodiment of Fig. 1, highlighting features of the conveyor frame.
[0014] Fig. 3b is a partial isometric view of the conveyor
system with
reference to line 3b-3b of Fig. 3a.
[0015] Fig. 4 is a partial transverse sectional view of the
conveyor system
according to Fig. 1, highlighting features in the region of the endless belt.
DETAILED DESCRIPTION
[0016] The following detailed description is merely exemplary in nature and
is
not intended to limit the disclosure or the application and uses of the
disclosure.
A person skilled in the relevant art will recognize that other configurations
and
arrangements can be used without departing from the scope of the disclosure.
Furthermore, there is no intention to be bound by any expressed or implied
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theory presented in the preceding technical field, background, brief summary,
or
the following detailed description.
[0017] Reference is made to Fig. 1, which shows a service line 10
having a
conveyor system 20 for moving a wheeled structure 11, in accordance with an
embodiment. As used herein, the term service line is not intended to be
restrictive, and may encompass for example an automatic vehicle wash station
(e.g. for cars, commercial trucks, etc.), a manufacturing or assembly line
(e.g. for
cars, trucks, non-powered mobile units, etc.) as well as a repair or detailing
station (e.g. for cars, trucks, etc.). In addition, the term wheeled structure
is not
intended to be restrictive, and may encompass for example powered landborne
vehicles (e.g. trucks, automobiles, tractors, recreational vehicles, etc.),
non-
powered landborne mobile units (e.g. recreational trailers, utility trailers,
etc.),
and airborne vehicles (e.g. airplanes, etc.).
[0018] The conveyor system 20 is adapted to transport a wheeled
structure
along a longitudinal length of the service line 10. As presented in Fig. 1,
service
line 10 is shown in the form of a car wash station having a wash tunnel 22.
Accordingly, the conveyor system 20 includes a service zone 24 within the
region
of the wash tunnel 22 through which the vehicle is transported for a wash
cycle.
The conveyor system 20 also includes a loading zone 26 adjacent a tunnel
entrance 28, where vehicles align and initially load onto the conveyor system
20.
[0019] The conveyor system 20 is configured as a dual-belt system
comprising a pair of endless belts mounted in a longitudinal direction through
the
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service line 10. The endless belts 36a, 36b are positioned in parallel and
spaced-apart relationship relative to one another through the loading and
service
zones 26, 24. In the region between the pair of endless belts 36a, 36b, there
may be positioned a central stationary platform 38 of removable panels that
permit access to regions under the pair of endless belts 36a, 36b, in
particular for
servicing and maintenance. It will be appreciated that where the conveyor
system 20 is provided with two or more endless belts to transport the wheeled
structure along the service line 10, the endless belts will move in
synchronous
motion. As the arrangement for each of the endless belts 36a, 36b is
substantially identical, the endless belts 36a, 36b are herein collectively
referred
to as the endless belt 36 unless otherwise specified.
[0020] Turning now to Figs. 2a, 2b and 2c, the conveyor system 20 is
generally supported within a trench 40 having a depth suitable to house the
required drive and guide mechanisms, and to permit manoeuvrability to service
personnel. The endless belt 36 has an upper transport portion 42 and a lower
return portion 44, and extends along the conveyor system 20 between a drive
end 46 and an idler end 48. The drive end 46 and idler end 48 provide axially
elongated rollers 50, 52 rotatably supported on a conveyor frame 54, to guide
the
endless belt 36 around the respective drive and idler ends 46, 48.
[0021] The drive end 46 includes a drive module 56 adapted to engage and
move the endless belt around the drive and idler ends 46, 48. The drive module
56 may be an electric motor as shown, and may include at least one drive
member 58 to engage the endless belt 36 and move it around the respective
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drive and idler ends 46, 48. As shown, the drive member 58 is provided in the
form of a sprocket drum 60 adapted with teeth 62 to engage complementary
tracks (not shown) on the inward surface 64 of the endless belt 36. The
conveyor system 20 will additionally include guide members 66 supported upon
the conveyor frame 54 to support the lower return portion 44 of the endless
belt
36 as it moves back towards the idler end 48 on the underside of the conveyor
system 20. As shown, the guide members 66 are provided in the form of rollers.
[0022] In motion, the upper transport portion 42 of the endless belt 36
moves
in tension from the idler end 48 towards the drive end 46 by drive member 58,
while the lower return portion 44 moves in a slackened state from the drive
end
46 towards the idler end 48.
[0023] Turning now to Figs. 3a and 3b, shown is an enlarged view of the
conveyor system 20 with the endless belt 36 and associated support structure
removed to highlight features of the conveyor frame 54. The conveyor frame 54
includes a plurality of cross-members 68 positioned transversely relative to
the
longitudinal direction of the service line 10. The cross-members 68 are
dimensioned to span the width of the trench 40, and are adapted to mount on
opposing surfaces 70, 72. Each cross-member 68 also provides at least one
footing 74 at approximately a midpoint thereof, extending to a floor 76 of the
trench 40 to provide additional load-bearing performance to the conveyor frame
54.
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[0024] Arranged in the longitudinal direction, the conveyor frame 54
additionally provides a plurality of support rails that extend the
longitudinal length
of the service line 10, from the idler end 48 to the drive end 46. The support
rails
are arranged as two inner support rails 78a, 78b and two outer support rails
80a,
80b. The inner support rails 78a, 78b are generally positioned symmetrically
about the longitudinal centerline of the service line 10, while the two outer
support rails 80a, 80b are situated proximal to the longitudinal walls of the
trench
40. The inner support rails 78a, 78b and the outer support rails 80a, 80b may
be
fixedly attached in place by rivets, threaded fasteners (e.g. bolts),
metallurgic
bonding (e.g. welded attachment) or any other suitable means to achieve a
secure attachment.
[0025] Having reference to Fig. 4, the inner support rails 78a, 78b
cooperatively define a gap spacing for the central stationary platform 38
provided
between the endless belts 36a, 36b. The inner support rails 78a, 78b each
provide a respective seat 82a, 82b configured to receive and support the
central
stationary platform 38. In the embodiment shown, the central stationary
platform
38 is provided in the form of fiberglass or thermoplastic grating. In
addition, for
each endless belt 36, the respective opposing inner and outer rails 78a, 80a
define a gap spacing to receive a support deck 84. The support deck 84
generally includes a plurality of modular grid panels 86 adapted to be
positioned
end to end relative to one another along the longitudinal length of the
service line
10. The modular grid panels are provided with a length that aligns the point
of
contact between adjacent grid panels on a transverse cross-member 68,
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providing weight-bearing support thereto. The support deck 84 is positioned
between the upper transport portion 42 and lower return portion 44 of the
endless
belt 36, generally in close proximity to the upper transport portion 42. In
this way,
the support deck 84 provides support to the upper transport portion 42 of the
endless belt 36, and thereby a load placed thereon from a wheeled structure
placed upon the conveyor system 20. To facilitate sliding of the endless belt
over
the support deck 84, a wear plate 88 may be provided between the upper
transport portion 42 and the support deck 84. The arrangement of the inner and
outer support rails 78a, 78b, 80a, 80b may additionally be used to mount the
1(:) guide member 66 supporting the lower return portion 44 of the endless
belt 36.
As shown, the inner and outer support rails 78a, 80a provide respective guide
hangers 90, 92 that support the guide member 66 in a transverse direction
relative to the longitudinal direction of the service line 10. As shown, the
guide
member 66 is provided with a plurality of rollers 94 that support an outward
surface 96 of the endless belt 36 along the lower return portion 44.
[0026] Continuing with Fig. 4, also provided between the upper
transport
portion 42 and the lower return portion 44 of the endless belt 36, and in
particular
between the support deck 84 and the lower return portion 44 is a debris
deflector
98. The debris deflector 98 provides a barrier to protect the lower return
portion
44 from debris falling from the support deck 84, in particular where the
support
deck 84 is provided in the form of the modular grid panels. The debris
deflector
98 is generally mounted on an angle directed downwardly towards the
longitudinal centerline of the service line. The debris deflector 98 may be
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mounted on dedicated brackets, or may be mounted on the guide hangers 90, 92
used for supporting the guide members 66 (as shown). The debris deflector 98
is
generally configured to provide a contiguous barrier between adjacent cross-
members, so as to maximize the protection from falling debris. In some
embodiments, the debris deflector 98 may be provided in the form of multiple
panels arranged and fastened in side-by-side relationship to one another.
[0027] It will be recognized that the arrangement of the support deck
84, the
debris deflector 98 and the longitudinally-spaced cross-members 68 define a
partial enclosure in the region between the upper transport portion 42 and the
lower return portion 44 of the endless belt 36. To assist in reducing the
likelihood
of freezing conditions on the conveyor system 10, in particular sections
exposed
to the outside environment, such as the loading zone 26 shown in Fig. 1, at
least
a portion of the conveyor system 20 may include a heater in these partial
enclosures between adjacent cross-members 68. Referring to Figs. 3 and 4, the
conveyor system 20 provides a heater 100 positioned between the support deck
84 and the debris deflector 98, extending in the longitudinal direction across
one
or more of the partial enclosures delimited longitudinally between adjacent
cross
members 68. Accordingly, the partial enclosures containing the heater 100
provide a region of higher heat concentration relative to other areas within
the
trench 40, in particular the area below the debris deflector 98. In this way,
the
support deck 84, the endless belt 36 supported thereon, and the wear plate 88
positioned therebetween receive heat from the region of higher heat
concentration, thereby reducing the likelihood of a freeze event in the
conveyor
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system 20. It will be appreciated that freeze events in conveyor systems can
result in extensive damage to the endless belt 36 and/or drive module 56.
[0028] To enable passage of the heater 100 between adjacent partial
enclosures separated by the cross-members 68, the cross-members 68 are
adapted with one or more pass-through apertures 102, depending on whether
the heater is adapted to pass once through the desired heated portion, or in a
serpentine path therethrough. In the embodiment shown in Fig. 4, two pass-
through apertures are provided for each side of the conveyor system 20.
[0029] It will be appreciated that the heater 100 may take on a variety
of
forms. For example, the heater 100 may be configured as a convective heater,
such as a convective tube heater including both smooth and finned-tube
varieties. A convective tube heater will generally be part of a fluid circuit
having
an electric or gas-fired heater module to deliver a heated fluid therein. The
heater 100 may also be configured as a radiant heater such as a gas-fired
radiant tube heater.
[0030] The debris deflector 98 may be formed from any suitable material
including but not limited to metal (e.g. steel, aluminum, etc.),
thermoplastics (e.g.
polypropylene, polyethethylene, etc.) and composites. To promote direction of
the emitted heat from heater 100 towards the support deck 84, the debris
deflector 98 may be adapted with at least a selected level of thermal
reflectivity.
The thermal reflectivity may be achieved by constructing the debris deflector
98
in the form of a radiant barrier. Alternatively, a radiant barrier may be
separately
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formed and applied to the debris deflector 98, for example in the form of a
thin
radiant barrier sheet attached thereto. Radiant barriers are typically highly
reflective materials (e.g. aluminum or polished stainless steel foil) applied
to a
substrate. Exemplary substrates may include kraft paper, oriented strand
board,
plastic films and plywood. For environments that experience high moisture
levels, for example a car wash tunnel, the substrate may be of metal or
thermoplastic construction. Exemplary thermoplastic substrates may include
polypropylene or polyethylene foam core. In general, the material applied to
the
substrate should exhibit an emittance of less than 0.25, as measured by ASTM
C1371. In addition to polished metallic films, low-emittance coatings such as
metal oxide may be used on a suitable substrate. It will be appreciated that
the
side of the debris deflector 98, or separately formed sheet, facing the
support
deck 84 is the side adapted to receive the highly reflective material. In
other
words, the highly reflective material, and thus the effective side of the
radiant
barrier is intended to face the region of higher heat concentration between
the
debris deflector 98 and the support deck 84.
[0031] It will be appreciated that, although embodiments of the
disclosure
have been described and illustrated in detail, various modifications and
changes
may be made. While preferred embodiments are described above, some of the
features described above can be replaced or even omitted. Still further
alternatives and modifications may occur to those skilled in the art. All such
alternatives and modifications are believed to be within the scope of the
disclosure.
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