Note: Descriptions are shown in the official language in which they were submitted.
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METHOD AND SYSTEM FOR CONVEYING ARTICLES
AND AN APPARATUS FOR DOING THE SAME
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of priority from U.S. Provisional Patent
Application No. 63/165,533, filed on March 24, 2021, the entire disclosure of
which is
incorporated by reference herein in its entirety. [Are we including the new
matter from 4499-
7-CIP-CON-2-CIP-2 in this application? If so, then this should claim priority
to that app:
17/380,993 filed 7/20/21 ¨ make sure the PCT Request claims priority to this
application.]
[Missing 4499-7-CIP-CON-2-CIP = 16/675,105 filed 11/5/19 and now issued.
Please add: U.S. Patent Application Serial No. 16/675,105, filed on November
5, 2019 (now
U.S. Patent No. 11,066,243), which is a Continuation-In-Part Application of
and claims the
benefit of priority from] This application is related to and incorporates by
reference the
entire disclosures of the following applications and patents: U.S. Patent
Application Serial
No. 16/119,804, filed August 31, 2018 (now U.S. Patent No. 10,464,754), which
is a
Continuation Application of and claims the benefit of priority from U.S.
Patent Application
Serial No. 15/673,014, filed on August 9, 2017 (now U.S. Patent No.
10,065,801), which is
a Continuation Application of U.S. Patent Application Serial No. 15/041,668,
filed on
February 11, 2016 (now U.S. Patent No. 9,745,133, issued August 29, 2017),
which is a
Continuation Application of U.S. Patent Application Serial No. 14/641,126,
filed on March
6, 2015 (now U.S. Patent No. 9,260,247, issued February 16, 2016), which is a
Continuation
in Part Application of U.S. Patent Application Serial No. 14/154,141, filed on
January 13,
2014 (now U.S. Patent No. 9,061,830, issued June 23, 2015), which claims
priority from
U.S. Provisional Patent Application No. 61/751,722, filed on January 11, 2013.
FIELD OF THE INVENTION
The invention relates generally to power-driven conveyors and, more
particularly,
to belt conveyors advancing on steep inclines to elevate articles, especially
tires up
substantially vertical inclines.
BACKGROUND OF THE INVENTION
In a tire manufacturing plant, tires molded in rows of tires presses are
deposited on
a trench conveyor and transported to an inspection, balance, or trim station.
Because trench
conveyors are typically positioned below the presses at a relatively low
elevation, incline
conveyors are used to elevate the tires received from the trench conveyor to
the level of the
presses or higher for transport to subsequent finishing stations. Belt
conveyors, such as
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modular plastic belt conveyors with high-friction conveying-surface
characteristics, work
well on shallow inclines. On steeper inclines, however, belts with conveying
surfaces
textured with inverted cones or other non-skid protrusions work well when new.
As the
protrusions wear, tires begin to slide down the conveying surface as the belt
advances up a
steep incline. Rubber-topped belts are not so susceptible to wear, but the
slippery mold-
release material used to ease ejection of the tires from the presses coats the
rubber conveying
surface of the belt, which then loses its effectiveness as a high-friction
surface.
Consequently, incline angles are limited to a maximum of about 25 off
horizontal. Such
shallow inclines have a large footprint, taking up valuable floor space. Even
if tires could
be prevented from sliding along the conveying surface on steep inclines, there
must be
provisions to prevent tires from falling away from the belt. A wall or other
static structure
in sliding contact with high-friction articles, such as tires, being lifted on
the incline may
damage the articles and will increase the load, requiring an oversized belt
and drive system
In tire warehouses or stores and service stations stocking large numbers of
tires, the
tires are usually stacked to great heights. Further, the tires may be stacked
on shelves or
second levels and thus begin to be stacked at heights over 6 feet. Conveyors
may be used to
elevate the tires to the level of the tire storage or higher for transport to
additional floors.
Traditional conveyors use friction or protrusions to prevent the tires from
sliding down the
inclined conveyor or from falling off of the side of the conveyor belt.
However, friction and
protrusions are not fail-safe methods and tires often fall off of the conveyor
causing harm
to people and property located near the conveyor.
The tire distribution process often includes transporting large quantities of
tires from
the plants where they are manufactured to the various facilities where tires
are delivered to
consumers and/or mounted on vehicles. The processes for transporting tires
from these
plants to wholesalers, retailers, and service centers typically involve the
use of large vessels.
For example, semi-trailers are used for transportation over the road, rail
cars are used for
transportation via rail, and shipping containers are used for transportation
over water.
Further, these vessels often provide storage of tires prior to and after
transport.
To minimize the costs associated with such storage and transportation, it is
desirable
to pack tires into each storage and/or transportation vessel in such a manner
as to maximize
the density of tires within the vessel, while providing satisfactory stability
of the loaded tires
and avoiding permanent deformation of the loaded tires. Maintenance of tires
under a
compressive load has been found to improve the stability of the loaded tires.
However,
compression may lead to permanent deformation of tires in some stacking
configurations.
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Additionally, to minimize the costs associated with storing the tires once
they arrive
at their destination (e.g., facilities where tires are delivered to consumers
and/or mounted
on vehicles such as warehouses and car repair shops), it is desirable to pack
tires into the
storage location in such a manner as to maximize the density of tires within
the storage
location, while providing satisfactory stability of the stored tires to
prevent injury and save
space and avoiding permanent deformation of the stored tires, which may be
stored for
months or even years.
When the storage and/or transportation within the vessel is complete, tires
are
typically manually unloaded from the vessel onto a conveyor or pallet. A
variety of
implements exist for such handling of tires. For example, U.S. Pat. No.
3,822,526, issued to
Black in 1974 and incorporated herein in its entirety, discloses a device for
manipulating
tires. However, a device does not exist that sufficiently eliminates the
difficulties of
manually stacking tires in a storage and/or transportation vessel, and
unloading the
compressed tires from the same vessel. Moreover, no sufficient device
currently exists to
eliminate the reliance on the vessel to maintain a compressive load on tires.
Although
loaders for tires exist, for example, a machine loader and a loader to create
a straight stack
of tires, the existing loaders are not designed to stack tires in a
herringbone pattern. Further
still, the current practice is to rest tires directly against the wall and
floor of the trailer or
boxcar. As a result, the weight of the stacks is unevenly distributed causing
further
compression and strain on tires. Thus, a lower-compression system for cradling
tires during
storage and shipping is desired.
Belt conveyors for tires have been produced to transport tires up to various
heights.
See U .S . Pat. Pub. No. 2008/0053796 to DePaso et al. ("DePaso"). The entire
disclosure of
DePaso is incorporated by reference in its entirety.
Thus, there is a need for an elevating conveyor capable of transporting
articles,
especially tires and solar panels, up steep inclines. Additionally, there is a
need for an
elevating conveyor capable of transporting large tires, such as tractor
trailer tires and tractor
tires, and solar panels.
SUMMARY OF THE INVENTION
Certain embodiments of the present invention relate to a conveyor embodying
features that address these needs.
Although many of the embodiments are focused on conveyors for tires, the
invention
may be used in any application where articles are conveyed to different
locations. For
example, some embodiments are directed to a conveyor for tires while other
embodiments
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are directed to conveyors for solar panels, boxes, wheels, large spools, large
rings, rubber
components, etc. Further, some embodiments are directed to a conveyor for
traditional car
and/or SUV tires while other embodiments are directed to a conveyor for
tractor trailer (i.e.,
eighteen-wheelers, semi trucks, semi trailers, or semis) tires, tractor tires,
and/or farm
machinery tires. Typically, the size and shape of the tire changes depending
upon the use of
the tire. For example, tires for small cars and/or light trucks may range from
about 24" to
about 32" in diameter. Tires for a large trucks and/or semi trailers may range
from about
32" to about 48" in diameter. Tires for tractors or other farm machinery may
range from
about 32" to about 74" in diameter.
One aspect of the present invention is to provide a conveyor to move tires or
articles
up to different heights. The height and angle of the conveyor may be
adjustable in some
embodiments.
On a conventional tire inspection line, tires brought on a conveyor or like
equipment
may be stopped at a midway point where information may be read from the
barcode affixed
to the tires. This is done to identify the type and size of the tires being
inspected and sort
them into the tires to be sent to the next process and elsewhere. Therefore,
one aspect of the
present invention is to provide a tire sorting apparatus capable of reliably
reading
information from a tire identifier, such as a barcode, formed on the surface
of a tire without
damaging the tire.
It is also an aspect of the present invention to provide a conveyor system
comprising
a conveyor belt, support elements to support the articles being conveyed, a
support frame
for the belt and to raise the conveyor belt upward, and a power source. The
conveyor belt
may include sections secured together, one or more pieces of belt material,
strengthening
mechanisms either below or between the one or more pieces of belt material to
support the
support elements, an upper surface, and an under surface. The power source may
comprise
electrical components and a motor. Note that the terms "cleat" and "support
element" can
be used interchangeably herein.
In some embodiments, the conveyor may be specially designed to move passenger
car and light truck tires upwardly at incline angles up to 60 degrees. In
other embodiments,
the conveyor may be specially designed to move semi truck and tractor tires
upwardly at
incline angles up to 60 degrees. In still other embodiments, the conveyor is
designed to
convey tires of any size substantially vertically, i.e., at an incline of
approximately 90
degrees relative to the horizontal.
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In various embodiments, the features of the conveyor include: a 18" wide 2 ply
rubber covered top belt sliding flat at about 60 FPM, one or more 4" high
urethane cleats
bolted to the belt on approximately 60" centers, a curved cleat pattern to fit
tire contour, one
up/stop/down switch at the bottom end, a lhp 115V 13 FLA electric motor with
speed
reducer mounted under bottom end, a thermal overload motor protector, a rubber
lagged
conveyor belt drive pulley, a plain idler pulley with belt tensioner, a high
strength steel
tubing truss conveyor frame, and a base plate. In additional embodiments, the
conveyor may
include: an off switch at the top end, a portable stand with casters to hold
the top end at a
fixed height, a portable stand with casters with a hand-winch adjustable top
end height,
up/emergency and stop/down switches at both ends of the conveyor with UL
listing, a 24"
wide belt for tractor trailer size tires, a 6" high single cleat for vertical
tire lift installation,
straight cleats for handling boxes, bags, and general merchandise, and a
smooth or rough
top belt for shallow inclines_ In some embodiments, the width of the belt is
larger than 24"
and in other embodiments the width of the belt is less than 24".
In various embodiments, the cleats may be attached, secured, or interconnected
to
the belt using a set of two bolts. Further, the bolts may be 1/4" x 1-1/4" #1
elevator bolts
with hardware. The cleats may also include holes for the bolts or other
interconnection
mechanisms.
In some embodiments, the cleats may flip up when going up the conveyor and
flip
down when going down the back of the conveyor. In one embodiment, the cleats
may be
hinged to the belt such that they can flip up and down. Other flip mechanisms
may also be
contemplated by one skilled in the art. In some embodiments, the cleats are
permanently
attached to the belt. In other embodiments, the cleats are removable. In one
embodiment,
the cleats are attached without the use of screws.
In some embodiments, the cleats may be flexible. Thus, each cleat may be
constructed entirely from an elastomeric material that provides flexibility.
In one
embodiment, the cleat or support element is flexible along the length of cleat
such that when
a tire or article is positioned on the conveyor belt, the two cleats bend in a
direction opposite
the direction of belt travel along the conveying path. In other embodiments
they may be
rigid.
In various embodiments, the cleats or tire support elements have a unique
shape to
hold tires on a conveyor belt. Thus, the first and second tire support
elements each has a
front section having an tire-supporting face that has a first curve that is
curved along the tire
support element's length and toward the direction of belt travel. The tire
support element
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also has a back section with a second curve that is curved along its length
and in the direction
of belt travel. The second curve is typically greater than the first curve.
Additionally, each
of tire engaging support elements has a flat conveyor contacting surface that
engages the
outer tire-conveying surface of the conveyor belt. The support element may
also have a top
surface that is positioned at an angle relative to the flat conveyor
contacting surface.
In various embodiments, the system may comprise one or more motors, which may
be changed out to use motors having different power capabilities. In further
embodiments,
the motor(s) may be detachable and removable.
In some embodiments, the conveyor is foldable for storage flat on the ground
or flat
against a wall. In other embodiments, the conveyor may be foldable and stored
in the
location of use. Therefore, when a user needs to use the conveyer, he or she
just has to pull
the conveyor down. The pull-down and storage motion may be similar to a Murphy
bed in
some embodiments Further, the conveyor may be pulled down from a specific rack
or other
storage area.
In some embodiments, the support elements or cleats are bolted onto the belt.
A
gasket that can be rubber may also be used to increase the strength of the
interconnection.
Additionally, bolting the cleats onto the belts reduces the cost of the
system.
In various embodiments, the conveyor may have rubber feet to help it stick to
the
ground/floor. The feet may be made of materials other that rubber in alternate
embodiments.
Thus, the bottom of the conveyor may contact the floor in one or more places
depending on
the embodiment. In other embodiments, the conveyor may be positioned on a rail
such that
the conveyor can slide along the rail to different storage areas. Thus, in an
embodiment, the
conveyor moves along the rails in a similar manner as library ladders. One
skilled in the art
can image a rail system similar to the rail systems described herein.
In various embodiments, the conveyor may include an endless conveyor belt
looped
around rotating drive elements, such as sprockets, drums, or pulleys, which
advance the
conveyor belt in a direction of belt travel along a conveying path. The
endless conveyor belt
may have an outer, article-conveying surface and an inner, drive surface
engaged by the
drive elements. On a steeply inclined elevating portion of the conveying path,
the articles
are conveyed vertically or at a steep angle. The articles are maintained in
position and
blocked from sliding down the outer surface of the conveyor belt on the
steeply inclined
portion of the conveying path by support elements or cleats that extend
outwardly from the
outer surface. The support elements are periodically spaced along the length
of the conveyor
belt to form individual bins for the articles. A steep incline for a given
conveyor belt may
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be defined as a conveying path that is so steep that typical vibrations,
jolts, or surges cause
conveyed articles supported on support elements to fall from the conveyor belt
advancing
along the incline. In various embodiments, the conveyor may be inclined up to
an angle of
60 degrees relative to the horizontal plane.
In various embodiments, the conveyor may further comprise an adjustable base
comprising the support stand, a first tubing extending from the support stand,
a threaded bar
extending from the first tubing, a second tubing receiving an end of the
threaded bar, and a
nut. The nut may be configured to adjust a height of the threaded bar such
that rotation of
the nut in a first direction translates the second tubing away from the
support stand and
rotation of the nut in a second direction translates the second tubing towards
the support
stand. The nut may comprise a first nut and the adjustable base may further
comprise a
second nut, wherein the second nut is positioned between the second tubing and
the first
nut The adjustable base may comprise four of each of the first tubing, the
threaded bar, the
second tubing, and the nut.
In some embodiments, the floor-to-floor vertical tire conveyor ("VTC")
requires
minimal ground floor space next to the mezzanine and is also capable of
clearing existing
structures, such as fire service lines. Although the term VTC is used herein,
the VTCs can
convey articles other than tires. In some embodiments, the VTC is
substantially straight and
a user must remove the tire from the top of the conveyor or the top of the
conveyor must be
interconnected to a mechanism or machine that removes the tire from the top of
the
conveyor. One disadvantage of the straight VTC is that a hole is typically cut
into the
mezzanine floor to accommodate the straight VTC. Having a hole in the
mezzanine floor
can be dangerous and can interfere with existing fire sprinkler water lines
and electric
lighting, both of which are typically positioned immediately underneath the
mezzanine
floor. Another disadvantage of the straight VTC design is that every single
article or tire
that goes up the conveyor must be removed from the conveyor manually when it
arrives at
the top end. With the inclined, but not vertical, conveyor, this is not
necessarily the case
because the articles can fall off of the top of the conveyor onto the floor or
another (e.g.,
horizontal) conveyor.
Thus, a VTC that automatically discharges the articles/tires at the top end of
the
conveyor may be desired. Accordingly, in other embodiments of the VTC, the top
end of
the VTC has a nose-over portion that allows for easy unloading (or loading for
descent) of
tires and keeps the operator clear of both moving conveyor parts and the
mezzanine edge.
Here, the base of the conveyor could be positioned outside of the mezzanine
structure and
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within the limited distance between service bays (or other constraints) and
the edge of the
mezzanine. Additionally, the nose-over VTC could avoid interference with
existing fire
sprinkler water lines and electric lighting, both of which are typically
positioned
immediately underneath the mezzanine floor. The cleat interconnected to the
belt for the
nose-over VTC may be shorter and of a different configuration than the cleat
for the straight
VTC. However, the same cleat may be used for both conveyors in various
embodiments.
As discussed herein, the upper/outward-facing surface of the conveyor belt is
typically referred to as the "article-conveying surface" and a forward and
upward-oriented
portion of the cleat is referred to as the "article-supporting face." This is
because on an
incline conveyor (i.e., non-vertical conveyor), the belt bears the brunt of
the conveyed
article's weight and the cleats act as supports to keep the articles (e.g.,
tires) from sliding
backwards down the belt. However, when the conveyor is a vertical conveyor
(for example,
a VTC) the roles of the belt as an "article-conveying surface" and the cleat
as a "article-
supporting face" are reversed, meaning that on a VTC the cleat is the primary
contact with
the article (e.g., tire), but the weight burden is equally shared between the
cleat and the belt.
In some embodiments of the VTC and other conveyors described herein, the
conveyor frame is constructed of standard commercial quality ("CQ") steel
tubing rather
than the high strength ("HS") tubing generally used. This is advantageous
because the CQ
steel tubing is less expensive than HS tubing and the HS tubing is not
necessary for all
conveyors. However, some embodiments include HS tubing or a combination of CQ
and
HS tubing.
Various embodiments of the VTC and other conveyors described herein include
two
tubes or rails directly next to each other that are positioned between and
substantially
perpendicular to the longitudinal frame rails and proximate to a center of the
frame length.
The tubes/rails may be square or rectangular shaped such that they extend
around the
perimeter of the frame. These two rails or tubes permit the conveyor frame to
be cut into
two pieces, e.g., to facilitate installation, because the frame can be cut
between the two
tubes/rails and each piece will maintain its shape. Then, the two pieces are U-
bolted back
together to form one conveyor frame using U-bolts and fastening equipment.
In some embodiments of the VTC and other conveyors described herein, the frame
comprises sheet metal paneling on all or a portion of the sides of the frame.
The paneling
can extend between about 1 ft. and about 8 ft. along the side of the conveyor
from the end
(either the top or bottom end). In preferred embodiments, the sheet metal
paneling extends
about 4 ft. from each end. The sheet metal paneling is typically provided for
safety purposes,
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e.g., to keep people, heads, arms, hands, fingers, legs, feet, etc. out of the
portions of the
conveyor comprising moving parts and the portions of the conveyor where most
injuries
occur.
In various embodiments of the VTC and other conveyors described herein, the
conveyor comprises a 1/2 hp motor or a 1/4 hp motor. Alternatively, any of the
conveyors
described herein can be constructed with a motor that is smaller than 1/4 hp
or a motor that
is larger than 1/2 hp.
In some embodiments of the VTC and other conveyors described herein, the
conveyor comprises an 18"-wide rubber top cover belt with a friction-resistant
bottom
cover. Various embodiments include a 5-7/16" high/tall cleat that attaches to
the outer face
of the belt. The cleat may be interconnected to the belt via two bolt
fasteners, flat washers,
lock washers, and nuts, or any other attaching mechanism known in the art The
cleats may
be urethane or other hard material, e g , plastic, hard rubber, metal, etc
In various embodiments of the VTC and other conveyors described herein, the
cleat
has various shapes and dimensions depending on the specific use by the user,
the location
of the conveyor, the items being conveyed, and the angle of the conveyor
relative to the
horizontal ground. In some embodiments, the cleat has a 5" overall height and
features for
careful handling of tires. For example, the cleat can have an extended radius
of curvature
opposite the article supporting / carrying surface radius and at the cleat tip
(upper end) to
deter tires or other articles from falling off. Some cleats have narrow widths
and edges with
radii of curvature to prevent damage to the tire's inner bead. Further,
various cleats
described herein are manufactured of a urethane composition. In some
embodiments, the
VTC cleat has a carrying surface (i.e., article-supporting face) that is more
rounded than
cleats of prior designs, in order to better fit the tire bead contour.
In some embodiments of the VTC, the conveyor is motor driven at the bottom end
of the conveyor, meaning the motor is positioned at the bottom end of the
conveyor. In other
embodiments, the VTC comprises a motor at the top end of the conveyor.
Various portions of the conveyors described herein can vary depending on the
specific use of the conveyor. For example, some conveyors may have tighter
frame
dimensions and features to facilitate installation within tight clearance
restrictions. Further,
there is a balance between the conveyor belt width, sufficient traction
between the belt and
the conveyor belt drive pulley to carry the conveyed article (e.g., tire
load), and keeping
overall dimensions as tight as possible. The conveyor belt width could be
variable, but it has
to be countered with the drive pulley diameter for sufficient traction. For
example, the
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conveyor belt can be between about 18" wide and about 10" wide. Further,
smaller diameter
drive and idle drum pulleys are used in some embodiments.
In some embodiments of the VTC and other conveyors described herein, the
conveyor comprises a 10"-wide, 2-ply rubber cover on both sides of the belt.
In this
embodiment, the conveyor belt drum drive pulley has rubber lagging wrapped
around its
circumference and a 4.5" outside diameter (-0.D."). The rubber contact between
the belt
and the drive pulley provides for maximum traction between the two.
Various embodiments of the VTC and other conveyors described herein have a
high-
efficiency, helical gearmotor mounted at the top end of the conveyor frame for
maximum
belt-to-pulley traction. The gearmotor plus the roller chain and sprockets are
all enclosed
within the conveyor frame for safety and to facilitate installation through
tight clearances,
in some embodiments.
Some embodiments of the VTC and other conveyors described herein comprise a
low-profile, custom-design belt tension take-up adjustment to keep all
dimensions of the
adjustment below the highest point of the conveyor belt drum idle pulley.
In some embodiments, once the articles are conveyed up the incline, they may
be
transferred to an outfeed conveyor for transport to downstream finishing
stations or other
storage sections. Further details of exemplary slide-preventing cleats or pair
of cleats may
extend outwardly from the outer, article-conveying surface of the conveyor
belt. In an
embodiment, the cleats may be integrally formed with the belts. In another
embodiment, the
cleats may be secured to a threaded insert in the belt by a bolt or the like
through a bore
formed in a block of the cleat.
In some embodiments, the cleats are secured to the conveyor belt. In other
embodiments, the cleats are secured to a metal drive belt provided under the
conveyor belt.
Thus, the conveyor belt may have apertures in the belt such that the cleats
can extend
upwardly from the drive belt and above the conveyor belt In alternative
embodiments, the
cleats are secured to a metal (or other material) support within the conveyor
belt (i.e.,
between two layers of the conveyor belt). The cleats may be secured or
interconnected to a
belt or other part of the conveyor through the use of screws, pins, rivets,
bolts, nails, glue,
adhesive, sewing, clamps, bonding, welding, or any other mechanism now known
or later
conceived.
In various embodiments, the cleats are various sizes and shapes depending on
the
tire or article to be conveyed. In one embodiment, the conveyor belt may
include support
elements or cleats of many different sizes. The cleats may fold up in order to
support an
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article to convey or may fold down such that it does not inhibit or interfere
with the articles
being conveyed. Thus, in this embodiment, the cleats that are of a size not
currently being
utilized are folded down such that they are substantially flat against or
within the belt. In
other embodiments, the cleats that are of a size not currently being utilized
may be folded
into the center of the conveyor belt such that they do not interfere with the
articles being
conveyed.
In various embodiments, the conveyor belt may be a modular plastic conveyor
belt
constructed of a series of individual belt modules made of a thermoplastic
polymer, such as
polypropylene, polyethylene, acetal, or a composite material, in an injection
molding
process. A threaded metallic insert may be inserted into the module during or
after molding
to serve as an attachment point for a support element. The details of one such
insert and its
use are described in U.S. Pat. No. 6,926,134, "Plastic Conveyor Belt Module
with
Embedded Fasteners," which is incorporated by reference herein in its entirety
Of course,
other methods may be used to fasten the support elements to the conveyor belt.
In some embodiments, the conveyor belt sections comprising cleats may be
interconnected to one another and to other similar belt sections without
cleats in a side-by-
side orientation and end-to-end by hinge rods through hinge eyes to form an
endless
conveyor belt.
In one embodiment, the system may comprise two cleats that are spaced apart
laterally across the width of the conveyor belt. The cleats may have article-
supporting faces
defining planes oblique to the direction of belt travel and intersecting at a
point on the belt
below or behind the cleats on the steep incline. The two cleats provide two
points of support
for round articles, such as tires, and the space between them allows debris or
fluids to drop
from the tire and off of the belt.
In one embodiment, the belt is replaced with rollers or a roller array. The
rollers
provide a low-friction, rolling restraining surface that is especially useful
with high-friction
articles, such as tires. Further, the conveyor belt described as a plastic
conveyor belt may be
a flat belt or a flat-top chain in other embodiments. Another embodiment of an
elevating
belt conveyor embodying features of the present invention may include a roller
array to
prevent conveyed articles from falling off the belt.
One skilled in the art will appreciate that the conveyor and its features may
vary
depending upon the combination of elements in various embodiments. In some
embodiments, the cleats have a rounded shape such that the curve of the cleat
matches the
curve of the tire being conveyed or transported. Thus, the curve of the cleat
is slightly larger
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than the curve of the tire so that the tire will sit in and fit into the
cleat. In still other
embodiments, the cleat may have a different shape. For example, the cleat may
not be
curved. Rather, the cleat may be flat like a wall or tile. The cleat may also
be shaped like a
post or rod. Still further, the cleat may be V-shaped or U-shaped and only one
cleat may be
used to support each tire or conveyed article.
In some embodiments, the cleat may only come up to the midpoint of the side of
the
tire. In other embodiments the height of the cleat is greater than the height
of the tire lying
on its side, i.e., the width of the tire. In still further embodiments, the
height of the cleat is
somewhere between the midpoint of tire's side height and the top of the tire's
side when the
tire is lying on its side.
In various embodiments, one cleat per tire or conveyed article may be used. In
other
embodiments, two cleats per tire or conveyed article may be used. In other
embodiments, 3
or more cleats per tire or conveyed article may be used Additionally, in some
embodiments
one cleat may be used for one tire or conveyed article and two or more cleats
may be used
for another tire or article. Thus, the number of cleats could change
throughout the conveyor.
In still more embodiments, the position of the cleats may be varied depending
upon
the shape and size of the tire or article conveyed. For example, the cleats
may be spaced
further apart and positioned at less of an angle relative to horizontal if the
radius of the tire
is large, whereas the cleats may be positioned closer together and at a
greater angle relative
to horizontal if the radius of the tire is small.
Although the invention has been described with application to tires, the
invention
also finds application to transporting other articles. For example, boxes,
solar panels,
windows, construction equipment, car or automobile components, tractor
components,
pallets of products, etc. may be transported on the conveyors.
In some embodiments, the conveyor may be configured with a conveyor belt,
roller
bars, and/or any other mechanism for moving tires. The conveyor may be
configured to be
located at any height above a platform to facilitate access by a worker. In
one embodiment,
the conveyor may be configured about three feet above the platform. The
conveyor may be
configured to automatically move tires in one or more directions. For example,
in one
embodiment, the conveyor may be configured to move tires from a placement
station to any
desired location, such as, for example, a tire loading system, a tire
unloading system, a
forklift, a railcar, and/or a tire rack. In another embodiment, the conveyor
may be configured
to move tires to/from a location such as, for example, a tire unloading
system, a forklift, a
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railcar, a tire rack, a tire storage location or the like to/from the
placement station for manual
loading of tires into racks or storage areas in the tire load station.
In some embodiments of the conveyor system, humans may load articles or tires
onto the conveyor (typically the bottom of the conveyor) and unload articles
or tires off of
the conveyor (typically the top of the conveyor) as a part of the system. In
various
embodiments, one or more persons load the tires and a different one or more
persons unload
the tires or articles. In alternate embodiments, machines or robots may load
and unload the
articles and tires. In additional embodiments a combination of humans, robots,
and machines
may be used to load and unload the articles or tires.
Lean manufacturing principles may be applied throughout embodiments of the
invention to facilitate efficiency in tire loading, unloading, and/or storage.
For example, in
one embodiment, value stream mapping is used to analyze logistics data
provided by a
company to create Pareto analysis to identify high volume, high turn-over tire
SKUs (i e ,
stock control units). A manufacturing plant analysis is implemented to
determine the
capacity and production rate of a given customer to determine the size,
capacity, number,
and/or breadth of tire loading, unloading and/or storage needed to fulfill
capacity and
production goals. For example, for higher customer inventory levels, fully-
automated
loading, unloading and/or storage systems may be desired. However, for lower
inventory
levels, customers may use partially-automated loaders, unloaders, and/or
storage systems to
maximize efficiency and lower overall costs.
In yet other embodiments, the systems and methods of the present invention are
facilitated by one or more human and/or computerized operators. For example,
an operator
monitors robot loaders and/or unloaders, monitors system settings and/or
identifies racks
that require replacement or repair. Operators also drive forklifts,
load/unload tires, and/or
the like to facilitate overall system usage.
One aspect of embodiments of the present invention is to provide a system
capable
of handling all sizes of vehicle tires, providing maximum compression of
tires, and
minimizing the manual labor required for loading, unloading, stacking, and/or
storing the
articles or tires.
In some embodiments of the system, tires are ricked or stacked in a
herringbone
pattern to facilitate compression and/or space management. The system and
method also
includes the stacking of tires in any other suitable arrangement that would
allow the
transport rack to perform similar functions. Moreover, the system and method
may include
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any variation or angle of herringbone patterns that would allow the transport
rack to perform
similar functions as disclosed herein.
As one with ordinary skill in the art appreciates, the proper alignment of
tires in the
herringbone pattern depends upon the geometry of tires being stacked. Thus,
the system
contemplates and accommodates incorporation of an automated system for control
of the
loader system. The control system automatically senses tire geometry based on
sensors
located at an upstream position on the conveyor, or alternatively,
accommodates the manual
input of information. In both cases, however, the control system uses
information that is
indicative of tire geometry, such as outside diameter, inside diameter, and/or
tread width, to
determine the rotation and translation of each tire to produce the desired
stacking pattern.
With respect to herringbone stacking patterns, the relevant output variables
may include the
angle of deviation from vertical associated therewith the axis of rotation of
tires in
successive rows as well as the number of tires in each row and the number of
rows in each
stack. Furthermore, the control system may determine the appropriate amount of
compression to apply to the stacked load, and the corresponding number of rows
in the stack,
to avoid permanent deformation of tires. The control system may consider a
variety of
factors in determining the appropriate compressive loads to apply. In one
embodiment, these
factors include the material properties and/or hardness of tires (usually
rubber), tire
geometry and stacked orientation, and the time and temperature environment to
which
compressed tires will be subjected. In addition, empirical data and experience
may be
incorporated to optimize the control of the system.
As used herein, warehouse racks include any type of rack that is distinct,
including
for example, pallets, racks such as those manufactured by Ohio Rack, Inc., or
the like.
In some embodiments, the conveyor system may comprise one or more scanners to
facilitate identifying each tire or article. For example, in one embodiment,
the system
comprises two scanners configured on both sides of a two-lane conveyor. The
scanners may
be configured both above and below the conveyor and/or articles to facilitate
reading the
articles' labels/SKUs. In alternate embodiments, the scanner may be a barcode
scanner, a
radio-frequency scanner, optical scanners, vision systems and/or any other
type of scanner
for reading and/or identifying tire or article labels and/or SKUs. The scanner
may be
configured with a CPU and/or any other computing system or unit. The scanner
may also
be configured to communicate with the rack loading system, conveyor, and/or
any other part
of the system or any other system described herein. Alternatively, RFID tags
and readers
may be used with the system.
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In one embodiment, each tire on a conveyor and/or a warehouse storage area is
the
same type, size, and/or SKU number, or may be designated for the same
destination or
storage area. Tires may be delivered to storage areas and/or a warehouse rack
on a conveyor.
In additional or alterative embodiments, articles and tires may be delivered
to storage areas
and/or a warehouse rack on two or more conveyors. Further, the tire or article
may be
scanned and identified then loaded on to the appropriate conveyor for storage
in the
appropriate area. Thus, one type of tire may be loaded onto one conveyor to be
stored in a
first area and a different type of tire or article may be loaded onto a second
conveyor to be
stored in a second area that is different from the first area.
In some embodiments, the conveyor system and the rack loading system may also
be configured to stack tires or articles based upon identification information
received from
the scanner. For example, in one embodiment, the rack loading system may be
configured
to receive tire identification information from the scanner and to use the
tire identification
information to determine what tire stacking configuration to use. That is, for
smaller
diameter tires, the rack loading system may stack tires in layers of five
tires, for example.
For larger diameter tires, the rack loading system may stack tires in layers
of four tires, for
example.
In various embodiments, the one or more conveyors may elevate the tires to a
stop
position in front of one or more position pick-and-place loaders. The pick-and-
place loaders
may each comprise a support-mounted actuator system, each of which controls an
extendable/ retractable arm that is adapted to seize the tire or article from
the conveyor.
In some embodiments, the system is configured to sort and queue tires
horizontally.
For example, the system comprises one or more tire transportation devices,
such as, access
conveyors that connect to one or more sub-conveyors. In an embodiment, an
access
conveyor may move the tires from the main unloading conveyor to various sub-
conveyors.
The sub-conveyors, in turn, may move tires to/from towers. Some conveyors may
be
configured to be computer-controlled devices to facilitate sorting, queuing
and/or routing of
the tires. In one embodiment, the tires are loaded randomly and scanners are
used to sort,
queue and/or route the tires when they are unloaded from towers.
In another embodiment, some conveyors may be configured with one or more
scanners to obtain tire identifying information to facilitate sorting and
queuing the tires. The
scanners may be configured like scanners and communicate with the conveyors to
facilitate
directing each SKU of tire to a different sub-conveyor for loading into a
particular tower.
Each tower is configured to hold between 10 and 30 tires of a single SKU.
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In one embodiment, a queuing system may comprise an inbound queue of tires or
articles that have been unloaded from a trailer, railcar, forklift and/or
other transportation
mechanism. For example, a number of tires or articles are queued on each side
of the
queuing system.
In various embodiments, the system may also be configured with a control panel
to
facilitate worker operation of the conveyor. For example, the worker may use a
panel to
raise or lower the conveyor in order to facilitate access to tires, storage
areas, and racks. In
another embodiment, a load station may be configured with one or more scanners
or cameras
to detect the height of rack, storage floor, storage area, tires, and the
conveyors and raise or
lower the conveyor based on whether the height of the racks, tires, storage
floor, storage
area, or conveyor meets a predetermined height.
The scanner computing unit or any other computing unit used or described
herein
may be connected with each other via a data communication network The network
may be
a public network and assumed to be insecure and open to eavesdroppers. In the
illustrated
implementation, the network is embodied as the Internet. In this context, the
computers may
or may not be connected to the Internet at all times. For example, the
customer computer
may employ a modem to occasionally connect to the Internet, whereas the bank
computing
center might maintain a permanent connection to the Internet. Specific
information related
to the protocols, standards, and application software utilized in connection
with the Internet
may not be discussed herein. For further information regarding such details,
see, for
example, Dilip Naik, "Internet Standards and Protocols" (1998); "Java 2
Complete," various
authors (Sybex 1999); Deborah Ray and Eric Ray, "Hosting HTML 4.0" (1997);
Loshin,
"TCP/IP Clearly Explained" (1997). All of these texts are incorporated by
reference herein
in their entireties.
It may be appreciated that many applications of the present invention may be
formulated. One skilled in the art may appreciate that a network may include
any system for
exchanging data or transacting business, such as the Internet, an intranet, an
extranet, DSL,
WAN, LAN, Ethernet, satellite communications, and/or the like. It is noted
that the network
may be implemented as other types of networks, such as an interactive
television (ITV)
network. The users may interact with the system via any input device such as a
keyboard,
mouse, kiosk, smart phone, e-reader, tablet, laptop, ultrabook'TM, personal
digital assistant,
handheld computer (e.g., Palm Pilot ), cellular phone, or the like. Similarly,
embodiments
of the invention could be used in conjunction with any type of personal
computer, network
computer, workstation, minicomputer, mainframe, smart phone, etc. Moreover,
although the
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invention is frequently described herein as being implemented with TCP/IP
communications protocols, it may be readily understood that the invention may
also be
implemented using IPX, Appletalk, IP-6, NetBIOS, OSI or any number of existing
or future
protocols. Moreover, the present invention contemplates the use, sale or
distribution of any
goods, services or information over any network having similar functionality
described
herein.
In accordance with various embodiments of the invention, the Internet
Information
Server, Microsoft Transaction Server, and Microsoft SQL Server, may be used in
conjunction with the Microsoft operating system, Microsoft NT web server
software, a
Microsoft SQL database system, and a Microsoft Commerce Server. Additionally,
components such as Access or SQL Server, Oracle, Sybase, Informix MySQL,
Interbase,
etc., may be used to provide an ADO-compliant database management system. The
term
"webpage" as it is used herein is not meant to limit the type of documents and
applications
that might be used to interact with the user. For example, a typical website
might include,
in addition to standard HTML documents, various forms, Java applets,
Javascript, active
server pages (ASP), common gateway interface scripts (CGI), extensible markup
language
(XML), dynamic HTML, cascading style sheets (C SS), helper applications, plug-
ins, and/or
the like.
A system user may interact with the system via any input device such as, a
keypad,
keyboard, mouse, kiosk, smart phone, e-reader, tablet, laptop, ultrabookrm,
personal digital
assistant, handheld computer (e.g., Palm Pilot , Blackberry , iPhonee, iPad ,
Android ), cellular phone, or the like. Similarly, the invention could be used
in conjunction
with any type of personal computer, network computer, work station,
minicomputer,
mainframe, smart phone, tablet, or the like running any operating system such
as any version
of Windows, MacOS, i0S, OS/2, Be0S, Linux, UNIX, Solaris, MVS, tablet
operating
system, smart phone operating system, or the like, including any future
operating system or
similar system.
In one embodiment of the present invention, a tire sorting apparatus that
includes a
mounting means for mounting a tire in a plane perpendicular to the center axis
of the tire, a
tire grip means for gripping the inner periphery of the tire and positioning
the center axis of
the tire, an identifier reading means for reading a tire identification
marking formed on the
surface of the tire, and a holding means for holding the identifier reading
means. The tire
grip means may further include three grip arms arranged at the vertexes of a
triangle within
a plane perpendicular to the center axis of the tire and extending in a
direction parallel to
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the center axis of the tire and an arm opening and closing mechanism for
opening the three
grip arms concentrically around the circle circumscribing the triangle. The
holding means
may further include a holding unit for holding the identifier reading means
and a rotation
drive unit for rotating the holding means around a rotating axis parallel to
the center axis of
the tire. And the center of the circumscribing circle is aligned with the
rotating axis of the
holding unit.
Some embodiments of the system of the present invention may further include a
tire
inside diameter detecting means for detecting a tire inside diameter from
positional data or
travel distance data of the three grip arms when the grip arms are gripping a
tire. This allows
not only acquisition of information from a tire identifier of a tire but also
accurate
measurement of the inside diameter of the tire. Hence, the possibility of
rechecking the
information on the tire identifier may further improve the accuracy of tire
sorting.
Some embodiments of the system of the present invention may include a rotation
radius changing means for changing the distance between the identifier reading
means and
the rotation axis of the holding unit and a detecting position control means
for controlling
the rotation radius changing means in such a manner as to move the identifier
reading means
to the position of the tire identifier based on the data of the tire inside
diameter detected by
the tire inside diameter detecting means. Thus, the rotation radius of the
identifier reading
means may be changed according to the tire size. Therefore, information may be
read from
the tire identifier even when there is a change in tire size.
Additional embodiments of the system of the present invention may provide a
tire
sorting apparatus that has a mounting means having a plurality of rotating
bodies rotating in
contact with the lower surface of the tire and a through hole through which
the three grip
arms may be extended toward the inner periphery of the tire.
In some embodiments of the system, devices to help in the compression of the
tire
stacks may be included. Some tire stacking systems, however, continue to rely
heavily upon
manual labor to accomplish the stacking of tires. For example, U.S. Pat. No.
5,697,294
issued to Keller et al. on December 16, 1997, ("Keller I") discloses an
exemplary tire
compression device and US. Pat. No. 5,816,142 issued to Keller et al. on
October 6, 1998,
("Keller II") discloses another tire compression device intended for use with
a forklift. Both
Keller I and Keller II are incorporated by reference herein in their
entireties. The Keller I
and Keller II devices allow a preset load to compress a stack of tires as the
stack is loaded
into a truck trailer. Initially, the forklift elevates and supports the preset
load. Then, once
tires are stacked beneath the elevated load, the forklift allows the load to
be lowered against
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a stack of tires. As a result, the load exerts a downward pressure on the
stack of tires, thereby
compressing the tires. Once the initial stack is compressed, additional
uncompressed tires
are loaded on top of the stack until the stack reaches the ceiling of the
truck trailer. Then,
the forks of the forklift are raised, partially releasing the pressure applied
against the
compressed portion of the stack and allowing it to expand, while compressing
the previously
uncompressed portion until the entire stack is equally compressed. This
process is repeated,
stack by stack, until the entire trailer is full of stacked, compressed tires.
Other devices exist
that load tires into a truck trailer and similarly compress tires within the
trailer. In each of
these cases, tires are maintained in compression by the storage and/or
transportation vessel
itself. However, no assurance exists that the vessel was designed or is
suitable to maintain
such loads. In fact, vessels are frequently damaged as a result of such use.
Various embodiments of the present invention include an apparatus for loading
a tire
onto a rack The apparatus includes an automated tire conveyor, one or more
scanners, and
one or more robots to pick the tires off of the conveyor. The system may
additionally include
an apparatus for unloading a rack of tires, which includes a load station
configured with a
lift. The lift raises a rack of tires to a platform, where an unloader may
manually or
automatically move tires from the rack to a conveyor.
Further, some embodiments of the present invention include methods and systems
for sorting and unloading tires into a store or warehouse for storage and sale
as well. For
example, the systems for sorting and unloading tires may include one or more
automated
conveyors, scanners, and storage structures. For example, in the sorting
system, the scanner
may read information off of incoming tires and communicate the tire
information to a system
of conveyors, which in turn directs each tire to a specific storage structure
based upon the
tire information (e.g., size, type, etc.).
In various embodiments, drive-in storage may also be included in the conveyor
system configured with one or more computing systems, such as those described
herein, to
communicate with other loading or unloading systems of the system disclosed
herein. For
example, an unloading system within the system disclosed herein may
communicate with
drive-in storage when a first rack, which is being unloaded, is all or
partially-empty such
that a second rack may be delivered from the drive-in storage to the unloader.
In another
embodiment, an unloader or loader communicates with the drive-in storage when
daily
customer orders show that there is additional demand for a specific tire SKU
(i.e., stock
control unit). The rack may then be pulled from the drive-in-storage using,
for example, a
pull system applying lean manufacturing principles.
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In some embodiments, the conveyor system may also include a system for
loading,
sorting, or unloading tires. The system may be automated or computer
controlled. The
system may be used in a plant that manufactures tires, and sorts and stores
tires coming off
the assembly line, and then dispenses tires in a desired order for shipment.
Further, the
system may also be used for loading and unloading articles or tires at a final
destination,
such as a tire shop or warehouse, where tires may be stored.
One aspect of the invention is a method for conveying articles up steep
inclines. In
one embodiment, the method for conveying articles up steep inclines comprises:
(a)
conveying articles on the conveying surface of an endless conveyor belt along
a steep incline
in a direction of belt travel; (b) blocking conveyed articles from sliding
down the conveying
surface of the conveyor belt on the steep incline; and (c) restraining
conveyed articles
leaning away from the conveying surface with a restraining surface moving in
the direction
of belt travel to prevent the leaning articles from falling away from the
conveying surface
of the conveyor belt on the steep incline.
The present invention includes a method of packing tires that includes placing
one
or more rows of tires against a bottom frame, adding an intermediate frame on
top of the
one or more rows of tires, compressing the tires, and attaching a vertical
member to the
intermediate frame. The method additionally includes adding one or more
additional rows
of tires on top of the intermediate frame, adding a top frame, compressing the
one or more
additional rows of tires, and attaching a vertical member to the top frame.
By way of providing additional background, context, and to further satisfy the
written description requirements of 35 U.S.C. 112, the following references
are
incorporated by reference in their entireties for the express purpose of
explaining the nature
of conveyors and to further describe the various tools, pieces, and other
apparatuses
commonly associated therewith:
US. Pat. Pub. No. 2012/0325903 to Takahashi describes a tire sorting apparatus
for
reliably reading information from a tire identifier, such as a barcode, formed
on the surface
of a tire without damaging the tire. Placed under a tire-mounting table is a
tire grip that has
three grip arms arranged circularly in a plane perpendicular to the tire
center axis and link
mechanisms for spreading the grip arms. Placed above the mounting table is a
barcode
reader rotating means for rotating a barcode reader held by a barcode reader
holder. The
rotation axis of the barcode reader is aligned with the center of the circle
formed by the grip
arms of the tire grip.
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U.S. Pat. Pub. No. 2009/0148260 to Leimbach et al., which is incorporated
herein
by reference in its entirety, discloses a tire loading apparatus and method of
packing tires
that includes placing the tires in a rack, compressing the tires, and
assembling the rack. The
apparatus includes one or more conveyors, scanners, and robots that load tires
from a
conveyor to a rack. A tire unloading apparatus is also disclosed. The
unloading apparatus
includes a scissor mechanism to rise and lower tire racks to an unloading
platform. The
unloading apparatus additionally includes one or more unloaders and conveyors.
The sorting
and unloading of tires is accomplished with one or more automated conveyors,
scanners,
and storage structures for reading information from incoming tires and using
the tire
information to sort and store the tires. A rack to improve compression and
support of tires
during storage and shipment is also disclosed.
U.S. Pat. No. 6,97,499, issued to Leimbach, et al. on March 4, 2003,
("Leimbach")
discloses an example of a tire loading system The unloading system and method
described
herein may include features or steps (which may be in any order) described in
Leimbach,
which is incorporated by reference in its entirety.
U.S. Pat. Pub. No. 2010/004399 to Terazono discloses bead core and a bead
filler
and is incorporated by reference in its entirety.
U.S. Pat. Pub. No. 2012/0092149 to Fujisawa discloses an inspection apparatus
arranged with a plurality of cameras located at relatively displaced
circumferential positions
and set for the respective shooting positions different from each other in the
axial direction
of the tire. Thus the images of the inner circumferential surface of the tire
are shot by the
plurality of cameras as the tire is rotated circumferentially relative to the
plurality of
cameras. Fujisawa is incorporated herein by reference in its entirety.
U.S. Pat. Pub. No. 2011/0013177 to Crim discloses an apparatus and method for
verifying a laser etch on a rubber sample. In one embodiment, the apparatus
includes a tire
production line, a sample holding device, a laser haying a diode, and a servo-
assembly. The
laser of the apparatus is configured to etch indicia on a sidewall of a tire
on the tire
production line and is further configured to etch at least one line in a
rubber sample on the
sample holding device. Crim is incorporated herein by reference in its
entirety.
U.S. Pat. No. 7,249,496, issued to Kunitake, et al. on July 31, 2007,
("Kunitake")
discloses an uniformity inspection line with a decision-only line having first
UF machines
exclusive for the measurement of the uniformity of a tire sorted and
distributed on an
automatic sorting line and a correction-only line haying second UF machines
for the
correction and re-measurement of the uniformity characteristics of a tire
having uniformity
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characteristics outside specific values measured on the above decision-only
line. Kunitake
is incorporated herein by reference in its entirety.
U.S. Pat. No. 7,340,946, issued to Gotou, et al. on March 11, 2008, and U.S.
Pat.
Pub. No. 2007/0084275 to Gotou, et al. disclose a method and a device for
inspecting a tire,
the method comprising the steps of, in a rim assembly station separated from
an inspection
station having a tire inspector installed thereon, forming a rim/tire assembly
in a setup by
assembling one side and the other side rims and with an inspected tire and,
when an
inspection is performed, transforming the rim/tire assembly from the rim
assembly station
to the tire inspector on the inspection station, whereby a preparatory
operation time in the
tire inspector can be shortened to shorten a cycle time. The Gotou patent and
Gotou
publication are incorporated herein by reference in their entireties.
U.S. Pat. No. 7,487,814, issued to Mizota on Feb. 10, 2009, discloses an
object to
provide a tire reinforcing layer forming device which can form, by a single
device, plural
reinforcing layers whose cord directions intersect one another. A reinforcing
material piece,
which is distributed to an upper conveying path, is affixed from a left end
side of a drum
toward a right side, while the drum is rotated in a direction of arrow CW.
Mizota is
incorporated herein by reference in its entirety.
U.S. Pat. No. 7,347,317, issued to Aizawa, et al. on March 25, 2008, discloses
methods and devices for measuring elongation, wear, and internal temperature
of a conveyor
belt to catch signs of conveyor belt failure such as breakage by detecting a
magnetic field
from a magnetic body by using a magnesium sensor, as well as a rubber magnet
sheet as a
magnetic body and a method of producing the sheet, the rubber magnet sheet
being able to
be used while it is embedded in the conveyor belt. Aizawa is incorporated
herein by
reference in its entirety.
U.S. Pat. No. 7,543,698, issued to Haskell on June 9, 2009, and discloses an
article
elevator for moving lightweight open ended containers from a first level to a
second level
vertically spaced from the first level and is incorporated herein by reference
in its entirety.
The article elevator includes an input section at the first level for
receiving container bodies.
An elevator section is positioned for receiving container bodies from the
input section. A
discharge section is located at the second level for receiving container
bodies from the
elevator section. A plurality of arms is movably mounted above the input
section, the
elevator section, and the discharge section. Each of the arms moves a group of
container
bodies from the input section over the elevator section to the discharge
section so that
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successive groups of container bodies are moved to the discharge section from
the input
section.
U.S. Pat. No. 3,910,405, issued to Couperus, et al. on Oct. 7, 1975, and
discloses a
belt elevator for elevating loose bulk material from one level to another. The
belt elevator
comprises a pair of cooperating endless belt conveyors whose forward runs are
juxtaposed
to face one another with an edge of one in sealing engagement with the other,
the material
being retained therebetween. A first belt conveyor is provided with raised
edges which
engage and seal with the edges of the other. The first conveyor is also
provided with
generally evenly spaced transversely positioned cleats or raised portions
which, together
with the raised edges, forms pockets to contain material being elevated. The
stiffness of the
first belt conveyor is greater than that of the second belt conveyor. The
second belt conveyor
is troughed at the entry portion for receiving the material to be elevated
which material is
discharged from the first belt conveyor at a discharge point at the higher
level The belts are
maintained in tension to insure edge engagement and the retention of material
therebetween.
Couperus is incorporated herein by reference in its entirety.
Receiving hoppers and varying numbers of cleats may be used to convey loose
material such as dirt, stones, etc. Additionally, the cleats may be about 20
to 30 inches apart
in the direction of belt travel, or preferably 24 inches apart. In an
alternate embodiment, the
cleats may be about 50 to 70 inches apart in the direction of belt travel, or
preferably 60
inches apart. If an article is conveyed, the cleats may be spaced apart
between about 1.0 and
about 2.0 times the length of the article conveyed, or preferably between
about 1.25 and
about 1.75 times the length of the article conveyed, or more preferably about
1.5 times the
length of the article conveyed.
The conveyor may include handles and a dolly with wheels to promote movability
of the conveyor. The handles can be any size, shape, or material known in the
art. For
example, the handles may be metal or metal with rubber coatings. The handles
may be bar-
like, round, or square. The dolly can contain one or more wheels and will have
at least one
leg or axel.
Different numbers of cleats or support elements can be used together to convey
an
article. Typically, the taller the cleat is, the fewer cleats need to be used.
For example, one
tall (8.0 inch) cleat can be used to convey an article, where as two or three
short (1.25 inch)
cleats may be needed to convey an article.
U.S. Pat. Pub. No. 2007/0135960, to Shibao et al., discloses a production
evaluation
managing system in a factory including facilities in a plurality of production
processes from
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materials to products and a means for evaluating the products based on at
least one of
inspection and testing characterized by comprising a network connecting the
facilities in
respective production processes with the evaluating means, and a means for
collecting
through the network field data of the facility in a production process
pertaining to the
production of a product corresponding to the information of evaluation
results, based on the
information of evaluation results of the products outputted from the
evaluating means. By
this, when a nonconformity is found from the information of evaluation results
based on at
least one of inspection and testing of the product, field data of the facility
in a production
process pertaining to production of a product corresponding to the information
of evaluation
results can be collected and analyzed immediately and the problem with the
production
process can be investigated immediately in a short time. Shibao is
incorporated herein by
reference in its entirety.
US Pat Pub Na 2007/0289847 to Nakamura is incorporated herein by reference
in its entirety and discloses a rubber member conveying device and a rubber
member
supplying system. The device and the system rapidly promote the shrinkage of
the rubber
member, thereby avoiding the length variation of the rubber member in the
processing step
for the rubber member. A rubber member supplying system comprises a belt
conveyor
which supplies a to-be-cut material having an internal strain, a cutter which
cuts the to-be-
cut material supplied by the belt conveyor to form a rubber member, and a
rubber member
conveying part which conveys the rubber members. The rubber member conveying
part
comprises an endless belt, and rollers supported by supporting parts that are
provided at the
endless belt. The rubber member is conveyed on the rollers while exposed to
vibrations.
Accordingly, the shrinkage in the rubber member caused by the internal strain
thereof is
substantially completed in the conveying operation.
U.S. Pat. No. 4,534,461, issued to Silverthorn, et al. on Aug. 13, 1985, and
discloses
a conveyor construction for conveying materials, such as grain, to an elevated
location. The
conveyor construction comprises a base or supporting structure and an auger
conveyor is
mounted horizontally on the base. Grain is fed into a hopper at one end of the
auger and the
discharge end of the auger is provided with a pair of kicker paddles which
propel the grain
laterally into the lower end of a vertical endless belt conveyor. The endless
belt conveyor
includes a plurality of integrally molded cleats that convey the grain
upwardly within a
vertical passage in the conveyor housing and the grain is discharged from the
upper end of
the housing. The vertical conveyor is mounted for pivoting movement relative
to the auger
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conveyor to adjust the angularity of the vertical conveyor. Silverthorn is
incorporated herein
by reference in its entirety.
U.S. Pat. No. 4,727,419, issued to Yamada, et al. on Feb. 23, 1988, and is
incorporated herein by reference in its entirety. Yamada discloses a system in
case of
detecting tire information marks engraved in a side wall portion of tire in
the form of
protrusion or recess, width and inner diameter of tire are detected to provide
a tire size
signal, after a first camera head is driven into a given position in
accordance with the tire
side signal, an identification mark engraved in the size wall portion of tire
is optically
detected by the first camera head to derive a position signal, and after a
second camera head
is driven into a given position in accordance with the position signal, the
tire information
marks are optically detected by the second camera head to derive a tire
information signal.
In this manner, the tire information marks can be detected in a rapid and
accurate manner.
US. Pat. No. 4,700,078, issued to Mizuno, et al. on Oct. 13, 1987, and
discloses a
method and system for detecting tire information marks. Tire information marks
for
denoting tire kind, tire size, etc. formed in a surface of side wall of a tire
as a protrusion or
groove having a triangular cross section are optically detected by
illuminating the surface
of side wall of the tire from a first direction substantially perpendicular to
the surface of the
side wall of the tire and a second direction inclined with respect to the
surface of the side
wall of the tire, and picking up an image of the surface of the side wall of
the tire thus
illuminated from the two different directions to derive an image signal. The
image signal
thus derived is converted into a bivalent signal, and is thinned to produce a
mark pattern.
Then the mark pattern is compared with a thick standard mark pattern. When a
substantial
part of the detected mark pattern is included in the standard mark pattern,
the detected mark
pattern is recognized to be identical with the standard mark pattern. Mizuno
is incorporated
herein by reference in its entirety.
U.S. Pat. No. 5,092,946, issued to Okuyama, et al. on Mar. 3, 1992, U.S. Pat.
No.
5,415,217, issued to Okuyama, et al. on May 16, 1995, and U.S. Pat. No.
5,194,107, issued
to Okuyama, et al. on Mar. 16, 1993. The Okuyama patents disclose a method and
an
apparatus for sticking a belt-like member, wherein a belt-like member prepared
by cutting
a raw material of the belt-like member on a conveyor at two front and rear
locations, is
conveyed by the conveyor, wrapped around a cylindrical drum and stuck to the
drum. The
inclination angle of the cut line at the leading end of the belt-like member
is measured at the
time of cutting, the inclination angle of the cut line at the trailing end is
measured at the time
of cutting, and by comparing the inclination of the cut line at the trailing
end with the
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inclination angle at the leading end, an amount of connection for the
inclination angle is
calculated. The three Okuyama patents are incorporated by reference herein in
their
entireties.
In one embodiment, the conveyor comprises an endless conveyor belt having an
outer article-conveying surface. The conveyor belt advances in a direction of
belt travel
along a conveying path that includes a steeply inclined portion. The conveying
belt also
includes support elements that extend outward from the outer article-conveying
surface of
the conveyor belt at periodically spaced positions and retention means are
disposed along
the steeply inclined portion proximate the support elements prevent conveyed
articles from
falling away from the conveyor belt on the steeply inclined portion.
In various embodiments, the conveyor system comprises an endless conveyor belt
having an outer article-conveying surface. The conveyor belt advances in a
direction of belt
travel along a conveying path that includes a steeply inclined portion The
conveying belt
further includes support elements that extend outward from the outer article-
conveying
surface of the conveyor belt. An article-restraining surface facing the
article-conveying
surface of the conveyor belt is positioned outward of the support elements
across gaps along
the steeply inclined portion of the conveying path. The article-restraining
surface engages
outwardly leaning conveyed articles moving upward on the steeply inclined
portion of the
conveying path in low-friction contact. The article-restraining surface may be
the outer
surface of a belt advancing in the direction of belt travel or the outer
surfaces of an array of
rollers rotating in the direction of belt travel on contact with outwardly
leaning conveyed
articles.
In one embodiment, the conveyor for conveying articles up inclines comprises:
an
endless conveyor belt having an outer article-conveying surface and advancing
in a direction
of belt travel along a conveying path including an inclined portion; a
plurality of support
elements extending outwardly from the outer article-conveying surface of the
conveyor belt
and spaced apart at an increment approximately equal to about 1.5 times a
length of the
article conveyed, where the plurality of support elements comprises pairs of
two support
elements and each support element in the pair is positioned proximate to the
other support
element in the pair and with a space between the two support elements, where
each support
element comprises: curved section having an article-supporting face, which is
curved at a
first radius of curvature and is positioned in the direction of belt travel,
and a back side
opposite the article-supporting face, the back side is curved with a second
radius of
curvature, where the first radius of curvature is smaller than the second
radius of curvature;
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a block-like bottom section with a flat bottom that engages the outer article-
conveying
surface of the conveyor belt; and a top opposite the bottom, where the top is
positioned at
an angle relative to the flat bottom; two securing mechanisms for each support
element to
secure the support elements on the conveyor belt; a support frame with a
support stand
positioned proximate to a floor surface and support bars; a drive pulley
interconnected to
the support frame and positioned at the top of the support frame, where an
underside of the
conveyor belt engages an outer surface of the drive pulley; an idle pulley
interconnected to
the support frame and positioned at the bottom of the support frame, where an
underside of
the conveyor belt engages an outer surface of the idle pulley; and a motor for
moving the
conveyor belt around the drive pulley and idle pulley.
In a further embodiment, a first support element in one pair of support
elements has
an article-supporting face defining a first plane oblique to the direction of
belt travel and a
second support element in the pair of support elements has an article-
supporting face
defining a second plane oblique to the direction of belt travel. The first
plane and the second
plane intersect at a point on the conveyor belt below the first support
element and the second
support element. In another embodiment, the support elements are contoured in
shape to
mate with the conveyed article. In one embodiment, the support elements are
made of an
elastomeric material that conforms to the shape of a conveyed article on the
inclined portion
of the conveying path. In additional embodiments, the conveyor further
comprising a
retention mechanism for preventing the conveyed articles from falling off of
the conveyor
belt, said retention mechanism positioned along the inclined portion of the
conveying path.
The conveyor may alternatively comprise an article-restraining surface
positioned above
and facing the article-conveying surface of the conveyor belt, where the
article-restraining
surface is spaced away from the support elements, and where the article-
restraining surface
engages outwardly leaning conveyed articles moving upward on the inclined
portion of the
conveying path in low-friction contact. In one embodiment, the inclined
portion of the
conveying path is approximately 60 degrees as measured from a horizontal
plane. In some
embodiments, the inclined portion of the conveying path is approximately 90
degrees as
measured from a horizontal plane. The conveyor may be positioned at an
inclined angle
relative to the horizontal ground, i.e., between about 50 and substantially
vertical or about
85 to 95 or the conveyor can be relative to the horizontal ground.
In one embodiment, a conveyor for conveying articles up inclines is provided,
the
conveyor comprising: an endless conveyor belt having an outer article-
conveying surface
and advancing in a direction of belt travel along a conveying path including
an inclined
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portion; a plurality of support elements extending outwardly from the outer
article-
conveying surface of the conveyor belt and spaced apart at least a distance
between about
1.0 and 2.0 times a length of the article conveyed on said conveyor belt,
wherein each
support element comprises: a upright section having an upper portion and an
article-
supporting face generally positioned in the direction of belt travel; a block-
like bottom
section with at least one hole and a flat bottom, wherein the bottom engages
the outer article-
conveying surface of the conveyor belt, and wherein the at least one hole is
positioned
proximate a leading edge of the support element; and a top positioned at the
upper portion
of the upright section and opposite the bottom, wherein the top has a flat
surface
substantially parallel to the flat bottom of the block-like bottom section; at
least one securing
mechanism for each support element to secure the support elements on the
conveyor belt,
wherein a portion of the securing mechanism is positioned in the hole of the
block-like
bottom section of the support element; a support frame with a support stand
positioned
proximate to a floor surface and support bars; a drive pulley interconnected
to the support
frame and positioned at the top of the support frame, wherein an underside of
the conveyor
belt engages an outer surface of the drive pulley; and an idle pulley
interconnected to the
support frame and positioned at the bottom of the support frame, wherein an
underside of
the conveyor belt engages an outer surface of the idle pulley.
In further embodiments, the inclined portion of the conveying path is
approximately
90 degrees as measured from a horizontal plane. In some embodiments, the
support frame
comprises a substantially vertical portion connected on a top end to a curved
portion, which
is connected to a horizontal portion, and/or the conveyor further comprises a
solid belt-
carrying anti-friction surface positioned at the curved portion of the support
frame. In some
embodiments, the conveyor further comprises four separate return wheels to
carry the
conveyor belt over a return curved portion and back to a bottom of the support
frame.
In one embodiment, a method for conveying articles up steep inclines is
provided,
the method comprising: providing a conveyor for conveying articles up an
incline, said
conveyor comprising: an endless conveyor belt having a lateral extent and a
longitudinal
extent, and an outer article-conveying surface that is designed to advance in
a direction of
belt travel along a conveying path including an inclined portion; a plurality
of support
elements, with each support element having a same width (w), length (1), and
height (h),
wherein each support element of said plurality of support elements is
interconnected to said
outer conveying surface by two independent fasteners that penetrate through
said outer
article-conveying surface, wherein each of said support elements has a front
section having
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an article-supporting face that is oriented in the direction of belt travel,
each of said support
elements having a conveyor contacting surface that engages the outer article-
conveying
surface of the conveyor belt, each of said support elements constructed of
urethane material
that provides strength along the supporting elements, wherein a second support
element in
the plurality of support elements is spaced apart from a first support element
in the plurality
of support elements by a predetermined distance; a support frame with a
support stand, said
support frame having two, longitudinally extending side bar supports extending
parallel to
each other and connected to each other by a plurality of support struts; at
least one pulley
operably connected to said support frame that engages said conveyor belt; a
motor operably
connected to said at least one pulley; moving said endless conveyor belt in
the direction of
belt travel using the motor, the drive pulley, and the idle pulley; conveying
articles on the
outer article-conveying surface of the conveyor belt; advancing the conveyed
articles in the
direction of belt travel along a conveying path including the inclined
portion; blocking
conveyed articles from sliding down the conveying surface of the conveyor belt
on the
inclined portion by using said plurality of support elements; and removing the
conveyed
articles from the conveyor belt.
In some embodiments, the predetermined distance is between about 1.25 and 1.75
times a length of an article conveyed on said conveyor belt. In various
embodiments, the
conveyed articles are tires and/or the inclined portion of the conveying path
is approximately
90 degrees as measured from a horizontal plane.
In some embodiments, a conveyor for conveying articles up inclines may
comprise:
an endless conveyor belt having an outer article-conveying surface and
advancing in a
direction of belt travel along a conveying path; a plurality of support
elements extending
outwardly from the outer article-conveying surface of the conveyor belt and
spaced apart at
least a distance between about 1.0 and 2.0 times a length of the article
conveyed on said
conveyor belt, wherein each support element comprises: a support frame with a
support
stand and an H-stand, the support stand positioned proximate to a first floor
surface and
support bars and the H-stand positioned proximate to a second floor surface
above the first
floor surface; an idle pulley interconnected to the support frame and
positioned at the bottom
of the support frame, wherein an underside of the conveyor belt engages an
outer surface of
the idle pulley; and a drive pulley interconnected to the support frame and
positioned at the
top of the support frame, wherein an underside of the conveyor belt engages an
outer surface
of the drive pulley.
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A first portion of the conveying path may be approximately 90 degrees as
measured
from a horizontal plane and a second portion of the conveying path may be
approximately
parallel to the horizontal plane. The support frame may comprise a
substantially vertical
portion connected on a top end to a curved portion, which may be connected to
a horizontal
portion. The support stand may be positioned at an end of the substantially
vertical portion
and the H-stand may be configured to support the horizontal portion.
In various embodiments, a method for conveying articles up steep inclines may
comprise: providing a conveyor for conveying articles up an incline, said
conveyor
comprising: an endless conveyor belt having a lateral extent and a
longitudinal extent, and
an outer article-conveying surface that is designed to advance in a direction
of belt travel
along a conveying path including an inclined portion; a plurality of support
elements, with
each support element having a same width (w), length (1), and height (h),
wherein each
support element of said plurality of support elements is interconnected to
said outer
conveying surface by two independent fasteners that penetrate through said
outer article-
conveying surface, a support frame with a support stand and an H-stand, the
support stand
positioned proximate to a first floor surface and support bars and the H-stand
positioned
proximate to a second floor surface above the first floor surface; at least
one pulley operably
connected to said support frame that engages said conveyor belt; a motor
operably
connected to said at least one pulley; moving said endless conveyor belt in
the direction of
belt travel using the motor and the at least one pulley; conveying articles on
the outer article-
conveying surface of the conveyor belt; advancing the conveyed articles in the
direction of
belt travel along the conveying path including the inclined portion; blocking
conveyed
articles from sliding down the conveying surface of the conveyor belt on the
inclined portion
by using said plurality of support elements; and removing the conveyed
articles from the
conveyor belt.
A first portion of the conveying path may be approximately 90 degrees as
measured
from a horizontal plane and a second portion of the conveying path may be
approximately
parallel to the horizontal plane. The support frame may comprise a
substantially vertical
portion connected on a top end to a curved portion, which may be connected to
a horizontal
portion. The support stand may be positioned at an end of the substantially
vertical portion
and the H-stand may be configured to support the horizontal portion.
In various embodiments, a portable conveyor system for conveying articles up
inclines may comprise: a conveyor comprising: a conveyor frame; a first pin
disposed at an
end of the conveyor frame; a pair of pulleys disposed at opposite ends of the
conveyor frame;
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a belt configured to revolve around the two pulleys; and at least one cleat
disposed on an
outer surface of the belt and configured to receive and move an object along
the conveyor
frame; a support arm having two frame members disposed opposite each other and
a pair of
arm brackets at an end of each of the two frame members, the support arm
including a
second pin and a third pin, the second pin received by a first arm bracket in
the pair of arm
brackets and the third pin received by a second arm bracket in the pair of arm
brackets,
wherein the third pin pivotably connects the support arm to the conveyor
frame; and a
portable base comprising a base frame, at least one wheel secured to the base
frame, a first
pair of brackets secured to the base frame, and a second pair of brackets
secured to the base
frame and opposite the first pair of brackets, the first pair of brackets
configured to receive
the first pin thereby pivotably coupling the conveyor to the portable base and
the second
pair of brackets configured to receive the second pin thereby pivotably
connecting the
support arm to the portable base
The at least one wheel may be rotatable 360 degrees. The base frame may
comprise
at least one hollow tube configured to receive a fork of a forklift. The
conveyor and the
support arm may each be configured to move between a first position and a
second position.
The support arm may be substantially parallel to the conveyor frame and the
conveyor frame
may be substantially parallel to the portable base when in the second
position. The second
pin may be unconnected from the portable base when the support arm is in the
second
position. The third pin may pivotably couple the support arm to the conveyor
frame near a
mid-section of the conveyor frame.
In some embodiments, a method for moving a portable conveyor system comprised:
removing a portable conveyor system from a shipping container, the portable
conveyor
system in a second position, the portable conveyor system comprising a
conveyor; a support
arm; and a portable base; the conveyor comprising a conveyor frame; a first
pin disposed at
a first end of the conveyor frame; a pair of pulleys disposed at the first end
and a second end
opposite the first end of the conveyor frame; a belt configured to revolve
around the two
pulleys; and at least one cleat disposed on an outer surface of the belt and
configured to
receive and move an object along the conveyor frame; the support arm
comprising two
frame members disposed opposite each other and a pair of arm brackets at the
end of each
of the two frame members; the support arm including a second pin and a third
pin; the second
pin received by a first arm bracket in the pair of arm brackets and the third
pin received by
a second arm bracket in the pair of arm brackets, wherein the third pin
pivotably connects
the support arm to the conveyor frame, and the portable base comprising a base
frame; at
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least one wheel secured to the base frame; a first pair of brackets secured to
the base frame;
and a second pair of brackets secured to the frame and opposite the first pair
of brackets; the
first pair of brackets configured to receive the first pin thereby pivotably
coupling the
conveyor to the portable base and the second pair of brackets; locking the at
least one wheel
to prevent movement of the portable base; lifting the conveyor, thereby
pivoting the
conveyor upwards from the portable base at the first pin and causing the
support arm to
pivot downwards from the conveyor at the third pin; removing the second pin;
aligning the
second pair of brackets and one of the pair of arm brackets of the frame
members; inserting
the second pin through the second pair of brackets and the first bracket in
the pair of arm
brackets of the frame members; and securing the second pin to secure the
portable conveyor
system in a first position.
The pin may be secured using one or more cotter pins. The at least one wheel
may
be rotatable 360 degrees The base frame may comprise at least one hollow tube
configured
to receive a fork of a forklift. The support arm may be substantially parallel
to the conveyor
frame and the conveyor frame may be substantially parallel to the portable
base when in the
second position. The second pin may be unconnected from the portable base when
the
support arm is in the second position. The third pin may pivotably couple the
support arm
to the conveyor frame near a mid-section of the conveyor frame.
In various embodiments, a portable stand comprises: a support arm having two
frame
members disposed opposite each other and a pair of arm brackets at an end of
each of the
two frame members, the support arm including a second pin and a third pin, the
second pin
received by a first arm bracket in the pair of arm brackets and the third pin
received by a
second bracket in the pair of arm brackets, wherein the third pin pivotably
connects the
support arm to a conveyor frame of a conveyor; and a portable base having a
base frame, at
least one wheel secured to the base frame, a first pair of brackets secured to
the base frame
and a second pair of brackets secured to the base frame and opposite the first
pair of brackets,
the first pair of brackets configured to receive the first pin thereby
pivotably coupling the
conveyor to the portable base and the second pair of brackets configured to
receive the
second pin thereby pivotably connecting the support arm to the portable base.
The at least one wheel may be rotatable 360 degrees. The support arm may be
configured to move between a first position and a second position. The support
arm may be
substantially parallel to a conveyor frame when in the second position. The
second pin may
be unconnected from the portable base when the support arm is in the second
position. The
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third pin may pivotably couple the support arm to a conveyor frame near a mid-
section of a
conveyor frame.
While various configurations of the conveyor are herein specified, this
description
is only exemplary and is not intended to limit or otherwise narrow the
invention. The
conveyor may include any number of components in any potential combination
thereof as
desired for achieving the desired function for desired article shape and size
and incline.
One or ordinary skill in the art will appreciate that embodiments of the
present
invention may be constructed of materials known to provide, or predictably
manufactured
to provide the various aspects of the present invention. For example,
materials used in the
support structure of the conveyor may include, for example, metal, composites,
plastics, and
other synthetic and natural materials. Further, the belt of the conveyor may
be comprised of
rubber, latex, synthetic rubber, synthetic materials, polymers, and natural
materials.
As used herein, the term "a" or an entity refers to one or more of that entity
As
such, the terms "a" (or "an"), one or more and "at least one can be used
interchangeably
herein. It is also to be noted that the terms "comprising", "including", and
"having" can be
used interchangeably.
As used herein, "at least one, one or more, and "and/or" are open-ended
expressions that are both conjunctive and disjunctive in operation. For
example, each of the
expressions "at least one of A, B and C", "at least one of A, B, or C", "one
or more of A, B,
and C", "one or more of A, B, or C" and "A, B, and/or C" means A alone, B
alone, C alone,
A and B together, A and C together, B and C together, or A, B and C together.
The phrases "device", "apparatus", "conveyor", "conveyor apparatus", and
"conveyor device" are used herein to indicate the invention device.
The phrase "removably attached", "removable", and/or "detachable" is used
herein
to indicate an attachment or connection of any sort that is readily releasable
or disconnected.
This Summary of the Invention is neither intended nor should it be construed
as
being representative of the full extent and scope of the present invention.
The present
invention is set forth in various levels of detail in the Summary of the
Invention as well as
in the attached drawings and the Detailed Description, and no limitation as to
the scope of
the present invention is intended by either the inclusion or non-inclusion of
elements,
components, etc. in this Summary of the Invention. Additional aspects of the
present
invention will become more readily apparent from the Detailed Description,
particularly
when taken together with the drawings.
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The above-described benefits, embodiments, and/or characterizations are not
necessarily complete or exhaustive, and in particular, as to the patentable
subject matter
disclosed herein. Other benefits, embodiments, and/or characterizations of the
present
disclosure are possible utilizing, alone or in combination, as set forth above
and/or described
in the accompanying figures and/or in the description herein below. However,
the Detailed
Description, the drawing figures, and the claims set forth herein, taken in
conjunction with
this Summary of the Invention, define the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Those of skill in the art will recognize that the following description is
merely
illustrative of the principles of the invention, which may be applied in
various ways to
provide many different alternative embodiments. This description is made for
illustrating
the general principles of the teachings of this invention and is not meant to
limit the
inventive concepts disclosed herein
The accompanying drawings, which are incorporated in and constitute a part of
the
specification, illustrate embodiments of the invention and together with the
general
description of the disclosure given above and the Detailed Description of the
drawings given
below, serve to explain the principles of the disclosures.
Fig. 1 shows one embodiment of a nose-over vertical tire conveyor;
Figs. 2A and 2B show another embodiment of a nose-over vertical tire conveyor;
Fig. 3 shows the nose-over vertical tire conveyor of Figs. 2A-B conveying
tires and
with a stand and ramp on the second floor;
Fig. 4 shows the top end of the nose-over vertical tire conveyor of Figs. 2A-3
without the belt;
Fig. 5 shows the bottom end of the nose-over vertical tire conveyor of Figs.
2A-3
without the belt;
Fig. 6 shows an embodiment of a nose-over vertical tire conveyor;
Fig. 7 shows an embodiment of a nose-over vertical tire conveyor;
Figs. 8A, 8B, 8C, and 8D show an embodiment of a cleat for a vertical tire
conveyor according to embodiments of the present invention;
Fig. 9 is a front perspective view of a vertical tire conveyor according to
embodiments of the present invention;
Fig. 10 is a front perspective view of the conveyor of Fig. 9 shown without
the belt
guard;
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Fig. 11 is a front perspective view of the conveyor of Fig. 10 shown conveying
tires;
Fig. 12A is a front perspective view of the conveyor of Fig. 10 shown without
the
conveyor belt;
Fig. 12B is a zoomed in view of the upper or top end of the conveyor of Fig.
12A;
Fig. 13 is a front perspective view of the conveyor of Fig. 12A shown with the
solid belt-carrying anti-friction surface removed to show the belt return
carrying surface;
Figs. 14A and 14B are rear perspective views of the conveyor of Fig. 10 shown
without the conveyor belt such that the mechanism by which the belt returns
inside the
conveyor frame can be seen;
Figs. 15A and 15B show the standalone return wheel assembly;
Fig. 16 shows a belt tracking aid called a belt liner;
Figs 17A, 17B, 17C, and 17D show a cleat for a vertical tire conveyor
according
to embodiments of the present disclosure;
Fig. 18 is a front perspective view of a nose-over vertical tire conveyor
according
to embodiments of the present disclosure;
Fig. 19 is a zoomed in view of a first end of the conveyor of Fig. 18;
Fig. 20 is a zoomed in view of a second end of the conveyor of Fig. 18;
Fig. 21 is another zoomed in view of the second end of the conveyor of Fig.
18;
Fig. 22A is front perspective view of a conveyor on a portable stand in a
first
position according to at least one embodiment of the present disclosure;
Fig. 22B is another front perspective view of the conveyor on the portable
stand of
Fig. 22A;
Fig. 23A is a front perspective view of the conveyor on the portable stand of
Fig.
22A in a second position;
Fig. 23B is a side view of the conveyor on the portable stand of Fig. 22A in
the
second position;
Fig. 24A is a front perspective view of the portable stand of Fig. 22A; and
Fig. 24B is a side view of the portable stand of Fig. 22A.
It should be understood that the drawings are not necessarily to scale, and
various
dimensions may be altered. In certain instances, details that are not
necessary for an
understanding of the invention or that render other details difficult to
perceive may have
been omitted. It should be understood, of course, that the invention is not
necessarily
limited to the particular embodiments illustrated herein.
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DETAILED DESCRIPTION
The invention described herein relates to a conveyor used in any application
where
an article (such as a tire) may need to be transported or lifted more than
five feet. Such
applications include moving tires and articles during manufacture, after
manufacture to be
shipped, loading tires and articles on the shipping vessels, unloading the
tires and articles
off of the shipping vessels, and moving the tires and articles within stores
and warehouses
to their final storage place.
It should be appreciated that the particular implementations and embodiments
shown
and described herein are illustrative of the invention and are not intended to
otherwise limit
the scope of the present invention in any way. Indeed, for the sake of
brevity, trivial and
conventional features and aspects of the present invention are not described
in extensive
detail herein. It should be understood that the legal scope of the description
is defined by
the words of the claims set forth at the end of this disclosure The detailed
description is to
be construed as exemplary only and does not describe every possible embodiment
since
describing every possible embodiment would be impractical, if not impossible.
Numerous
alternative embodiments could be implemented, using either current technology
or
technology developed after the filing date of this patent, which would still
fall within the
scope of the claims. Furthermore, the connecting lines shown in the various
figures shown
herein are intended to represent exemplary functional relationships and/or
physical
couplings between the various elements of the system. It should be noted that
many
alternative or additional functional relationships or physical connections may
be present in
a practical conveyor apparatus, conveying system, conveying method, tire
sorting system,
and tire loading system.
Figure 1 shows one embodiment of a nose-over vertical tire conveyor 100. The
nose-
over vertical tire conveyor 100 is very compact with a small footprint and
suitable for
retrofitting spaces such as tire service areas. Such conveyors may be used to
move, for
example, tires bottom to top or top to bottom of the conveyor. In other words,
the conveyor
may be used to move tires from a first floor to a second floor or from the
second floor to the
first floor. The VTC 100 includes a frame 106 with a stand 104, which may be a
base plate
bolted-down to the ground floor 102, at the bottom end 108. The frame 106 may
be
comprised of high-strength steel tubing on approximately 60" centers, in some
embodiments. The VTC 100 extends from the ground floor 102 to the mezzanine
(or second)
floor 110. The height H1 between the ground floor 102 and mezzanine floor 110
can vary,
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but the embodiment shown contemplates a height H1 of about 10.0 ft, or between
about 8.0
ft. and 14.0 ft.
The VTC 100 has a belt (not visible in this view) with cleats 112
interconnected
thereto, a belt take-up adjuster, belt take-up adjustment frames 114, a motor
116, and an H-
stand 120. The belt can be between about 10" and about 20" wide. In a
preferred
embodiment, the belt is about 18" wide. The cleats 112 can be any known cleats
112, but
are preferably between about 4" tall and 7" tall. In a preferred embodiment,
the cleats are 6"
high/tall urethane cleats that are bolted onto the belt.
The motor 116 can be any known motor, but is a 15V motor in some embodiments.
The motor 116 may be interconnected to one or more roller chains, sprockets,
and safety
guards. The roller chains may be speed reducer roller chains in some
embodiments. Thus,
the roller chain transfers power between the speed reducer and the drive shaft
positioned
through the drive pulley, via sprockets In some embodiments, the nose-over VTC
100 has
a right-angle speed reducer that is mounted under the conveyor frame at the
top end 122. In
other embodiments, the nose-over VTC 100 has an in-line motor and speed
reducer mounted
under the conveyor frame. However, either of these motors and speed reducers
could be
used in any conveyor described herein.
The H-stand 120 positions the top end 122 of the conveyor 100 at the desired
height
H2 above the mezzanine floor 110. In some embodiments, this height H2 is
between about
2.0 ft. and about 5.0 ft. In a preferred embodiment, the height is about 4.0
ft. or about 4 ft.
1 in. The conveyor 100 extends a length L2 horizontally along the mezzanine
floor 110. In
some embodiments, this length L2 is between about 4 ft. and 7 ft. In a
preferred embodiment,
this length L2 is between about 5 ft. and about 6 ft. In a more preferred
embodiment, this
length L2 is about 5.5 ft.
The depth or length Li of the conveyor can vary. In some embodiments, the
length
Li is between about 10" and about 14". In a preferred embodiment, the length
Li is about
11-1/8". The conveyor 100 needs more floor space than the length Li because it
must
accommodate the articles being conveyed and any hand rails added to the frame
to protect
and enclose the articles being conveyed. Thus, the length L3 is the amount of
floor space
needed by the VTC 100. In some embodiments, the length L3 is between about 2
ft. and
about 4 ft. In a preferred embodiment, the length L3 is about 30- (2.5 ft.).
If an opening in
the mezzanine floor 110 is necessary for the conveyor 100 to extend from the
ground floor
102 to the mezzanine floor 110, then¨assuming the hole has a rectangular
shape¨the
opening should extend the length L3 in one direction and should be a few
inches larger than
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the diameter of the largest conveyed tire or article in the other direction.
The perimeter of
an opening in the mezzanine floor 110 should have a hand rail extending around
the entire
perimeter for safety reasons.
Similar to other conveyors described herein, the conveyor 100 can be comprised
of
two sections bolted together at a double rail or double square portion 118,
which could be
positioned at either location shown in Fig. 1. Having the conveyor frame 106
be comprised
of two pieces makes installation and transportation of the conveyor easier.
Figures 2A-B show another embodiment of a nose-over vertical conveyor 200.
Fig.
2A is a perspective view and Fig. 2B is a side view of the conveyor 200. The
conveyor 200
comprises a frame 206 and belt 224 with cleats 212. The bottom end 208 is the
idle end and
the upper end 210 is the drive end in this embodiment because the motor 216 is
positioned
at the top drive end 210. The motor 216 is interconnected to the drive pulley
via a roller
chain or drive belt (not visible in this view) and sprockets Thus, proximate
the motor 216
and covering the roller chain and sprockets is a guard 202. The motor 216 can
be an electric
motor and include a speed reducer in some embodiments. The motor can be
positioned at
the bottom end 208 in other embodiments. The bottom end 208 includes a stand
204 that
can be bolted to the floor. The idle pulley 228 is positioned at the bottom
idle end 208 with
the belt tension adjustment mechanism 218.
The nose over conveyor 200 also includes one or more belt return rollers 226
to
direct and guide the belt 224 in the proper direction, i.e., around the 90
bend. In these views,
the returning belt 224A (i.e., the portion of the belt not conveying articles
and moving from
the drive end to the idle end) and the returning cleats 212A (i.e., the cleats
not conveying
articles and moving from the upper end 210 to the bottom end 208) can be seen.
Additionally, the horizontal portion 214 of the conveyor 200 is typically the
portion
positioned on the second floor or mezzanine. The horizontal portion 214 may
have the belt
224 positioned at a downward angle relative to the horizontal plane in order
to eject or drop
conveyed articles (e.g., tires) off of the conveyor without a person having to
take the article
off of the conveyor 200.
Figure 3 shows the nose-over vertical tire conveyor 200 of Figs. 2A-B
conveying
tires 300 and with an H-stand 308 and a ramp 302 on the second floor 304. The
ramp 302
may be a plurality of gravity rollers at the top discharge end 210 to assist
in removing the
tires 300 from the conveyor 200. The bottom idle end 208 is positioned on the
ground 306.
Figure 4 shows the top end of the nose-over vertical tire conveyor of Figs. 2A-
3
without the belt and Fig. 5 shows the bottom end of the nose-over vertical
tire conveyor of
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Figs. 2A-3 without the belt. In Figs. 4 and 5 the idle pulley 228 and the
drive pulley 232 are
visible. Additionally, the belt return rollers 226 can be seen.
Figure 6 is a perspective view of the nose-over vertical tire conveyor of
Figs. 2A-5
with the ramp 302 at the end of the discharge end 210. Here the ramp 302 is
shown with
gravity rollers or bars 310 to slide the tires 300 or articles off of the
conveyor 200 and onto
the mezzanine floor 304. One advantage of the nose-over vertical tire conveyor
200 is that
minimal ground floor clearance is required.
Figure 7 shows another embodiment of a nose-over vertical tire conveyor 700.
The
conveyor 700 has a frame 706 with a stand or base 704 on the bottom idle end
708. The
conveyor 700 also has a conveyor belt 724 with cleats 712 interconnected to
the belt 724.
The top drive end 710 has a motor 716 and a guard 702 covering the drive belt
or chain and
sprocket. The embodiment shown also includes a ramp (also called a "staging
platform"
herein) 736 at the end of the conveyor's top or discharge end 710_ The ramp
736 can have
gravity rollers or bars 4807 to slide the tires 4400 or articles off of the
conveyor 700 and
onto the mezzanine floor 734. The conveyor 700 includes an H-stand at the
discharge end
710 to position the discharge end 710 at the proper height above the mezzanine
floor 734
and to support the discharge end 710. The staging platform 736 may not extend
all the way
down to the mezzanine floor 734 and, instead, may have a second stand 4874 on
the end of
the staging platform 736 opposite the conveyor 700. The staging platform 736
can vary in
length L5 depending on the end user's needs. For example, the length L5 of the
staging
platform 736 is between about 2.0 ft and about 5.0 ft. in some embodiments. In
a preferred
embodiment, the length L5 of the staging platform 736 is about 36" (3 ft.).
One advantage
of the staging platform 736 is that it provides for safe unloading of articles
and safe loading
of articles (i.e., loading for descent). The staging platform 736 also keeps
operators clear of
moving drive parts in the drive end 710 and away from the mezzanine edge.
The height H1 of the mezzanine floor 734 above the ground floor varies
depending
on the installation location and the conveyor 700 can vary as well. However,
in the
embodiment shown the height H1 is between about 6.0 ft. and about 12.0 ft. In
one
embodiment, the height H1 of the mezzanine floor 734 above the ground floor is
about 8.0
ft.
Another advantage of the nose-over VTC 700 is that it has a small base
footprint and
can be confined within a distance L4 of the mezzanine's edge, which means it
is clear of
bay work areas and is positioned around fire sprinkler water lines 738 and
other electrical
lines. In some embodiments, the distance L4 of the edge of the base stand 704
to the
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mezzanine edge is between about 12" and about 36". In a preferred embodiment,
the
distance L4 of the edge of the base stand 704 to the mezzanine edge is about
24". On the
ground level, the conveyor 700 has easy and clear access to the loading face
of the conveyor
700.
In some embodiments, the conveyor 700 has controls on both ends 708, 710 of
the
conveyor, e.g., up, down, and emergency stop. In various embodiments, the
motor 716 is a
115 VAC motor with a speed reducer and safety guards 702. Thus, the conveyor
700
requires minimal ground floor clearance next to the mezzanine and is also
capable of
clearing existing structures such as fire service lines and electrical lines.
The top-end nose
over allows for easy unloading (or loading for descent) of tires or other
articles and keeps
the operator clear of moving conveyor parts and the mezzanine edge.
Figures 8A-D show an embodiment of a cleat 800 for a vertical tire conveyor
according to embodiments of the present invention Specifically, Fig 8A is a
perspective
view of the cleat 800, Fig. 8B is a top plan view of the cleat 800, Fig. 8C is
a side view of
the cleat 800, and Fig. 8D is a rear view of the cleat 800. In some
embodiments, the cleat
shown is for a nose-over vertical tire conveyor; however, the cleat can be
used with other
vertical and incline or non-vertical conveyors.
In some embodiments, the cleat 800 is a 4.0" tall cleat. In other embodiments,
the
cleat 800 is a 2.0" cleat, a 5.0" cleat, a 6.0" cleat, an 8.0" cleat, or any
height between 3.0"
and 8.0". The cleat 800 may also include holes 802 for bolts or other
attachment or
interconnection mechanisms. In one embodiment, the holes 802 have a diameter
between
about 1/8" and 1". In a preferred embodiment, the holes 802 have a diameter of
about 0.28".
The cleat 800 can have a flat lower area 804 (also called a "block" herein) or
a curved block
804. In one embodiment, the under surface 806 of the block 804 has a radius of
curvature
R6 between about 4" and about 8" and the block 804 has a width W1 between
about 1.5"
and about 3.5". In a preferred embodiment the under surface 806 of the block
804 has a
radius of curvature R6 of about 6.0" and the block 804 has a width of 2.5".
The block can
have a flat or a curved upper surface 808. In one embodiment, the height H2 of
the block
804 (i.e., from the under surface 806 to the upper surface 808) is between
about 1/2" and
about 1.0". In a preferred embodiment, the height H2 of the block 804 (i.e.,
from the under
surface 806 to the upper surface 808) is about 3/4-. The outer edge of the
block 804 can
have a square corner or a rounded corner. In one embodiment, the radius of
curvature R5 of
the corner of the block 804 is between about 1/16" and about 1/2". In a
preferred
embodiment, the radius of curvature R5 of the corner of the block 804 is about
1/4".
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In some embodiments, the cleat 800 also has a curved section 810. The curved
section 810 has a back side 812 (i.e., the side facing away from the article
conveyed) and an
article-supporting face (also called a "carrying surface") 814 positioned
opposite the back
side 812. In one embodiment, the article-supporting face 814 has a larger
radius of curvature
R7 than the radius of curvature R8 of the back side 812. Thus, the radius of
curvature R7 of
the article-supporting face 814 may be between about 5.0" and about 12.0" and
the radius
of curvature R8 of the back side 812 may be between about 4.0" and about 12.0"
in some
embodiments. In a preferred embodiment, the radius of curvature R7 of the
article-
supporting face 814 is about 9.0" and the radius of curvature R8 of the back
side 812 is
about 8.0".
The cleat 800 also has atop 816 and sides 818. In one embodiment, the height
H1
from the under surface 806 to the top of the top 816 is between about 3.0" and
about 6.0".
In a preferred embodiment, the height H1 from the under surface 806 to the top
of the top
816 is about 4.0". In one embodiment, the length Li from one side 818 to the
other side is
between about 2" and about 5". In a preferred embodiment, the length Li from
one side 818
to the other side is about 3.25". Additionally, the top 816 may be flat or
curved.
In one embodiment, the entire width W2 of the cleat 800 is between about 1.0"
and
about 5.0". In a preferred embodiment, the width W2 of the cleat 800 is about
2.98". Further,
the holes 802 are positioned a distance W3 from the edge of the block 804,
where the
distance W3 is between about 0.5" and about 2". In a preferred embodiment, the
holes 802
are positioned a distance W3 from the edge of the block 804, where the
distance W3 is about
1.13". Additionally, the holes 802 are positioned a distance W4, W5 from the
side 810,
where the distance W4, W5 is between about 1/4" and about 1". In a preferred
embodiment,
the holes 802 are positioned a distance W4, W5 from the side 810, where the
distance W4,
W5 is about 0.56". The cleat 800 can be urethane or any known material in the
art. The cleat
800 may have a narrow width Li and radius edges 5150 to prevent damage to the
conveyed
tires' inner beads.
Figure 9 is a perspective front view of a vertical nose over conveyor 900
according
to embodiments of the present invention. Figure 10 is similar to the conveyor
of Fig. 9 but
without the belt guard 901. The conveyor 900 comprises a conveyor belt 906
that revolves
around two pulleys 920 (visible in Fig. 12A), one each at a top end 903 and a
bottom end
905. Cleats 904 are secured to the conveyor belt 906 at intervals and are used
to carry tires
300 up and down along the conveyor frame 922. Fig. 9 is a "non-use" form with
a belt guard
901 placed on the conveyor 900 at the bottom end 905 to prevent personnel from
getting
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entangled with the belt cleats 904. The conveyor belt 906 and conveyor frame
922 are
narrower than in previous nose-over designs in order to minimize the conveyor
900
footprint.
The conveyor 900 also includes a motor 950 interconnected to the one of the
pulleys
920 pulley via a roller chain or drive belt 924 (visible in Fig. 13) and
sprockets 930. Thus,
proximate the motor 950 and covering the roller chain and sprockets is a guard
980. The
motor 950 can be an electric motor and include a speed reducer in some
embodiments. The
motor 950 is positioned near the top end. The motor 950 can be positioned at
the bottom
end 903 in other embodiments. The bottom end 903 includes a stand 912 that can
be bolted
to the floor. The conveyor 900 also includes a motor cage 972 on which the
motor 950 may
be positioned. The top end 905 includes an extension 902 of the frame 922. The
extension
902 may comprise a pair of U-shaped tubing extending from the frame 922 at the
top end
905 to prevent a user from contacting the top end 905 (including cleats 904)
In some
embodiments the extension 902 may not be U-shaped and may be any shape
extending from
the top end 905. In some embodiments, the extension 902 may extend from the
top end 905
and the motor frame 972. In other embodiments, the conveyor 900 may not
include the
extension. It will be appreciated that any conveyor described herein may
comprise the
extension 902.
Figure 11 shows the conveyor of Fig. 10 conveying tires 300.
Figure 12A is a perspective front view of the conveyor of Figs. 10 and 11
shown
without the conveyor belt 906. Fig. 12B is a zoomed in view of the top end of
the conveyor
900 of Fig. 12A. In this embodiment, the upper rounded part of the conveyor
frame 922 has
a different belt-carrying surface 926 than other embodiments. Specifically,
the conveyor
frame 922 has a solid sheet or plate 926 at the curved upper end of the frame
922, whereas
the belt-carrying surface on the vertical portion of the conveyor frame is
tubular rails 928.
In other embodiments, for example the conveyor frame 206 shown in Fig. 4, the
top carrying
surface is a continuation of the vertical tubular rails around the curve of
the frame 206. The
solid belt-carrying surface 926 at the upper curved portion of the frame 922
in Figs. 12A-B
is an anti-friction surface that supports the belt 906 around the curve. The
reduced friction
at the curve reduces wear on the belt 906 as well as reduces wear on the drive
components
of the conveyor 900 (e.g., motor, gearbox, roller chain, sprockets, etc.). In
one embodiment,
the anti-friction surface is UHMW (ultra-high-molecular-weight) polyethylene.
In other
embodiments, the anti-friction surface may include other engineered plastics
that have a
favorable low coefficient of friction and abrasion-resistant properties.
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Figure 13 shows the conveyor frame 922 of Fig. 12A with the solid belt-
carrying
anti-friction surface 926 removed to show the belt return carrying surface
that is contained
within the conveyor frame 922.
Figure 14A is a rear perspective view of the conveyor 900 of Figs. 9-13 shown
without the conveyor belt 906 such that the mechanism by which the belt
returns inside the
conveyor frame 922 can be seen. In other embodiments, the belt 906 was carried
by a series
of rollers, where each roller had a shaft that was mounted in plates on both
sides of the
conveyor frame. In the small footprint, vertical, nose-over conveyor of Figs.
9-14B, the
conveyor 900 has four separate return wheels 932 (an additional return wheel
is adjacent to
the visible return wheels 932) to carry the belt over the conveyor curve and
back to the
bottom of the conveyor frame. In other embodiments, the conveyor 900 may have
less or
greater than four wheels. Each return wheel 932 has its own shaft 934,
bearing, and base
936, as well as a mounting bracket 938 designed with an important belt
tracking feature
Figure 14B is an enlarged view of the top of the conveyor of Fig. 14A and
shows
how the return wheel assembly 932 is mounted inside the conveyor frame 922.
When the
return wheel assembly 932 is installed, it rests on a shelf 940 that is a part
of the conveyor
frame 922 and uses two fasteners (in the embodiment shown, socket head cap
screws) to fix
the return wheel assembly 932 to the conveyor frame 922. When tightened, the
two fasteners
oppose each other about a fulcrum 942 (i.e., the bar-shaped feature seen in
Fig. 15A),
allowing the return wheel assembly 932 to pivot in order to influence the belt
motion with
the goal of centering the belt 906 within the frame 922. Fig. 14B also shows
added nose
loops, which help protect personnel from the belt cleat at the top end of the
conveyor.
Figures 15A and 15B show the standalone return wheel assembly 932. Fig. 15A is
a
perspective front view and Fig. 15B is a perspective rear view of the
standalone return wheel
assembly 932. In some embodiments the standalone return wheel assembly 932 is
adjustable
so as to adjust a steering of the belt. However, in other embodiments, the
standalone return
wheel assembly 932 is not adjustable and thus, may comprise less parts. For
example, the
base 936 may be integrated with the mounting bracket 938.
Figure 16 shows an additional belt tracking aid¨sometimes called a belt liner
944.
The belt liner 944 has three components: a roller 946, a shaft 948, and
bracket 951. The
three components are shown assembled. The belt liner 5444 places hard limits
on the belt's
ability to track away from center and is a secondary measure to aid in ideal
belt tracking. In
other words, the belt liner 944 prevents the belt from moving too far away
from an end of
the frame 922.
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Figures 17A-D show another embodiment of a cleat 904 (also called a support
element herein) and an improved version of the cleat shown in Figs. 8A-D. The
cleat 904 of
Figs. 17A-D fastens to the conveyor belt at the leading edge 906 of the cleat
904. With the
cleat 904 fastened in this way, along with its long base 908, the cleat 906
can better support
a heavy tire being conveyed vertically without causing the belt 906 to fold
back on itself.
This design supports the goal of having a minimally tensioned belt, which
increases the life
of conveyor components. The cleat 904 is also designed to aid in tire
disengagement at the
top end of the conveyor 900 by minimizing the tire contact area as the cleat
904 approaches
the top belt pulley 920.
Figure 18 shows a perspective front view of another vertical nose over
conveyor
1800. The conveyor 1800 is generally the same as or similar to the conveyors
100, 200, 700,
900 described above. The conveyor 1800 comprises a frame 1802 extending from a
first end
1804 to a second end 1806, a first pulley (not visible) positioned at the
first end 1804, a
second pulley (not visible) positioned at the second end 1806, a motor 1808
configured to
drive the second pulley, a belt 1810 that rotates around each of the first
pulley and the second
pulley, and cleats 1812 attached to the belt 1810. As previously described,
the conveyor
1800 may be used to move objects, such as tires 300, from the first end 1804
to the second
end 1806.
In some embodiments, the conveyor 1800 may comprise a horizontal extender 1814
which may extend the second end 1806 horizontally away from the first end
1804. The
horizontal extender 1814 may be, for example, between about lft to 5ft. In
other
embodiments, the horizontal extender is about 1.0ft, 1.25ft, 1.5ft, 1.75ft,
2.0ft, 2.25ft, 2.5ft,
2.75ft, 3.0ft, 3.25ft, 3.5ft, 3.75ft, 4.0ft, 4.25ft, 4.5ft, 4.75ft, 5.0ft, or
any range therebetween.
In other embodiments, the horizontal extender 1814 may be less than lft or
greater than 5ft.
In some embodiments, the horizontal extender 1814 enables a middle, vertical
portion 1816
of the conveyor 1800 (and thus, also the first end 1804) to be positioned away
from the
mezzanine floor. In such embodiments, the horizontal extender 1814 may enable
space
between the middle, vertical portion 1816 and a wall or support for the
mezzanine floor such
that a user can walk underneath the horizontal extender 1814 and behind the
middle, vertical
portion 1816. In other embodiments, the horizontal extender 1814 may, for
example,
position an unloading zone of the second end 1806 away from an edge of the
mezzanine and
may keep users a safe distance away from the edge.
The conveyor 1800 may also comprise an extension 1818 extending from the
second
end 1806 of the frame 1802. The extension 1818 may provide clearance for a
cleat 1812 as
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the cleat 1812 rotates around the pulley. The extension 1818 may comprise a
pair of U-
shaped tubing extending from the frame 1802 at the second end 1806 to prevent
a user from
contacting the second end 1806 (including cleats 1812). In some embodiments
the extension
1818 may not be U-shaped and may be any shape extending from the second end
1806. For
example, the extension 1818 may be sized so as to cover a profile of a cleat
1812 rotating
around the pulley. In some embodiments, the extension 1818 may extend from the
second
end 1806 and motor frame 1820. In other embodiments, the conveyor 1800 may not
include
the extension. It will be appreciated that any conveyor described herein may
comprise the
extension 1818.
The conveyor 1800 may also comprise one or more panels 1822 coupled to the
frame
1802. The one or more panels 1822 may prevent a user from contacting moving
parts within
the frame 1802 such as the belt 1810, cleats 1812, pulleys, or any other
component of the
conveyor 1800 In the illustrated embodiment the one or more panels 1822
comprise a side
panel 1822, though it will be appreciated that in other embodiments the one or
more panels
1822 may comprise more than one panel and may cover any portion of the
conveyor 1800.
The one or more panels 1822 may also provide a surface to mount controls,
decals (e.g.,
safety decals, operating decals, etc.), hooks, or any other component thereon.
For example,
a control box may be mounted near the first end 1804 or the second end 1806 of
the conveyor
1800. The one or more panels 1822 may comprise sheet metal, though the one or
more
panels 1822 may comprise any other material. The one or more panels 1822 may
be welded
to the frame 1802, though in other embodiments the one or more panels 1822
Turning to Figure 19, an adjustable base 1824 of the conveyor 1800 is shown in
detail. The adjustable base 1824 may comprise a stand 1826 which may be bolted
to a floor.
The adjustable base 1824 may also comprise a first tubing 1828 extending from
the stand
1826 and a threaded rod 1830 extending from the first tubing 1828. In some
embodiments,
the threaded rod 1830 and the first tubing 1828 are integrated. In other
embodiments, the
threaded rod 1830 and the first tubing 1828 are secured to each other by, for
example,
adhesives, welds, or the like. In some embodiments, a first bore of the first
tubing 1828 may
be threaded and the rod 1830 may be threaded into the first inner bore. In
such embodiments,
an adhesive such as Loctite may be used to secure the rod 1830 to the first
tubing 1828. A
second end of the threaded rod 1830 may be received by a second inner bore of
a second
tubing 1836, a first nut 1832, and a second nut 1834. The second inner bore
may be smooth
such that the rod 1830 freely slides in and out of the second tubing 1836. The
first nut 1832
and the second nut 1834 may be, for example, hex nuts, however, the first nut
1832 and the
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second nut 1834 may be any type of nut. It will be appreciated that the first
nut 1832, the
second nut 1834, and the second tubing 1836 may be independent of each other.
The second
nut 1834 may be positioned between the first nut 1832 and the second tubing
1836 and the
second nut 1834 may act as an adjustment nut to adjust a height of the
conveyor 1800,
described in more detail below. It will be appreciated that in the illustrated
embodiment, the
adjustable base 1824 comprises four of each of the rod, the first tubing, the
second tubing,
the first nut, and the second nut. In other embodiments, the adjustable base
1824 may
comprise any number of rods, first tubings, second tubings, first nuts, and
second nuts.
The adjustable base 1824 may adjust a height of the conveyor 1800. When the
second nut 1834 is rotated, the rod 1830 may translate into and out of the
second tubing
1836. More specifically, when the second nut 1834 is rotated in a first
direction, the rod
1830 translates into the second tubing 1836 and the frame 1802 of the conveyor
1800 moves
towards the stand 1826, thus lowering the conveyor 1800 towards the floor.
When the
second nut 1834 is rotated in a second direction, the rod 1830 extends from
the second
tubing 1836 and the frame 1802 of the conveyor 1800 moves away from the stand
1826,
thus raising the conveyor 1800 away from the floor. Once a desired height
adjustment is
reached, the first nut 1832 is used as a jam nut that uses friction to prevent
rotation of the
second nut 1834. It will be appreciated that in the illustrated embodiment,
each of the four
rods may be adjusted to different lengths. For example, a first rod may be
adjusted to a first
length and a second rod may be adjusted to a second length different from the
first length.
The adjustable base 1824 provides an adjustment to a height of the conveyor
1800 between
about lin to 6in. In a preferred embodiment, the adjustable base 1824 provides
an
adjustment to the height of the conveyor 1800 between about 2in and 3in. It
will be
appreciated that in other embodiments, the adjustable base 1824 may provide
more than 6in
of adjustment or less than lin of adjustment. Such adjustments allow for the
stand 1826 to
be adjusted to variations in the floor. For example, two of the rods may be
adjusted to
account for an angle in the floor.
Turning to Figures 20 and 21, a close-up perspective view and a close-up side
view
of the second end 1806 of the conveyor 1800 are respectively shown. The
conveyor 1800
may comprise a motor frame 1820. The motor frame 1820 may act as a stand on,
for
example, a mezzanine floor and may provide support for the second end 1806 of
the
conveyor 1800. The motor frame 1820 may also house the motor 1808. The motor
1808
may be positioned at an end of the motor frame 1820 opposite the extension
1818 and a
back of the motor 1808 may face towards the middle, vertical portion 1816 of
the conveyor
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1800. Such positioning of the motor 1808 within the motor frame 1820 enables a
shortening
of a length of the motor frame 1820, thereby reducing a footprint of the motor
frame 1820
on the mezzanine floor. Such reduction in the footprint of the motor frame
1820 allows for
more floor space for other components outside of the conveyor 1800. More
specifically, a
length of a conventional motor frame may be 36" and a length of the motor
frame 1820 is
30".
During use a tire such as the tire 300 is looped over the cleat 1812 (whether
moving
tires from the first end 1804 to the second end 1806 or vice versa). When
moving tires from
the first end 1804 to the second end 1806, each cleat 1812 may be loaded with
a tire.
However, when moving tires from the second end 1806 to the first end 1804, a
tire may be
loaded on every three cleats 1812 so that a user unloading the tire at the
first end 1804 is not
unloading a tire as a new tire is being lowered. This is because the user
needs more time to
safely unload tires coming down the conveyor and means that the belt speed
does not have
to be slowed when moving tires down from the second floor. Alternatively,
tires can be
loaded on every cleat 1812 when moving tires down the conveyor from the second
floor if
the belt speed is slowed. In other instances, the tire may be loaded on any
cleat 1812
(whether the first, second, third, fourth, or fifth clear).
Figures. 22A-22B show a first and second perspective view, respectively, of a
conveyor 2200 on a portable stand 2202 in a first position. The stand 2202 may
aid in
conveyor transportation and assembly (of which, in some embodiments, assembly
may be
aided by the use of a forklift). The conveyor 2200 may be a floor-to-floor
incline conveyor
for conveying objects such as, for example, tires. In other embodiments, the
conveyor may
be a nose-over vertical tire conveyor such as described above. The stand 2202
may be
shipped separately from the conveyor 2200, though the stand 2202 may also be
shipped with
the conveyor 2200 in other instances. In some embodiments, the stand 2202 may
be installed
on the conveyor 2200 and the conveyor 2200 and the stand 2202 may be shipped
together
as one unit. The conveyor 2200 comprises a conveyor belt 2206 that revolves
around two
pulleys (not visible), one each at the top and bottom ends. Cleats 2204 (which
may be the
same as or similar to any cleats described herein) are secured to the conveyor
belt 2206 at
intervals along the belt 2206.
The conveyor 2200 also includes a motor 2250 (visible in Fig. 22B)
interconnected
to one of the pulley via a roller chain or drive belt and sprockets (not
visible). Thus,
proximate the motor 2250 and covering the roller chain and sprockets is a
guard 2280. The
motor 2250 can be an electric motor and include a speed reducer in some
embodiments. The
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motor 2250 can be positioned at the bottom end in some embodiments, as
illustrated. The
conveyor 2200 may also have a motor frame 2208 which houses the motor 2250, a
speed
reducer gearbox (not visible), and control switches 2252 (visible in Fig.
22A). A footprint
of the motor frame 2208 (and the assembly or configuration of the components
housed
within the motor frame 2208) may be sized to minimize a footprint of the motor
frame 2208
so as to achieve a shipping configuration, shown in Figs. 23A-23B. more
specifically, the
footprint or volume of the motor frame is sized so as to allow the conveyor
2200 to rest
substantially or near parallel to the base 2210 when in the shipping
configuration.
The conveyor 2200, as shown in Figures 22A-22B, is mounted to the portable
stand
2202. The stand 2202 includes hollow fork tubes or pockets and casters or
wheels, which
provide mobility in two configurations: a first, upright, or assembled
position¨shown in
Figures 22A-22B¨and a second, horizontal, or shipping position¨shown in
Figures 23A-
23B
Turning to Figures 24A-24B, the stand 2202 is shown in a front perspective
view
and a side view, respectively. The stand 2202 comprises a base 2210 and a
support arm
2212. In the illustrated embodiment, the base 2210 includes a frame 2214
shaped as a
rectangle, though it will be appreciated that the frame 2214 may be shaped as,
for example,
a square. The frame 2214 includes a pair of hollow fork tubes 2216 opposite
each other. The
fork tubes 2216 are configured to receive forks of a forklift, which provides
for easy
handling and movement of the conveyor 2200 by a forklift. The base 2210 also
includes
four casters or wheels 2218 that can each rotate 360 degrees so that the base
2210 (and thus,
the conveyor 2200) may be moved in any direction. The casters or wheels 2218
may also
be locked so as to prevent movement of the base 2210, whether during shipping,
use, or
otherwise. The casters or wheels 2218 are securely mounted to the frame 2214,
whether by
nuts and bolts, screws, welding, adhesion, or the like.
As shown, the base 2210 also includes a first pair of brackets 2220 and a
second pair
of brackets 2222 disposed on opposite sides of the frame 2214. The first pair
of brackets
2220 are configured to receive a first pin 2224 of the conveyor 2200 such that
the conveyor
2200 is configured to pivot about the first pin 2224 at the base 2210. The
first pin 2224 is
located near a bottom of the conveyor 2200. The second pair of brackets 2222
is configured
to receive a second pin 2226 of the support arm 2212 to secure the support arm
2212 to the
base 2210 during installation and use. A third pin 2228 is located near a mid-
section of the
conveyor 2200 and pivotably connects the support arm 2212 to the conveyor
2200.
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Though the support arm 2212 is shown in Figures 24A-24B as separate from the
conveyor 2200 and coupled to the base 2210, it will be appreciated that during
shipping¨
or when the conveyor 2200 is in the second position¨the support arm 2212 is
coupled to
the conveyor frame 2221 and is separated from the base 2210, as visible in
Figures 23A-
23B. The support arm 2212 is shown and described with the base 2210 in Figures
24A-24B
for clarity. In the illustrated embodiment, the support arm 2212 includes two
frame members
2230 opposite each other. The frame members 2230 may have a pair of brackets
2234 at
each end to receive the second pin 2226 and the third pin 2228. The support
arm 2212, as
shown, is in the shape of a rectangle, though in other embodiments the support
arm 2212
may be in the shape of a square or triangle. As previously described, the
second pin 2226
pivotably couples the support arm 2212 to the base 2210 and the third pin 2228
pivotably
couples the support arm 2212 to the conveyor 2200. The support arm 2212 also
includes a
cross bar 2232 extending across the two frame members 2230, though in some
embodiments
the support arm 2212 may not include the cross bar 2232. Though not shown, at
least one
hook may be coupled to or integrated with the frame members 2230 so as to
receive and
store, for example, a power cord. The power cord may be, for example 25'. In
other
embodiments, the power cord may be less than or greater than 25'. It will be
appreciated
that the at least one hook may be positioned anywhere on the stand 2202.
Though also not
shown, a retractable cord may be positioned anywhere on the stand 2202 or
positioned
anywhere on a conveyor to which the stand 2202 is installed to.
The conveyor 2200 may be shipped in the second position, shown in Figures 23A-
23B. In the second position, the support arm 2212 is substantially parallel to
the conveyor
frame 2221 and the conveyor 2200 is also substantially or near parallel to the
base 2210. As
shown in Fig. 23B, the conveyor 2200 has a low profile when in the second
position, and is
easy to ship in such configuration. Further, the conveyor 2200 can be unloaded
directly from
a trailer in the second position. To move the conveyor 2200 from the second
position to the
first position, the conveyor 2200 is lifted by, for example, a forklift, such
that the conveyor
2200 lifts and pivots away from the base 2210. When the conveyor 2200 is
lifted, the support
arm 2212 pivots downward and away from the conveyor 2200. While the conveyor
2200 is
raised, the second pin 2226 is removed and the brackets 2234 of the two frame
members
2230 are aligned with the second pair of brackets 2222 on the base 2210. When
the brackets
2234 of the two frame members 2230 and the second pair of brackets 2222 are
aligned, the
second pin 2226 is reinserted through the second pair of brackets 2222 and the
brackets
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2234 of the two frame members 2230. The second pin 2226 is then secured to the
base 2210,
whether by cotter pins or otherwise.
The conveyor 2200 and portable stand 2202 as described above with respect to
Figures 22A-24B provides for a mobile conveyor that self-contained, simple to
transport,
and to install with minimal personnel.
In some embodiments, an incline conveyor may be positioned on a moveable stand
to facilitate usage, storage, and/or shipping of the incline conveyor. In
other instances, the
VTC (straight or nose over) can be positioned on a movable stand to facilitate
usage, storage,
and/or shipping of the VTC.
While various embodiment of the present invention have been described in
detail, it
is apparent that modifications and alterations of those embodiments will occur
to those
skilled in the art. However, it is to be expressly understood that such
modifications and
alterations are within the scope and spirit of the present disclosure, as set
forth in the
following claims.
The foregoing discussion of the disclosure has been presented for purposes of
illustration and description. The foregoing is not intended to limit the
disclosure to the form
or forms disclosed herein. In the foregoing Detailed Description for example,
various
features of the disclosure are grouped together in one or more embodiments for
the purpose
of streamlining the disclosure. This method of disclosure is not to be
interpreted as reflecting
an intention that the claimed disclosure requires more features than are
expressly recited in
each claim. Rather, as the following claims reflect, inventive aspects lie in
less than all
features of a single foregoing disclosed embodiment. Thus, the following
claims are hereby
incorporated into this Detailed Description, with each claim standing on its
own as a separate
preferred embodiment of the disclosure.
Moreover, though the present disclosure has included descriptions of one or
more
embodiments and certain variations and modifications, other variations and
modifications
are within the scope of the invention, e.g., as may be within the skill and
knowledge of those
in the art, after understanding the present disclosure. It is intended to
obtain rights which
include alternative embodiments to the extent permitted, including alternate,
interchangeable and/or equivalent structures, functions, ranges or steps to
those claimed,
whether or not such alternate, interchangeable and/or equivalent structures,
functions,
ranges or steps are disclosed herein, and without intending to publicly
dedicate any
patentable subject matter. Further, the invention(s) described herein is
capable of other
embodiments and of being practiced or of being carried out in various ways. It
is to be
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understood that the phraseology and terminology used herein is for the purpose
of
description and should not be regarded as limiting.
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