Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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This application is a divisional application of Canadian Patent File No.
2,283,844
filed April 29, 1998.
'Technical Field
This invention relates to automated sorting of items such as parcels to a
variety of
output destinations and more particularly relates to conveyor systems which
have the
capability to rapidly and reliably discharge parcels (which can also be
referenced as
packages) or other items thereon to either side of a conveying path, such that
the packages
or other items may be transported elsewhere.
Background of the Invention
In modem high volume package delivery systems, package delivery services
utilize
I O a variety of material handling systems. Such material handling systems
often include package
conveying systems that divert packages to a variety of output destinations
such as chutes, bins
and conveyor systems.
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~ne of the most conventional types of conveyors is a
belt conveyor, which includes the use of an endless flexible
belt which passes over at least two cylindrical rollers, one of
which is a drive roller. packages are placed atop the
upwardly-directed "workangy' surface of the belt conveyor, and
are transported in a generally straight direction from end of
the conveyor to the other. mother type of conveyor is a
"roller" conveyor which con include powered or idling rollers
which contact, support, and in certain instances propel the
bottom of the package along its path.
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Systems for diverting objects from a :r~noving conveyor
have been available for many years. Such systems are useful
in discharging objects from a conveying surface at selected
stations located along the path of the conveying surface.
Some package diverting systems utilize a pusher element
or member mounted on or beneath a conveying surface which
when actuated ejects a package laterally across the conveying
surface to a desired discharge station. Many such systems
guide a pusher element laterally across the conveying surface
using a complex series of guide tracks, or elements mounted
beneath the conveying surface. Other systerns utilize a means
for elevating and tilting a package above and away from the
upper surface of a conveying surface so that the package may
be withdrawn to an awaiting chute or discharge station. Still
other systems have been known to collapse the conveying
surface such that the package falls to a subjacent conveying
surface on which the package is translated to a desired
discharge location.
U.S. Patent No. x.,462,511 discloses another conveyor
2o diverter. A side conveyor extends perpendicular from a main
conveyor. A set of diverting rollers. are configured
perpendicular to the main conveyor and are raised above the
upper surface of the main conveyor to cause an object to be
diverted from the surface of the main conveyor under force of
gravity across the set of diverting rollers.
United States Patent No. 1,549,499 discloses an
elevating means for use in connection with roller bed sorting
tables for raising a box or parcel a slight distance above the
plane of the roller bed to allow the box or parcel to be
3o withdrawn to an awaiting chute or discharge station. A box or
parcel to be discharged is brought to a state of rest at a sorting
station immediately above an elevating roller. The elevating
roller is raised by depressing a foot lever. The box or parcel
positioned over the elevating roller is raised off the roller bed
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which allows an operator to pull the box or parcel off the
roller bed on to an adjacent chute or discharge station.
A box or parcel switching unit for discharging a box
sideways on to an adjacent storage conveyor or chute is
disclosed in U.S. Patent No. 2,062,604. A box or parcel is
brought to a stopped position on a receiving conveyor and
overlying a discharge conveyor. The receiving conveyor is
dropped from beneath the box or parcel allowing it to come to
rest on the discharge conveyor. The box or parcel is then
Io translated off the surface of the discharge conveyor to an
awaiting adjacent conveyor or chute.
U.S. Patent No. 3,13S,23S discloses a conveyor system
with a powered diverter for diverting an object from the
surface of a main conveyor to an awaiting side conveyor. The
powered diverter includes an assembly of diverting wheels that
are oriented toward the side conveyor. The group of diverting
wheels are normally positioned below the upper surface of the
main conveyor so that objects traveling on the main conveyor
do not contact the diverting wheels. In order to divert an
?o object from the main conveyor to the side conveyor, the
diverting wheels are elevated so that they are slightly above the
upper surface of the main conveyor. Accordingly, an object
traveling down the main conveyor is diverted by contact with
the elevated diverting rollers.
U.S. Patent No. 3,291,279 to L)~G~od likewise
discloses a conveyor system with a powered diverter, which as
shown in Fig. 8 works in conjunction with a shifting Linkage
200. Chains of powered roller elements are used, which are
indexed upwardly to engage packages to eject them at an angle
from the original conveying path.
U.S. Patent No. 3,303,923 to l~avis discloses a
conveyor diverter mechanism which includes a number of
relatively thin conveying belts 25, 2f , and 27 which are
indexed upwardly as shown in Fig. 2 to engage and withdraw a
selected package.
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U.S. Patent No. 4,598,815 to Ada~na discloses a
powered roller diverter which includes a single row of
powered diverter rollers which can be selectively indexed
upwardly to engage and eject a packabe on a belt conveyor
path. The single row of diverter rollers is selectively indexed
upwardly from within a transverse gap between the
downstream roller of an upstream conveyor to the upstream
roller of a downstream conveyor, such that the rollers engage
and discharge a package sidewardly.
to U.S. Patent 110. a,73o,~~8 to Fazi~ discloses a 'bi-
directional mechanisrra" which, as shown well in Fig. l, shows
a plurality of elastomeric belts 7b mounted upon an indexable
table assembly associated with a conveyor asseanbly. '1'he belts
are supported by indexable rollers such that portions of the
belts can be indexed upwardly within elongate slots defined
between elongate conveyor rollers being part of the conveyor
assembly, to cause the belt portions to engage packages
otherwise atop the conveyor rollers, and to eject them to either
side of the conveyor path. The Kloosterhouse patent (U.S.
Patent No. 4,96~,84~1}, owned by the same assignee, likewise
discloses such a co~guration.
U.S. Patent No. 4,979,606 to Usui discloses a
transporting direction controlling device applicable to
conveyor systems. As shown in Figs. i-5 of the Usui patent,
the device utilizes a rotor member comprised substantially of a
cylindrical or disk-shaped roller which is tiltable in variable
directions for tilting the plane of the upper surface of the rotor
member. ~y tilting the direction of the plane and the rotating
direction of the rotor member, the transporting direction of a
3~ box or package may be changed. As shown in Figs 3(A) -
3(D) of Usui, force is exerted on an object by tilting the plane
of the rotating device. so that the object will be moved in the
direction tangent to the direction of travel of the upper most
portion of the tilted rotating device. In practice, Usui
describes using the rotating device in concert with a plurality
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of similar rotating devices to form a direction changing
station, as shown in Pigs. ~ and l~. As shown in Figs. 6 and
l, guide plates 116, 11~, and 312 are used to define a
direction change path for the object.
U'.S. Patent ~lo. 5,165,16 to Reed .discloses a three
way transfer conveyor which includes transfer belts which are
selectively driven to the left and to the right: at right angles to
the conveyor rollers. As in the Fcazio and I~lo~sterhouse
references, the rubber belts fit into elongate transverse "gaps"
IO between the conveyor rollers.
In some of those systems, diverter mechanisms are
utilized to divert an object from the upper surface of a
conveying surface by bringing the object to a complete stop
overlying the diverter mechanism and then either raising the
diverter mechanism or lowering the object so that the diverter
mechanism comes into contact with the object. Bringing the
object to a complete stop prior to being diverted causes a
significant reduction in the eff ciency and speed of operation
of the conveyor system. Some of those systems move a
2o diverter into the path of a moving object. Problems associated
with those systems include the inability to eject objects laterally
from the surface of a moving conveying system at ejection
speeds which are independent of the speed of the moving
conveyor system.
Other limitations in the prior art include an inability to
eject objects laterally at a high speed without encountering
rotation of the package or object as it is diischarged from the
surface of the moving conveyor. Furthermore, such systems
may be noisy and relatively difficult to repair when diverter
systems components fail.
Finally, some prio~° art systems are complex in
construction and require substantial disassembly in order to
replace the discharge elements should they wear out.
'Thus, there is a need in the art for a sorting conveyor
system that can discharge or eject an object from a conveying
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surface without bringing the object to a stop and without
changing the position or speed of the conveying surface.
There is also a need in the art far a sorting conveyor system
that can discharge or eject an object from a conveying surface
at high speeds and without undesired rotation of the object
during discharge. There is further a need in the art for a
sorting conveyor system that is quiet during operation and
which is easily repaired. Finally, there is a. need in the art for
a conveying device which allow for quick changes of
t0 replacement parts in order to reduce downtime.
Summary of the Invention
The present invention seeks to provide an improved
system for efficiently discharging items of various sizes and
weights from a moving conveying surface. The present
invention allows an object to be discharged laterally from the
surface of a moving conveyor independent of the speed of the
moving conveyor. An object may be discharged without
raising an object diverter or ejection mechanism into the path
of the moving object and without lowering the conveying
surface to allow a moving object to contact a subjacent object
diverter or ejection mechanism. Ths present invention is
simple in construction and may be easily maintained by the
quick removal and substitution of failed components.
Generally described, the present invention comprises a
conveying and diverting apparatus for selectively discharging
conveying parcels having a lower surface from a conveying
path, the conveying and diverting apparatus comprising a
3o conveyor defining an elongate gap transverse to the path, and a
substantially planar disc configured for extending upwardly
through the gap to contact the lower surface of the parcels, the
disc being powered to eject a parcel with a force lying
substantially parallel to said gap.
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fore particularly described, the present invention
comprises a conveying and diverting apparatus for selectively
discharging conveying parcels having a lower surface from a
conveying path, the conveying and diverting apparatus
comprising a conveyor defining an elongate gap transverse to
the path, the conveyor including at least one conveyor belt
assembly defining one edge of the gap, and a substantially
planar disc configured for extending upwardly through the gap
to contact the lower surface of the panels, the disc being
powered to eject a parcel with a force lying substantially
parallel to said gap.
The present invention also provides a conveying and
diverting apparatus for selectively discharging conveying
parcels having a lower surface from a conveying path, the
conveying and diverting apparatus comprising a conveyor
configured for conveying parcels along the conveying path by
supporting the lower surfaces of the parcels, the conveyor
defining an elongate gap transverse to the path, a substantially
planar disc rotatably anounted about an axis substantially
parallel to the conveying axis, the disc having a substantially
round periphery except for a peripherally reduced portion,
means for rotatably mounting the disc relative to the conveyor
gap such that when the disc is at a first rotational position, the
disc interferes with the parcels in the conveyor path, but when
the disc is at a second rotational position, the disc does not
interfere with the parcels in the conveyor path, and means for
selectively rotating the disc from the first to the second
rotational position, such that parcels on the conveyor may be
correspondingly selectively discharged from the conveying
path upon rotation of the disc timed to contact of the round
periphery portion with the lower surfaces of the parcels and to
discharge the parcels.
The present invention also provides a conveying and
diverting apparatus for selectively discharging conveying
parcels having a lower surface frort~ a conveying path,
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conveying and diverting apparatus compaxsing a conveyor
configured for conveying parcels along the conveying path by
supporting the lower surfaces of the parcels, the conveyor
defining an elongate gap transverse to the path, a substantially
planar disc rotatably mounted about an axis substantially
parallel to the conveying axis, the disc having a substantially
circular periphery, a disc supporting shaft substantially rigidly
attached to and supporting the disc, means for rotatably
mounting the disc supporting shaft relative to the conveyor gap
l0 along an indexing rotational axis such that the when the disc is
at a first indexed position, the disc interferes with the parcels
in the conveyor path; but when the disc is a;t a second indexed
position, the disc does not interfere with the parcels in the
conveyor path, and means for selectively indexing the disc
supporting shaft about is longitudinal axis while the disc
supporting shaft is rotating, such that parcels on the conveyor
may be correspondingly selectively discharged from the
conveying path upon the indexing of the disc supporting shaft
which causes the disc to contact the lower surfaces of the
parcels and to discharge the parcels.
Finally, the present invention, an apparatus for
conveying articles:~tharat~ comprising a first conveyor
portior~~econd conveyor portion spaced from the first
conveyor portion so as to define an elongate gap therebetween,~
~an ejection disc configured for extending through the gap and
the conveyor~p~-disc supporting shaft for supportithe disc,
and shaft rotating means :f~r rotatably driving the supporting
shaft, the ejection disc being configured to be removed from
the disc supporting shaft without disengaging the shaft rotating
3o means from the sh
Therefore, it is an aspect of the present invention to
provide an improved automated conveyor sorting system.
It is a further aspect of the present invention to provide
an improved ejection mechanism for ejecting items from a
conveying surface.
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It is a further aspect of the present invention to provide
a conveyor which is simple in construction.
It is a further aspect of the present invention to provide
a conveyor which is reliable in construction.
It is a further aspect of the present invention to provide
a conveyor which is simple in operation.
It is a further aspect of the present invention to provide
a conveyor which is cost-effective to manufacture, operate,
and maintain.
It is a further aspect of the present invention to provide
an improved conveyor which may be easily dismantled for
repair and maintenance.
It is a further aspect of the present invention to provide
an improved apparatus for conveying and sorting items that
can be repaired by quickly removing failed sub-assemblies.
It is a further aspect of the present invention to provide
a conveyor which operates at reduced noise levels.
C?ther aspects, features, and advantages of the present
invention will become apparent upon reading the following
~o detailed description of the preferred embodiment of the
invention when taken in conjunction with the drawing and the
appended claims.
Brief Description of the Drawings
Fig. I is a top plan view of an automated sorting system
embodying the present invention.
Fig. 2 is a side diagrammatic view of the automated
sorting system of Fig. 1.
3o Fig. 3 is a side diagrammatic view of a cog belt
conveyor system showing a self tensioning gear motor drive
sy stem.
Fig. 4 is an end view of part of the gear motor drive
system of Fig. 3.
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Fig. 5 is a side elevation view of a portable gear motor
mounted on a wheeled table.
Fig. 6 is an end view of a discharge drum ejection
mechanism of the present invention.
Fig. 7 is an end view of the discharge drum ejection
mechanism of Fig. b, showing a parcel being discharged to a
discharge chute.
Fig. 8 is a top plan view of a discharge drum of the
present invention.
1o Fig. 9 is a top plan view of a roller bed sorting system
embodying the present invention.
Fig. 10 is a top plan view of a tapered discharge drum
of the present invention.
Fig. 11 is a transaxial crossrsectional view of the tapered
discharge drum of Fig. 10.
Fig. 12 is a top plan view of a portion of a conveyor
systean according to the present invention, illustrating an
ejection disc I00 Iocated between upstream and downstream
conveyor belt assemblies 120, I21, respectively. A parcel 12
(also known as a package 12) is shown approaching the
ejection disc 100. If the ejection disc 100 ejects the parcel
i 12, the parcel will be urged into the area of a side chute 114.
If the ejection disc 100 does not eject the parcel I12, the
parcel will be passed from upper conveyor belt assembly 120
to lower conveyor belt assembly 121.
Fig. I3 is an "upstream" illustrative sectional view of the
configuration of Fig. 12, looking along the conveying axis,
showing an ejection disc 100 ejecting a package to the viewer's
right. The ejection disc 100 is shown in round solid line
outline, although as shown by the dotted line a flat spot 102 is
included which exists if a truncated section is provided as
discussed later.
Fig. 14 is a side elevational view of a portion of a
conveying configuration according to the present invention. A
package 212 is moved from conveyor belt assembly 220 to a
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downstream conveyor belt assembly 221. As may be seen, the
two conveyor belts include substantially planar upper
conveying surfaces, which lie substantially along the same
horizontal plane. A first embodiment of an ejection disc 200
is positioned intermediate the two belts, and is configured such
that its selective rotation causes a portion of the disc to be
moved upwardly into the path of the package (preferably from
below the package), such that the pac:~Cage is discharged
sidewardly relative to the two conveying belts.
Fig. I5 shows an isolated view of the I2°' diameter
ejection disc 200 as viewed from its downstream side and a
flat section 202. As -may be seen, when the ejection disc L00
is in its normal position, the flat section allows passage of the
package. However, when the ejection disc 200 is rotated, the
curved peripheral edge 201 of the ejection disc 100 rises
above the conveying surface, causing interference with a
package moving along its conveyor path and preferably
discharging the package.
Figs. 16 and 17 are views similar to Figs. I4 and 15,
2o respectively illustrate what happens when the ejection disc is
rotated 180 degrees about its rotational axis from that shown
in Figs. 14 and 15. As may be seen, when the ejection disc
200 is actuated through such rotation, its curved edge (having
a grip surface) rises above the conveyor surface, causing the
package to be lifted. As the ejection disc 200 is likewise
rotating, this engagement causes the package to encounter a
force substantially 90 degrees in relation to the conveying axis
of the package.
Fig. I8 is a side elevational view of a second disc
3o embodiment of the present invention, illustrating a parcel 312
being passed from an upstream conveyor belt assembly 320
towards a Lower conveyor belt assembly 321. An ejection disc
300 is shown contacting the underside of the package 312,
being indexed upwardly by use of an actuator 3~0, which
actuates a pivoting support member 333, which supports a
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motor 330, which rotatably drives a shaft 331, which is
substantially rigidly attached to the ejection disc 300.
Fig. 19 is a view similar to that to Fig. 18, except no
package is shown, and the ejecting disc 300 is in its "neutral"
or "withdrawn" position.
Fig. 20 is a side elevational view illustrating a first
mufti-segmented disc embodiment, round ejection disc 400 in
position between upstream and downstream conveyor belt
assemblies 420, 421, respectively. The ejection disc is
mounted to a shaft which is rotatably driven by a gear motor
430. The gear motor is mounted to a frame member which is
pivotably mounted about an axis P, and actuated about that axis
by an actuator 440. The actuator has essentially two positions,
the "ejecting position°', and a "retracted'" position which is
t 5 known in Fig. 20.
Fig. 21 is a front end view of a rear flanged plate
assembly 460 used in the Fig. 20 configuration.
Fig. 22 is a side elevational of a nr~otor 430 having a
shaft 431 having a rear flanged piste assembly 460 mounted
thereon.
Fig. 23 is a pictorial view of a half wheel segment 402
of the Fig. 20 configuration, configured mostly of molded
urethane in one embodiment. This half wheel seganent 402
includes an embedded metal rectangular rod 404.
~5 Fig. 24 is a pictorial view of a front steel plate of
approximately I/8 inch in thickness. This front plate includes
a two large slots 452, and two opposing small notches 453.
Fig. 25 is a right side elevational view of the first multi
segmented disc configuration, with two half wheel segments
402 installed thereon. No front plate or associated hardware
is yet in place.
Fig. 26 is a rear elevational view of that shown an Fig.
25, with the motor not shown.
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Fig. 27 is a front end view of the first mufti-segmented
disc 400 embodiment. showing the spring 470 and a pipe
spacer in place.
Fig. 28 is a right side elevational view of that shown in
Fig. 27.
Fig. 29 is a front end illustrative view of a second multi-
segmented wheel embodiment, shown in round configuration.
Fig. 30 is a pictorial view of that shown in Fig. 29,
except no tension spring is shown.
Fig. 31 is a side illustrative view of a portion of the
main disc portion 502 of the Fig. 30 configuratBOn, showing a
steel pin such as 510 in detail.
Fig. 32 is a top plan view of the secot~.d mufti-segmented 1
wheel embodiment according to the present invention,
illustrating the beveled interconnection between the insert
portion 503 and a main disc portion 504. Also shown is the
capturing provided by the front plate 550 and the rear flange
plate assembly 560. Finally shown is a pipe ring 513 which
can be placed on the front side of the front plate.
.Fig. 33 is a front view of a front plate 550, showing a
pair of holes and a key tab.
Fig. 34 is a side elevational view of the second rnulti-
segmented disc configuration according to the present
invention, showing the main wheel portion 502 and the
smaller insert portion 503 in place with a spring and pipe
washer likewise in place.
Fig. 35 is a rear isolated plan view of a rear flanged
plate assembly 560 according to the present invention, which
includes a rear plate 5Cal, and a rear flange 5b4.
Figs. 36 and 37 illustrate top plan and side elevational
views, respectively of third mufti-segmented ejection disc X00
according to the present invention. In this particular
embodiment, the mufti-segmented disc includes a "flat spot",
although as shown elsewhere in this application such a multi-
segment disc could not have a flat section.
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Detailed Description of the Preferred Embodiment
Referring now in more detail to the drawings, in which
5 Like numerals refer to like parts throughout the several
drawings, Fig. 1 shows a top plan view of an automated
sorting system embodying the present invention. With
reference to Figs. I , 2 and 3, the sorting system 10 preferably
includes a cog belt conveyor system 20 comprised of a pair of
t0 continuous cog belt conveyors 21 positioned in paraIIeI
spaced-apart relation. In a preferred form shown, the cog belt
conveyor system 20 forms a closed loop. As shown in Figs. 1
and 2, the cog belt conveyor system 24 may include a plurality
of ejection mechanisms ~0 for discharging items, such as
15 parcels 40, from the surface of the parallel cog belt conveyors
21 onto a variety of output destinations. such as receiving
chutes 45, a parallel conveyor {not shown), or a non-parallel
conveyor {not shown).
The parcels 40 may be loaded onto the cog belt
2o conveyor system 20 manually or by a feed conveyor 53. A
conventional centering roller bed 50 may be used to properly
orient the parcels 40 onto the conveying surfaces of the cog
belt conveyors 21, as shown in Fig. 1. C?ther sub-assemblies
of the sorting system I~ include a self-tensioning gear motor
?5 drive system 36 for providing proper tension in the cog belt
conveyors 21 of the cog belt conveyor system 20, as shown in
Fig. 6. The assemblies and sub-assemblies thus far noted and
shown will now be described in detail.
Referring still to Figs. 1 and 2, W a cog belt conveyor
3o system 20 is comprised of a pair of cog belt conveyors 21
configured in spaced-apart relation for transporting an object
such as parcel 4f# on the upper surface of the cog belt
conveyors 21. In the preferred form shown, the cog belt
conveyors ZI include a smooth outer conveying surface. Cog
35 teeth 22 are disposed along the inner surface of the cog belt
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conveyors 2I for engaging a cog belt drive mechanism
24.
The drive mechanism 24 preferably includes a drive
sprocket
26 configured for engagement with the cog teeth 22
disposed
along the inner surface of the cog belt conveyors
21, as shown
in Fig. 2. An electric motor (not shown) is preferably
functionally attached to the drive sprocket 26. As
shown in
Fig. 2, the cog belt conveyors 21 are supported at
the end
opposite the cog belt drive means 24 by an idle sprocket
25.
A feed conveyor 53 is provided for automatically
to loading objects, such as parcel 44, onto the cog belt
conveyor
system 20. A centering roller bed 50 is interposed
between
the feed conveyor 53 and the cog belt conveyor system
2(l.
The centering roller bed 50 is comprised of a plurality
of
rollers 52 configured in a herringbone configuration.
Preferably, the roller bed 50 serves to center and
properly
orient an object such as a parcel 40 onto the parallel
cog belt
conveyors 2I, as shown in Fig. 1. As shown in Fag.
1, a
plurality of discharge chutes 45 are provided adjacent
to the
cog belt conveyors 21 for receiving parcels 40 discharged
from the surface of the cog belt conveyors 21, as
will be
discussed and detailed below. It should be understood,
that a
variety of discharge destinations may be utilixed,
such as bins
and separate conveyors (not shown).
An alternate configuration for the cog belt conveyor
?5 system 20 is shown in Fig. 3. In the alternate conf
guration
for the cog belt conveyor system 20, the cog belt
conveyors
21 are supported by a pair of idler rollers 35. As
shown in
Fig. 3, the cog belt conveyors 21 of this embodiment
are
disposed about the idler rollers 35 such that the
outer
conveying surface of the cog belt conveyors 21 include
cog
teeth for engagenr~ent with a self-tensioning gear
motor drive
system 3b. The inner surface of the cog belt conveyors
21 are
smooth for engagement with the idler rollers 35.
The self tensioning gear motor drive system 3~ includes
a reversible gear motor 3g. As shown in pig. 4, the
reversibh
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gear motor 38 is attached to a drive shaft 42 on which is
disposed a pair of drive sprockets 43 for engaging and driving
the pair of parallel cog belt conveyors 21. As shown in Fig.
3, a pair of snub rollers 44 are utilized to keep the cog belt
conveyors 21 in continuous engagement with the drive
sprockets 43.
A tensioning mechanism 54 is provided for maintaining
proper tension in the cog belt conveyors 21 of this
embodiment of the present invention. As shown in Fig. 4, the
tensioning mechanism 54 is comprised of a tension spring 55
which is retained by a spring retaining member 52. At the
lower end of the tension spring 5j is a spring compression and
release member 56. The spring compression and release .
member Sb is actuated by hydraulic cylinder 57 which
contains hydraulic fluid 58. As is well known to those skilled
in the art, a suitable pneumatic cylinder may be used in place
of the hydraulic cylinder 57. 'Tension in the cog belt
conveyors 21 may be increased by manually actuating the
hydraulic cylinder 57, or operation of the tensioning
2o mechanism 54 nay be directed by a programmable logic
controller (not shown). It should be understood, that a variety
of tension spring mechanisms may be used in place of the
tensioning mechanism 54 for manually or automatically
maintaining constant tension in the cog belt conveyors 21.
Referring now to Figs. 4 and 5, a portable gear motor
60 is provided for powering the sprockets 40 and cog belt
conveyors 21 in the event of a failure of the reversible gear
motor 38. As show in Fig. 4, the portable gear motor 60 is
mounted on a wheeled table 63 to allow the portable gear
3o motor GO to be moved into any desired position. As shown in
Fig. 4, an emergency drive sprocket 68 is disposed on the end
of the drive shaft 42 opposite the reversible gear motor 38.
As shown in Figs. 4~ and S, the portable gear motor 6 0
includes a drive sprocket 69 for engagement with the
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emergency drive sprocket 68. A power card ?2 is included
for providing power to the portable gear motor 60.
Referring now to Figs. l, ~, 6 and 7, the sorting system
includes a plurality of ejection mechanisms 80 for ejecting
5 an object, such as a parcel 40, laterally from the upper surface
of the cog belt conveyors 21 to an adjacently disposed
discharge destination, such as a chute 4~, or other desired
discharge destination, such as a bin, or alternate conveyor.
The ejection mechanism 80, shown in Figs. l and 6, is
10 disposed medially of the parallel cog belt conveyors 21. The
ejection mechanism 80 is mounted subjacent to the upper
surface of the cog belt conveyors 21.
The ejection mechanism 80 includes a discharge drum
85 and a discharge drum drive motor 87, as shown in Figs. 6,
7 and 8. As shown in Figs. C and 8, the discharge drum 85 is
an elongate member defining a generally rectangular transaxial
cross-section and having upper and Iower surfaces 89a and
89b. The discharge drum 85 has first and second opposing
sides 86a and 86b. which are disposed adjacent to the upper
2o and lower surfaces 89a and 89b. Th.e first and second
opposing sides 86a and 86b are generally convex shaped and
are separated by the longer cross-sectional diameter of the
discharge drum 85.
As shown in Figs. 6, 7 and S, a plurality of flexible
ridges 92 . are disposed along the surfaces of the convex
opposing sides 86a and 86b of the discharge drum 85. The
flexible ridges 92 may be made from any suitable polymer
material such as polyurethane. As will be discussed below, the
flexible ridges 92 assist in ejecting an overlying object, such as
the parcel 40 from the conveying surface of the cog belt
conveyors 2I.
A discharge drum drive shaft 88 is configured through
the central longitudinal axis of the discharge drum 85. A
discharge drum drive sheave 93 is attached to one end of the
discharge drum drive shaft 88, as shown in Fig. 8. As shown
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in Fig. 6, a reversible discharge drum drive motor 87 includes
a drive motor sheave 9C for driving a drive belt 90 to impart
rotation to the discharge drum 85. As shown in Figs. I, 6 and
7, the axis of rotation of the discharge drum 8~ is defined by
the discharge drum shaft 88. The axis of rotation of the
discharge drum 85 lies along the axial center of the path of
travel of the cog belt conveyors 21. As shown in Figs. 6 and
7, the axis of rotation of the discharge drum 85 remains fixed
beneath the conveying surfaces of the cog belt conveyors 21.
In operation, the ejection mechanism 80 as used to
discharge an object such as the parcel 40 from the upper
surface of the cog belt conveyors 21, as shown in Fig. 7. The
configuration of the ejection mechanism 80, as shown in Fig.
6, represents the rest state of the ejection mechanism 80.
When the ejection mechanism is at rest, as illustrated in Fig. 6,
the upper surface 89a of the discharge drum 85 is in the ug
position, as shown in Fig. 6. In this configuration, the upper
surface 89a lies subjacent to the conveying surfaces of the cog
belt conveyors 2i. Accordingly, an object, such as a parcel
40, may freely travel over the ejection mechanism 80, if
desired.
In order to -eject the parcel 40 to an adjacent chute 45,
as shown in Fig. 7, the discharge drum drive motor 87 is
energized when the parcel 40 moves into a position
immediately above the ejection mechanism 80. If it is desired
that the parcel 40 be discharged to a chute 45 located to the
right of the ejection mechanism 80, the discharge drum drive
motor is energized so that the discharge drum rotates in a
clockwise manner, as shown in Fig. 7. It should be
understood, however, that the parcel 40 may be discharged to
the chute 45 located to the Left of the ejection mechanism 80
by reversing the polarity on the discharge drum drive motor
87 in a manner well known to those skilled in the art.
As shown in Fig. ?, energization of the discharge drum
drive motor rotates the discharge drum 85 clockwise or
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counterclockwise, as desired. As the discharge drum 8 5
rotates, one of the two convex opposing sides Sba rotates
through an arcuate path. The arcuate path begins below a
plane defined by the upper surface of the cog belt conveyors
21 and rises above that plane through an opening defined by
the space between the cog belt conveyors 21 or between the
roller arrays, shown in Fig. 9 and discussed below. 'The
arcuate path then terminates below the plane defined by the
surface of the cog belt conveyors 21.
Accordingly, one of the convex opposing sides 86a
contacts the lower surface of the parcel 40, as shown in Fig. 7,
and lifts the parcel 40 up and away from the surface of the cog
belt conveyors 21. The flexible ridges 92 disposed on the
surfaces of the convex opposing sides provide contact surfaces
t5 to assist in movement of the parcel 40 by increasing friction
between the convex opposing side and the parcel 4~.
As the discharge drum 85 continues to rotate, the parcel
40 is tilted away from the upper surfaces of the cog belt
conveyors 21 and onto an idler roller 4b interposed between
2o the cog belt conveyors 2I and the chutes 45, as shown in Fig.
?. Finally, as the discharge drum 85 completes a full I80
degrees of rotaeion, the parcel 40 is translated onto the chute
45 and off the conveying surfaces of the cog belt conveyors
21. Accordingly, rotation of the discharge drum 85, as
25 described, lifts, tilts, and translates the parcel 40 from the
conveying surfaces of the cog belt conveyors 21, and such
rotation returns the discharge dram to a rest position, as
shown in Fig. 6.
As shown in Fig. 9, an alternate embodiment of the
3o present invention provides an ejection mechanism 80 disposed
beneath the conveying surface of a roller bed conveyor 100.
The roller bed conveyor 100 defines a pair of spaced-apart
arrays of rollers. It should be understood that the rollers may
be powered or non-powered idler rollers. The rollers define
35 axes of rotation which are transverse t~ the axis of rotation of
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the discharge drum 85. The roller bed conveyor I00 and
ejection mechanism 80 may be positioned adjacent to desired
discharge destinations and interposed between two belt
conveyors 105 and 110, or the ejection mechanism and roller
bed 100 configuration shown in Fig. 9 may form part of a
continuous roller bed conveyor arrangement (not shown).
A tapered discharge drum 120 is shown in Figs. 10 and
11. As shown in Fig. l I, a transaxial cross-sectional view of
the tapered discharge drum I20 shows a generally rectangular
shaped discharge drum 120, defining convex opposing sides
123a and 123b separated by the longer diameter of the drum.
As shown in Fig. 10, the convex opposing sides 123a and
i23b of the tapered discharge drum 120 define flexible
ridges I26 and are tapered longitudinally, narrowing toward
the end having the drive sheave 96 for engagement with the
drum -drive motor 87 via a drive belt 90, as shown in Fig. b.
As shown in Fig. I, the tapered discharge drum also tapers
longitudinally narrowing in the direction opposite tU the of
travel of the cog belt conveyors 21. Accordingly, the second
2o end I25 of the tapered discharge drum I20 is wider than the
first end 124.
Discharge of a parcel 40 using the non-tapered
discharge drum ~5, as described above, tends to rotate the
parcel 40 as the parcel 40 is being discharged. Rotation of the
parcel is a result of the forward movement of the parcel 40
along the cog belt conveyors 21 in concert with the lateral
displacement of the parcel 40 by the discharge drum g5.
More specifically, as the tapered discharge drum 85 lifts the
parcel 40 off one of the cog belt conveyors 21, the other cog
3o belt conveyor continues to urge the parcel in a forward
direction, resulting in an unbalanced force that causes rotation
of the parcel 40. if desired, the tapered discharge drum 120
may be utilized to counteract rotation of the parcel 40 as it is
discharged from the cog belt conveyors 21, as shown in Fig.
7. That is, as a parcel 40 is discharged from the surface of the
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cog belt conveyors 21 by the tapered discharge drum, the parcel 40 is
contacted first by the
wider second end I25 of the tapered discharge drum 120 which urges the parcel
40 in a
direction counter to the direction of rotation caused by the cog belt conveyor
21. Accordingly,
the parcel 40 is discharged from the conveying surfaces of the cog belt
conveyors 21 without
undesired rotation.
It should be understood the ejection mechanism need not be a drum and that the
side
of the ejection mechanism that engages the parcels 40 need not be a continuous
surface.
The automated sorting system 10 is operated under the control of a digital
controller,
which may be a programmable logic controller (PLC) or a general purpose
microprocessor
which is found in a personal computer. Methods for programming such
controllers to operate
a sorting system of the type disclosed herein are conventional and known to
those skilled in the
art.
In operation, the number of and location of ejection mechanisms 80 and an
identification
code for each ejection mechanism 80 are input into the controller memory when
movement of
the sorting system 10 begins. Parcels 40 are induced sequentially onto the
roller bed SO from
the feed conveyor 53, as shown in Figs. 1 and 2. As shown in Fig. l, a
destination code for
each parcel 40 is entered into the controller memory using an optical reader
51, a keypad (not
shown), or a voice recognition input device (not shown) before the parcel 40
is directed onto
the cog belt conveyor system 20. A suitable optical reader system 51 for
imaging the
destination code from a label affixed to the parcel 40 is shown in ~T.S.
Patents 5,291,564;
5,308,960; 5,327,171 and 5,430,282 which may be referred to for further
details. The roller
bed 50, with herringbone configuration rollers 52, centers the parcel 40 so
that the parcel 40
squarely aligns about the longitudinal axis of the cog belt conveyor system 20
and on the
surfaces of the cog belt conveyors 21, as shown in Fig. 1.
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When the parcel 40 reaches a desired output destination,
such as a chute 45 in a position overlying a desired ejection
mechanism 80, the PLC energizes the discharge drum drive
motor 87 to actuate the ejection mechanism 80. Accordingly,
the discharge drum 85 rotates in the direction of the chute 45.
As the discharge drum 8S rotates about the discharge drum
drive shaft 88, one of the first and second convex shaped
opposing sides .arcuately translates between the pair of
continuous cog belt conveyors 21 and above the upper surface
of the continuous cog belt conveyors 21. '~Che discharge drum
85 rotates in the direction of the chute 45, and the parcel 40 is
Iifted from the surfaces of the cog belt conveyors 21, as shown
in Fig. 7. As the discharge drurr~ 85 continues to rotate in the
direction of the chute 45, the parcel 40 is tilted on to the idler
roller 46, as shown in Fig. ?. Finally, as the discharge drum
completes its rotation, as described in detail above, the parcel
40 is discharged onto the chute 45, as shown in Fig. 7. After
the parcel 40 is discharged to the chute 45, the discharge
drum 85 stops in a rest position, as shown in Fig. 6, and stands
2o ready to discharge a subsequent parcel 40. If it is desired that
package rotation be counteracted as the parcel is discharged to
the chute 45, a tapered discharge drum 120 may be utilized
instead of the discharge drum 85, as described above.
Use of the ejection mechanism 80, as described, allows
'5 the parcel 40 to be discharged from the surfaces of the cog
belt conveyors 21 independent of the speed of the parcel 40
moving along the cog belt conveyors 21. Additionally,
interaction of the flexible ridges 92 disposed along the
surfaces of the convex opposing sides of the discharge drum
30 85 or the tapered discharge drum 120 reduces noise created
by the impact of the discharge drum 85 with the overlying
parcel 40. Advantageousiy, failure of an individual ejection
mechanism 80, or the cessation of use of an individual ejection
mechanism 80 for the maintenance purposes does not create
35 downtime for the cog belt conveyor system 20. In the event
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of the cessation of use of an individual ejection mechanism g0y
the PLC may direct parcels to be discharged to alternate
discharge destinations and bypass the stopped ejection
mechanism g0. Furthermore, the discharge drums may be
quickly and easily replaced. Accordingly, downtime of the
cog belt conveyor system 20 is reduced.
Reference is now made to Figs. 12-3T in discussing the
general concept of providing a relatively narrow package-
ejecting disc, which can be used within a gap defined by two
conveyor belts or other conveying item. As will be discussed
in detail further below, the disc can be substantially round in
shape, or can include a '"flat spot", and can also either be of
substantially unitary construction or mufti-segmented.
Reference is first made to Figs. 12 and Z3 in order to
!5 explain the general narrow package-ejecting disc concept. Fig.
12 is a top plan view of a portion of a conveyor system
according to the present invention, illustrating an ejection disc
lOfl located between upstream and downstream conveyor belt
assemblies 120, 121, respectively, and rotatably driven about
an axis 105. Fig. 13 is an "upstream" sectional view taken
generally along the conveying axis, showing an ejection disc
10~ ejecting a package to the viewer's right.
As shown in Figs. 12 and 13, the parcel 112 is moved
along a generally straight conveyor axis 113, being first
positioned atop an upstream conveyor belt assembly 120, and
is conveyed towards and onto a second downstream conveyor
belt assembly I21, unless it is ejected. An ejection disc 100 is
rotatably located within a relatively narrow transverse "slot"
or "gap" 110 intermediate the two baits of the two assemblies
120, 121 to provide the ejection. It should be understood that
the gap is substantially narrow in that it is shorter along the
conveying dimension that in its transverse, perpendicular
dimension.
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A side chute 112 is positioned at approximately 90
degrees relative to the conveying axis 113, and received
ejected packages.
In Fig. 12, a parcel 12 is shown in approaching the
ejection disc 100. If the ejection disc 100 ejects the parcel
112, the parcel will be urged into the area of a side chute 114.
If the ejection disc 100 does not eject the parcel 112 as shown
in Fig. 13, the parcel is passed from the upstream conveyor
belt assembly 120 to the downstream conveyor belt assembly
12I. As may be seen, the two conveyor belts within the two
conveyor belt assemblies include substantially planar upper
conveying surfaces, which lie substantially along the same
horizontal plane.
As shown in Fig. 13 and as discussed in detail elsewhere,
the disc 100 can be round or may include a truncated section
defined in part by a flat spot 102. In either case, the
peripheral edge 101 of the ejection disc 100 is brought into
contact with the underside of the package as discussed later,
such that the parcel is discharge to the viewer's right as
2o viewing Fig. 13.
The gap 110 can be thought of as having a thickness
defined by the closest distance shown between the two
conveyor belts, and can be thought to extend above, below, and
to intersect the conveying axis.
Figs. 14-17 illustrate the use of a ejection disc 200 with
a flat spot defining a truncated section. Iinder this concept, a
'"truncated", disc is used which fits within the transverse slot
defined by the end of one belt conveyor and the beginning of a
second, downstream belt conveyor. This disc includes a
3o truncated section which operates much the same way as the
"truncated" drum described earlier. T'he truncated disc is
rotatably mounted on a fixed axis, and selective rotation causes
the disc to engage and eject a package, when rotation is
suitably timed.
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Reference is now made to Fig. I4, which is a side
elevational view of a conveyor configuration according to the
invention. A package 212 can be moved from an upstream
conveyor belt assembly 220 to a downstream conveyor belt
assembly 221, unless ejected by a ejection disc 200 as
described below. As may be seen, the two conveyor belts
within the two conveyor belt assemblies 220, 221, include
substantially planar upper conveying surfaces, which lie
substantially along the same horizontal plane.
to As in the configuration of Figs. 12 and I3, the ejection
disc 200 is positioned within and rotates within a transverse
gap 210 intermediate the two belts assemblies 220, 221.
As shown in Fig. 15, the ejection disc 200 includes a
flat section 202. When the disc 200 is in its unengaging or
'°neutral" position as shown in Fig. I~, the flat section 202
allows passage of the package. C3therwise, the disc 200 is at
least partially in the conveyor path.
Figs. 16 and 17 illustrate what happens when the ejection
disc is rotated 180 degrees about its rotational axis 20~ from
2o that shown in Figs. 14 and 1~. As may be seen, when the
ejection disc 200 is actuated through rotation, its curved
portion (having a gripping surface) rises above the conveyor
surface, causing the package to be lifted. As the disc is
likewise rotating, this engagement causes the package to
encounter a force substantially 90 degrees in relation to the
conveying axis of the package moving frorn upper conveyor
belt assembly 220 to upper conveyor belt assembly 221.
As noted above, the ejection disc 200 is rotatably
mounted relative to the conveying path of the packages in
3o contacts. This rotational axis, in the configuration shown in
Figs. I4-17, is substantially stationary, horizontal, and parallel
to the conveying axis of the packages above, although slight
variations may be provided as needed. The conveying axis lies
substantially along a drive shaft 231 which is rotatably driven
by an indexing servo motor 230. 'This indexing servo motor
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is configured to be selectively activated to rotate the disc 200
in either rotational direction9 allowing ejection to be provided
to either side of the conveying axis.
In one preferred embodiment shown in Fig. 15 and 17,
the outer edge of the ejection disc includes a plurality of teeth
203, which are in one preferred embodiment comprised of
rubber.
It should also be understood that alternative
configurations, which include chain or other drives allowing
l0 for the remote location of an indexing motor are contemplated
under the spirit and scope of the present invention.
Reference is now made to Figs. 1 ~ and 19, which
illustrate the use of around ejection disc 300 which is indexed
upwardly above the conveying surface within the gap 310
I5 between two conveyors by use of a pivoting action.
This configuration includes a round ejection disc 300
mounted to a shaft which is rotatably driven by a motor 330.
The motor 330, which can be continuously running if desired,
is mounted to a pivoting support member 333 which is
20 pivotably mounted relative to a stationary conveyor frame
member (not shown). 'this pivoting support member 333 is
pivotably mounted about a pivoting axis which is substantially
horizontal as well as transverse to and below the package
conveying axis path.
25 A linear actuator 340 is provided which actuates the
frame member 333, the ~anotor 330, and the disc 300 from a
retracted (non ejecting) position (see Fig. 1.g) to an extended
(ejecting) position (see Fig. 19).
As may be seen, when the actuator 340 (which may be
30 an air or other extendable cylinder) urges the disc 300
upwardly, the rotational axis 305 goes frown being
substantially horizontal to inclined. Hydraulic, pneumatic, or
other suitable actuation means known in the art can be used.
The narrow, substantially circular, ejection disc 300 fits
35 within the transverse "slot" 310 def°med by the end of an
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upstream belt conveyor assembly 320 and a downstream and
the beginning of a second, downstream belt conveyor assembly
321. The circular disc 340 is rotatably mounted on a
movable rotational axis 305. ~lhile in its "neutral" position as
shown in Fig. 22, the disc 300 does not contact the packages as
they pass from the upstream to the downstream conveyor.
1-Iowever, when actuated, the disc 300, being moved upwardly
to its "engaging't position shown in Fig. 21, contacts the
package on its circular edge. Rotation of the disc causes the
package to be discharged sidewardly.
The above motor 330 can be reversible to allow for
discharge to either side of the conveyor. If desired, the motor
can be left continuously running allowing the actuator to
determine when ejection occurs. The motor 330, as with all
the motors described in this application can be selected as
known in the art.
This concept. shown generally in Figs. 20-3'7, generally
relates to the use of a "quick change'° feature which allows the
narrow discs be quickly removed and replaced with little or no
tools and with minimal disturbance to adjacent machinery.
This is very important to those operating and maintaining said
machinery, in that downtime due to repairs are desired to be at
a minimum.
Figs. 20-28 show a first mufti-segm.~ent embodiment,
with a mufti-segmented ejection disc 400~
Figs. 29-35 show a second mufti-segment embodiment,
including a mufti-segmented ejection disc 500.
Figs. 3b-37 show a third mufti-segment embodiment,
including a mufti-segmented ejection disc 600.
Figs. 20-2g show a first mufti-segmented disc
embodiment, including a mufti-segmented ejection disc 400
which generally includes a pair of half wheel segments 402,
which are captured between a front plate 450 and a rear
flanged plate assembly 460 and maintained in place by use of a
tension spring 470, to form a substantially circular ejection
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disc 400, although a wheel with a flat spot is readily
contemplated.
Fig. 20 illustrates the mufti-segmented round ejection
disc 400 in position within a gap 410 between upstream and
downstream conveyor belt assemblies 420, 421, respectively.
The ejection disc 400 is mounted to a shaft 431 which is
rotatably driven by a gear motor 430. The gear motor 430 is
mounted to a pivotable support member 433 and actuated
about pivoting axis by an actuator 440. The pivotable support
1~ member 433 is pivotably mounted relative to an unshown
stationary frame member about a pivoting axis which is
substantially horizontal as well as transverse to and below the
package conveying axis path.
The actuator 440 has essentially two positions, an
"ejecting position'°, and a '°retracted" position, and is
configured to operate such that the mufti-segmented ejection
disc 400 can be raised generally upwardly and downwardly
within the gap 410 much as the disc 304 moved as shown in
Figs. 18 and 19.
2o For discussion purposes, the configuration will be
assumed to have a "front" and a "back°', although such terms
are not to be construed as being limiting. The "front'° of the
ejection disc 400 is the part oriented to the viewer's left as
viewing Fig. 20.
As shown in Fig. 22, attached to the shaft 431 of the
motor 430 is a rear flanged plate assembly 460, which
includes a rear plate 461, a rear flange 464, and a set screw
465. As shown in Fig. 2I, the rear plate 461 includes two
opposing large slots 462, and also includes two small notches
463. The large slots 462 are oriented approximately 90
degrees from the opposing smaller notchms 463. The rear
flange 464 is substantially rigidly attached to the rear plate
461, by welding or other means known in the art. The set
screw 465 allows for attachment of the rear flange 464 to the
shaft 431, as known in the art.
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Reference is now made to Fig. ?3, which is a pictorial
isolated view of a half wheel member 402$ two of which are
used for each disc 400. Each of the half wheel members 402
includes a corresponding embedded rod 404. At the front end
5 of each embedded rod is defined in embedded rod slot 405 or
other suitable engaging means, and at the opposite, rear, end is
an embedded rod hook 406 or other suitable engaging means.
As described elsewhere in this application, the embedded rod
slots 405 are each configured to accept one end of a tension
l0 spring 470, and the embedded rod hooks 406 are configured
to pass through slots 463 of the rear flange plate 461, and
engage the rear side of the rear flange prate 461.
Each of the half wheel members 402 is configured
mostly of molded urethane in one preferred embodiment with
15 the exception of the metal embedded rod 404. In one
preferred embodiment, the rods 404 heave a rectangular
transverse cross section.
Reference is now made to Fig. 24, which is an
illustration of a front steel plate 450 of approximately 1/8
inch in thickness. 'This front plate includes two opposing large
slots 452, and tw~ opposing small notches 453. The opposing
large slots 452 and two opposing small notches 453 of the
steel front plate 450 are similar in configuration to those
provided in the rear plate 461 of the rear flange plate
25 assembly 4600
As shown in Figs. 27 and 28, a tension spring 470 and a
"pipe" 471 are also included. A key 466 is used to provide a
keyed connection as described later.
As shown in Fig. 22, the rear flanged plate asseiribly
30 460 is mounted to the shaft 431 of the gear motor 430, by
passing the collar-shaped rear flange 464 over the
substantially circular outline of the shaft 431. When the rear
flange 464 is positioned at its desired location, a set screw 465
is installed in order to fix the rear flange 464 to the shaft 431
of the gear motor 430. A key as known in the art provided a
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keyed engagement between the rear flanged plate assembly
460 and the shaft 431.
After the rear flanged plate assembly 460 is mounted to
the shaft 431, the two half wheel members 402 are situated as
shown in Fig. 25, and held in place by the use of a front plate
450 as shown in Fig. 27.
When the two half wheel members 402 are in place as
shown in Fig. 26, it may be seen that the half knob segments
403 of the half wheel members 402, combine to provide
to substantially elliptically-shaped knobs, shown well in Fig. 26.
These knobs are partially contained by the large cut outs of the
front plate 450, which serves to capture the half wheel
members 402 bet~;veen the front plate 450 and the rear plate
461 of the rear flange plate assembly 460.
1 S When installed, the embedded rods 404 of the half
wheel members are configured such that their hooks 406 are
engaged with the "rear" side of the rear flange plate 461, as
shown in Figs. 25 and 26.
After positioned as shown in Fig. 25, the front plate 450
2o is positioned into place as shown in Fig. 27. As may be
understood, the front plate is placed relative to the half wheels
and their embedded rods 404, such that the front ends of the
embedded rods pass through the small notches 453 of the front
plate 450.
25 After the front plate 450 is in place, a tension spring
470 is stretched such that its two ends engage respective slots
405 in the front ends of the embedded rods 404, such that the
spring ends are engaged with the respective embedded rod
slots .405. However, before the spring 470 is situated into
30 place, a pipe spacer 471 is placed in engagement with the front
plate 450. The spring is then positioned into place, such that
the spring is engaged at its ends with the embedded rods, and
the medial portion of the spring 470 biases radially against the
end of the substantially short pipe spacer 471, which biases
35 inwardly onto the front plate 450.
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32
As shown in Fig. 27, a curved portion is provided in the
pipe spacer to accommodate the round nature of the spring,
and to discourage removal of the pipe spacer.
The pipe spacer 471, in one preferred embodiment, fits
about the end of the shaft 43I of the gear motor 430. This
engagement, combined with the biasing of the spring, tends to
maintain the pipe spacer in place.
A key 466 as known in the art to provide suitable
engagement between the rear flange 464 and the shaft 431, to
to discourage rotation therebetween.
Operation of the configuration shown in Figs. 20-28 is
similar to that discussed in reference to Figs. 18 and 19. ~.
motor 430 is used which drives the ejection disc 400, such
that when the motor 430 and rotating disc 400 is pivoted
upwardly by an actuator 440, the ejection disc engages and
discharges packages passing gap 410.
Although this configuration includes the use of an
pivoting configuration, if a flat spot is provided in one or both
of the half wheels 402, as may be understood, no pivoting is
required; the motion will be as described earlier with respect
to Figs. 14-I7.
In order to - change a wheel configuration, a user will
disengage the spring 470 from its location, remove the pipe
spacer 47I, remove the front plate 450, and remove and
replace as needed either or both of the half wheels 402. The
front plate 450 is then positioned as shown in Fig. 27 and 20,
and the pipe spacer 471 and spring 470 are situated into place
as shown in Figs. 20, 27, and 2~.
As noted above, although the multi-segmented ejection
3o disc 400 is shown as having a circular gripping perimeter
edge, a truncated portion could also be provided by providing
such a truncation in at least one of the half wheel segments
402.
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Figs. 29-35 show a second mufti-segment disc
embodiment 500, including a main disc portion 502, an insert
portion 503, and a spring 512.
The configuration of Figs. 29-35 includes a multi
segmented urethane wheel The wheel portion which contacts
the package takes the form of two urethane segments, a main
disc portion 502 and an insert portion 503. The main disc
portion 502 includes a large slot therein, and the smaller
insert portion is configured to slide within the slot of the main
to disc portion. As shown in Fig. 32, this insert can include a
beveled configuration, which tends to. provide engagement
between it and the main wheel portion. These urethane
members 502, 503, are drawn together by the use of a tension
spring 512, which has each of its ends engaging one of the
tS headed portions of embedded steel pins.
As shown in Figs. 29 and 3~, the main disc portion 502
includes an embedded pin 5I0. The embedded pin includes a
rear hook 520, and includes a front "headed" portion which
defines an annular slot 521.
20 The main disc portion X02 also includes an insert-
receiving slot which at its end includes a substantially arcuate
portion having a keyway slot therein. The keyway slot is
configured to accept a key as described elsewhere.
The insert portion 503 includes an insert portion pin
25 5I1 similar in configuration to pin 510 of the main portion
502. The insert portion 503 includes an arcuate end, which is
configured to conform substantially to a peripheral portion of
a shaft as described elsewhere.
Referring now also to Figs. 32 and 33, the rear flanged
30 plate assembly 560 also includes a rear plate 561, a rear
flange 564 rigidly attached thereto, and is keyed as known in
the art to engage the shaft.
The front plate 550 is configured !to include a key tab
551 to engage a keyway in the drive shaft 531, and includes a
CA 02441618 2003-09-24
t%~ 9~J490~0 PC'r/LJS9~J0~59~
34
pair of through holes j52 to allow passage of the through pins
510, 511. A pipe ring 570 is also used as described below.
The outer surface of both portions 502, 503 is provided
with gripping teeth or another suitable gripping surface such
as known in the art.
As shown in Fig. 32, the rear flanged plate assembly
560 fits onto a shaft 531 of a motor 530.
The two urethane portions 502, 503, are configured to
fit together in their configuration shown in Fig. 32, such that
the front plate and the rear plate 5 61 of the rear plate
assembly 560 tend to capture the urethane portions 502, 503,
along the length of the shaft 531 of the motor 530. The
urethane portions 502, 503, are drawn together by the use of
a spring 512, which has each of its ends engaging one of the
headed portions of the embedded steel pins and captures the
pipe ring 570 as shown.
A keyway is provided to allow keyed engagement
between the shaft 531 of the gear motor 530 and the front
plate 550, the main urethane wheel member 502, and the rear
flange plate assembly 560.
To replace one or both of the urethane portions 502,
503, the spring 512 is first removed, followed by removal of
the front plate 550. The urethane portions 502, 503, can
then be separated by sliding the smaller member 503, out of
the main slot of the larger member 502. Replacement of
either or both of the urethane members can then be effected.
After the urethane members are in place, the front plate 550 is
then replaced, followed by the spring 512. rf desired, a pipe
ring 570, as shown in Fig. 32, can be used to fit underneath
3o the spring 512 as shown in Fig. 34.
~peration of the disc 500, being round, is similar to the
disc 400, although a flat spot may be alternately provided to
be used with the pivoting configuration described in reference
to Figs. 1 ~ and 19.
CA 02441618 2003-09-24
w0 98/49080 PCT/IJS98I0859'7
Figs. 36 and 37 illustrate top plan and side elevational
views, respectively of third mufti-segmented ejection disc 600
according to the present invention, including a main disc
portion 602 and an insert portion 603 slidably insertable into
5 the main portion in a manner similar to that described
previously, with respect to, for example, Fig. 30. I-iowever, in
this configuration, a tension spring 612 is used which engages
at its ends to two respective pins each of which are installed in
the main disc portion on opposing sides of the main portion's
10 insert-receiving slot. The medial portion of the spring 612 is
stretched around a pin member extending through the insert
portion 603 and having upwardly (as shown in the drawings)
directed hooks which are biased downwardly (as shown in the
drawings), such that the spring force tends to cause the plastic
15 insert to remain seated within its position in the main wheel
portion.
This configuration may be used with a separate means
(not shown) to attach the combination of the two elements 602,
603 to a motor shaft 620, or may be modified to operate in
20 conjunction with other mounting elements such as a flanged
rear disc assembly and front disc assembly, motor, etc., to be
supported and driven thereby in manners similar to those
previously discussed.
In this particular embodiment 600, the mufti-segmented
25 disc 600 includes a "flat spot", although as shown elsewhere in
this application such a mufti-segment disc could not have a flat
section.
The thickness of the mufti-segmented disc 600 as shown
in Fig. 36, as well as the other discs may be within the range
30 of 1/2 inch to 3 inches, and can be approximately 12 inches in
peripheral diameter although other configurations are
contemplated without departing from the spirit and scope of
the present invention. The peripheral edge of the disc 600
intended to engage packages may be provided with engaging
CA 02441618 2003-09-24
WO 98/49080 PCT/IIS98108597
36
teeth or other suitable frictional engaging means known in the
art.
Therefore it may be seen that the invention provides an
improved conveying and discharge apparatus which provides
numerous improvements over the previously-described prior
art, not the least of which includes a simple yet effective
discharge device which can be easily replaced with little
downtime.
While this invention has been described in specific detail
with reference to the disclosed embodiments, it will be
understood that many variations and modifications may be
effected within the spirit and scope of the invention as
described in the appended claims.
