Overhead conveyor system

A system for transporting ferromagnetic work pieces and non-ferromagnetic work pieces, the system comprising:

• a frame, the frame comprising a first end and a second end;
• a pair of moving conveyor belt supported on the frame and extending between the first end and the second end of the frame, each of the moving conveyor belts having an inner surface and an outer surface and comprising a plurality of orifices therethrough;
• a magnetic system supported on the frame operable to generate a magnetic force to vertically retain ferromagnetic work pieces against the outer surface of the moving conveyor belt;
• a vacuum system supported on the frame, the vacuum system including a vacuum generator and a plurality of vacuum units, the vacuum system operable to generate a vacuum at at least a portion of the plurality of orifices through the conveyor belt to vertically retain the ferromagnetic work pieces and non-ferromagnetic work pieces against the outer surface of the moving conveyor belt;
• and
• a stacker unit supported on the frame, the stacker unit operable to selectively neutralize the first magnetic force generated by the first magnet to release the ferromagnetic work pieces from the moving conveyor belt at a transport location, the stacker unit operable to selectively interrupt the vacuum pulled by the first vacuum unit to release either or both of the ferromagnetic and non-ferromagnetic work pieces from the moving conveyor belt at the transport location;
• wherein at least one vacuum unit comprises:
• a base, the base comprising a bottom surface and a top surface that is located opposite the bottom surface;
• a divider wall disposed between the bottom surface and the top surface of the base, the divider wall creating a first chamber section and a second chamber section within the base;
• at least one aperture disposed through the bottom surface of the base;
• a first port and a second port disposed on the top surface of the base;
• a valve module disposed atop each port, the valve module comprising a body and a valve disposed within the body, the valve module further comprising a valve controller in communication with the valve, the valve controller configured to move the valve between an open position and a closed position such that when the valve is in the open position the vacuum is operable to lift and vertically retain either or both of the ferromagnetic work pieces and non-ferromagnetic work pieces on the at least one moving conveyor belt, when the valve is in the closed position either or both of the ferromagnetic work pieces and non-ferromagnetic work pieces are released from the at least one moving conveyor belt at the transport location;
• and
• an intake elbow, the intake elbow comprising an area where the vacuum can be temporarily stored once the valve of the first vacuum unit is moved from the open position into the closed position, wherein the stacker unit is in communication with the valve controller of the first vacuum unit to move the valve between the closed position and the open position.

A method for converting an overhead conveying system that uses magnetic force to transport work pieces from one location to another into an overhead conveying system that uses either or both magnetic force and vacuum to transport work pieces from one location to another, the method comprising:

• attaching a first vacuum generator and a second vacuum generator to the overhead conveying system;
• coupling a row of vacuum units to the overhead conveying system adjacent a row of magnetic units;
• adjusting a vertical height of the at least one row of vacuum units such that a bottom plane of the vacuum units is generally co-planar with a bottom plane of the magnetic units;
• coupling a first end of a first distribution duct to the first vacuum generator;
• coupling a first end of at least one first vacuum line to the first distribution duct;
• coupling a second end of the at least one first vacuum line to a valve located on each vacuum unit located near a first end of the overhead conveyor system;
• coupling a second end of the first distribution duct to the second vacuum generator;
• coupling a first end of the at least one second vacuum line to the first distribution duct;
• coupling the first end of the at least one first vacuum line to the second vacuum line;
• coupling a second end of the at least one first vacuum line to a valve located on each vacuum unit located near a second end of the overhead conveyor system;
• and
• creating at least one aperture through a moving conveyor belts.

The method of claim 30, further comprising:

• attaching a third vacuum generator to the overhead conveyor system;
• coupling a first end of a first header duct to the third vacuum generator;
• coupling a first end of a third vacuum line to the first header duct;
• and
• coupling a second end of the third vacuum line to a valve located on each vacuum unit disposed at an input end of the overhead conveyor system.