US 5,145,049 A · Pattern forming conveyor

Abstract

A conveyor continuously advances bundles issuing from a manufacturing line while manipulating them into a pattern for shipment. Comprised of three zones, the conveyor sequentially centers, rotates and organizes bundles for inclusion in a pattern in preparation for shipment without manual intervention. The conveyor is insensitive to bundle size within the parameters of the particular embodiment, and performs desired manipulation regardless of initial bundle placement or orientation. As no interruption in the flow of bundles is needed to manipulate bundles into patterns, no jamming of bundles occurs upstream from such patterns as they form. The conveyor increases the overall speed of handling bundles, and makes possible the automation of shipping procedures in manufacturing facilities.

Claims32

Dependent claims

A pattern forming conveyor for conveying bundles from a manufacturing line to a point of discharge, comprising:

a frame;
an elongated conveying surface disposed in said frame for continuously advancing bundles in a direction of bundle movement;
said conveying surface comprising first, second and third zones further comprising, respectively, means for centering bundles, means for rotating bundles, and means for discharging bundles, wherein:
said means for centering is automatically adjustable to urge a bundle to simultaneously shift laterally to one of a plurality of positions in either direction on said conveying surface and advance in said direction of bundle movement substantially without rotation of said bundle;
and
said means for rotating is adapted to urge a bundle to simultaneously rotate and advance a bundle in said direction of bundle movement toward said third zone;
means for controlling said means for centering, rotating and discharging bundles, whereby said means for centering is automatically adjusted;
and
power means for operating said conveyor adapted to drive said elongated conveying surface and said means for centering, rotating, discharging and controlling;
whereby bundles may be manipulated and organized into one of a plurality of predetermined bundle patterns in said third zone and discharged therefrom.

7 more elements

A pattern forming conveyor for conveying bundles from a manufacturing line to a point of discharge, comprising:

a frame;
an elongated conveying surface disposed in said frame for continuously advancing bundles in a direction of bundle movement;
said conveying surface comprising first, second and third zones further comprising, respectively, means for centering bundles, means for rotating bundles, and means for discharging bundles, wherein said means for centering bundles comprises:
a plurality of centering rollers organized in one or more rows and forming a portion of said elongated conveying surface;
means for rotating each of said centering rollers about respective axes of rotation;
means for adjusting said axes of rotation of said centering rollers in and out of alignment substantially perpendicular to said direction of bundle movement;
means for sensing the location of a bundle disposed on said conveying surface in said first zone, said means for sensing adapted to generate bundle location signals;
and
means for controlling said means for centering, rotating and discharging bundles, wherein said means for controlling is adapted to receive said bundle location signals and send control signals to said means for adjusting said centering rollers;
whereby said centering rollers may be adjusted to position a bundle on said conveying surface;
power means for operating said conveyor adapted to drive said elongated conveying surface and said means for centering, rotating, discharging and controlling;
whereby bundles may be manipulated and organized into one of a plurality of predetermined bundle patterns in said third zone and discharged therefrom.

9 more elements

A pattern forming conveyor for conveying bundles from a manufacturing line to a point of discharge, comprising:

a frame;
an elongated conveying surface disposed in said frame for continuously advancing bundles in a direction of bundle movement;
said conveying surface comprising first, second and third zones further comprising, respectively, means for centering bundles, means for rotating bundles, and means for discharging bundles wherein said means for rotating is adapted to urge a bundle to simultaneously rotate and advance a bundle in said direction of bundle movement toward said third zone, and said means for rotating bundles comprises:
first and second bundle rotation assemblies adapted to rotate bundles in opposite first and second directions, respectively, relative to said direction of bundle movement, said first and second bundle rotation assemblies comprising, respectively, a first and a second;
a plurality of bundle rotation rollers disposed in said frame in one or more rows at angles adapted to urge a bundle to simultaneously rotate and advance in a direction of bundle movement toward said third zone;
means for rotating said plurality of bundle rotation rollers at speeds which both urge a bundle to rotate and continue its advance in said direction of bundle movement, said means for rotating adapted to impart different speeds to two or more of said plurality of bundle rotation rollers;
and
means for raising and lowering said plurality of bundle rotation rollers above and below said conveying surface;
and
means for sensing the advance and rotation of a bundle in said second zone adapted to generate bundle rotation signals;
means for controlling said means for centering rotating and discharging bundles, wherein said means for controlling is adapted to receive said bundle rotation signals and send control signals to said means for raising and lowering said first or said second plurality of bundle rotation rollers;
and
power means for operating said conveyor adapted to drive said elongated conveying surface and said means for centering, rotating, discharging and controlling;
whereby either said first or said second plurality of bundle rotation rollers may be engaged to lift, rotate and advance a bundle above said conveying surface, and thereafter lower said bundle to said conveying surface;
and
whereby bundles may be manipulated and organized into one of a plurality of predetermined bundle patterns in said third zone and discharged therefrom.

13 more elements

A pattern forming conveyor for conveying bundles from a manufacturing line to a point of discharge, comprising:

a frame;
an elongated conveying surface disposed in said frame for continuously advancing bundles in a direction of bundle movement;
said conveying surface comprising first, second and third zones further comprising, respectively, means for centering bundles, means for rotating bundles, and means for discharging bundles;
wherein said means for rotating bundles comprises:
first and second bundle rotation assemblies adapted to rotate bundles clockwise or counterclockwise, respectively, relative to said direction of bundle movement, wherein:
said first bundle rotation assembly comprises:
a first plurality of bundle rotation rollers disposed in said frame in one or more rows at angles adapted to urge a bundle to both rotate and advance in a direction of bundle movement;
first means for rotating said first plurality of bundle rotation rollers at speeds which both urge a bundle to rotate and continue its advance in said direction of bundle movement;
and
first means for raising and lowering said first plurality of bundle rotation rollers above and below said conveying surface, wherein said first means for raising and lowering said first plurality of bundle rotation rollers comprises:
a first plurality of shafts slidably and vertically disposed in said frame, said first plurality of shafts adapted for mounting ones of said first plurality of bundle rotation rollers thereon;
means for sliding said first plurality of shafts comprising:
one or more third axles disposed in said frame, adapted to rotate in an arc;
a plurality of first lever arms attached to said one or more third axles adapted to displace respective ones of said first plurality of shafts upon rotation of said third axles in an arc;
and
means for rotating said one or more third axles in concert comprising a third cylinder, a first flat gear assembly and a first gear disposed on the end of each of said one or more third axles, said first gear engaged in said first flat gear assembly;
and
a first plurality of idler pulley pairs, ones of said idler pulley pairs engaged in each of said first bundle rotation rollers and adapted to facilitate raising and lowering said first bundle rotation rollers;
and
said second bundle rotation assembly comprises:
a second plurality of bundle rotation rollers disposed in said frame in one or more rows at angles adapted to urge a bundle to both rotate and advance in a direction of bundle movement;
second means for rotating said second plurality of bundle rotation rollers at speeds which both urge a bundle to rotate and continue its advance in said direction of bundle movement;
and
second means for raising and lowering said second plurality of bundle rotation rollers above and below said conveying surface, wherein said second means for raising and lowering said second plurality of bundle rotation rollers comprises:
a second plurality of shafts slidably disposed in said frame, said second plurality of shafts adapted for mounting ones of said second plurality of bundle rotation rollers thereon;
means for sliding said second plurality of shafts comprising:
one or more fourth axles disposed in said frame, adapted to rotate in an arc;
a plurality of second lever arms attached to said one or more fourth axles adapted to displace respective ones of said second plurality of shafts upon rotation of said fourth axles in an arc;
and
means for rotating said one or more fourth axles in concert comprising a fourth cylinder, a second flat gear assembly and a second gear disposed on the end of each of said one or more fourth axles, said second gear engaged in said second flat gear assembly;
and
a second plurality of idler pulley pairs, ones of said idler pulley pairs engaged in each of said second bundle rotation rollers and adapted to facilitate raising and lowering said second bundle rotation rollers,
means for sensing the advance and rotation of a bundle in said second zone adapted to generate bundle rotation signals;
and
means for controlling said means for centering, rotating and discharging bundles, wherein said means for controlling is adapted to receive said bundle rotation signals and send control signals to said means for raising and lowering said first or said second plurality of bundle rotation rollers, whereby either said first or said second plurality of bundle rotation rollers may be engaged to lift, rotate and advance a bundle above said conveying surface, and thereafter lower said bundle to said conveying surface;
power means for operating said conveyor adapted to drive said elongated conveying surface and said means for centering, rotating, discharging and controlling;
whereby bundles may be manipulated and organized into one of a plurality of predetermined bundle patterns in said third zone and discharged therefrom.

34 more elements

A pattern forming conveyor for conveying bundles from a manufacturing line to a point of discharge, comprising:

a frame;
a plurality of parallel rollers rotatably disposed in said frame substantially forming an elongated conveying surface for continuously advancing bundles in a direction of bundle movement;
said conveying surface comprising first, second and third zones further comprising, respectively, means for centering bundles, means for rotating bundles, and means for discharging bundles;
means for controlling said conveyor adapted for organizing one or more bundles in a pattern for shipping;
and
power means for operating said conveyor adapted to drive said parallel rollers, said means for centering bundles, said means for rotating bundles, said means for discharging bundles and said means for controlling;
wherein said means for centering bundles comprises:
a plurality of centering rollers spaced between said parallel rollers and forming a portion of said conveying surface;
means for rotating each of said centering rollers about an axis of rotation;
means for adjusting said axes of rotation of said centering rollers in and out of alignment with said parallel rollers;
means for sensing the location of a bundle disposed on said conveying surface in said first zone, said means for sensing adapted to generate bundle location signals;
and
wherein said means for rotating bundles comprises:
first and second bundle rotation assemblies adapted to rotate bundles clockwise and counterclockwise, respectively, relative to said direction of bundle movement, said first and second bundle rotation assemblies each comprising, respectively, a first or second:
plurality of bundle rotation rollers disposed in said frame between said parallel rollers at angles adapted to urge a bundle to both rotate and advance in a direction of bundle movement;
means for rotating said plurality of bundle rotation rollers at speeds which both urge a bundle to rotate and continue its advance in said direction of bundle movement;
and
means for raising and lowering said plurality of bundle rotation rollers above and below said conveying surface;
means for sensing the advance and rotation of a bundle in said second zone adapted to generate bundle rotation signals;
wherein said means for discharging bundles comprises
a stop plate adapted to stop the advance of said bundles in said direction of bundle movement;
a sub-frame;
a pusher plate supported by said sub-frame;
means for wiping said pusher plate across said conveying surface transverse to said direction of bundle movement attached to said sub-frame;
two or more lift fingers supported by said sub-frame and adapted to lift at least one of said bundle patterns above said conveying surface;
means for raising said two or more lift fingers above said conveying surface;
wherein said means for controlling is further adapted for receiving bundle location signals and sending responsive control signals to said means for adjusting said centering rollers;
receiving bundle rotation signals and sending responsive control signals to said means for raising and lowering said bundle rotation rollers;
and triggering said means for discharging when a bundle pattern is completed;
whereby a series of bundles conveyed from a manufacturing line are manipulated and organized into at least one of a plurality of predetermined bundle patterns in said third zone, and discharged therefrom.

27 more elements

A method for conveying, manipulating and organizing a group of two or more bundles into one of a plurality of bundle patterns on a conveyor, said bundles in said group arriving one at a time, and said conveyor advancing said bundles in a direction of bundle movement from a point of infeed to a point of discharge from said conveyor, comprising, for each bundle in said pattern, the steps of:

automatically adjusting a bundle laterally to one of a plurality of positions in either direction on the conveyor while said bundle simultaneously advances in a direction of bundle movement substantially without rotation;
automatically rotating said bundle as necessary in one of opposite first and second directions of bundle rotation for insertion in said one of said plurality of bundle patterns while said bundle simultaneously advances in said direction of bundle movement;
and
automatically accumulating said bundle against a stop plate, interrupting said direction of bundle movement until a complete bundle pattern is established against said stop plate;
said steps of automatically adjusting and automatically rotating being variably performed for each bundle in said group as required to completely establish said one of a plurality of bundle patterns;
and
automatically discharging said bundle pattern from said conveyor.

4 more elements

Dependencies are inferred from the claim text.

Abstract

Claims32

Dependent claims

A pattern forming conveyor for conveying bundles from a manufacturing line to a point of discharge, comprising:

a frame;
an elongated conveying surface disposed in said frame for continuously advancing bundles in a direction of bundle movement;
said conveying surface comprising first, second and third zones further comprising, respectively, means for centering bundles, means for rotating bundles, and means for discharging bundles, wherein:
said means for centering is automatically adjustable to urge a bundle to simultaneously shift laterally to one of a plurality of positions in either direction on said conveying surface and advance in said direction of bundle movement substantially without rotation of said bundle;
and
said means for rotating is adapted to urge a bundle to simultaneously rotate and advance a bundle in said direction of bundle movement toward said third zone;
means for controlling said means for centering, rotating and discharging bundles, whereby said means for centering is automatically adjusted;
and
power means for operating said conveyor adapted to drive said elongated conveying surface and said means for centering, rotating, discharging and controlling;
whereby bundles may be manipulated and organized into one of a plurality of predetermined bundle patterns in said third zone and discharged therefrom.

7 more elements

A pattern forming conveyor for conveying bundles from a manufacturing line to a point of discharge, comprising:

a frame;
an elongated conveying surface disposed in said frame for continuously advancing bundles in a direction of bundle movement;
said conveying surface comprising first, second and third zones further comprising, respectively, means for centering bundles, means for rotating bundles, and means for discharging bundles, wherein said means for centering bundles comprises:
a plurality of centering rollers organized in one or more rows and forming a portion of said elongated conveying surface;
means for rotating each of said centering rollers about respective axes of rotation;
means for adjusting said axes of rotation of said centering rollers in and out of alignment substantially perpendicular to said direction of bundle movement;
means for sensing the location of a bundle disposed on said conveying surface in said first zone, said means for sensing adapted to generate bundle location signals;
and
means for controlling said means for centering, rotating and discharging bundles, wherein said means for controlling is adapted to receive said bundle location signals and send control signals to said means for adjusting said centering rollers;
whereby said centering rollers may be adjusted to position a bundle on said conveying surface;
power means for operating said conveyor adapted to drive said elongated conveying surface and said means for centering, rotating, discharging and controlling;
whereby bundles may be manipulated and organized into one of a plurality of predetermined bundle patterns in said third zone and discharged therefrom.

9 more elements

A pattern forming conveyor for conveying bundles from a manufacturing line to a point of discharge, comprising:

a frame;
an elongated conveying surface disposed in said frame for continuously advancing bundles in a direction of bundle movement;
said conveying surface comprising first, second and third zones further comprising, respectively, means for centering bundles, means for rotating bundles, and means for discharging bundles wherein said means for rotating is adapted to urge a bundle to simultaneously rotate and advance a bundle in said direction of bundle movement toward said third zone, and said means for rotating bundles comprises:
first and second bundle rotation assemblies adapted to rotate bundles in opposite first and second directions, respectively, relative to said direction of bundle movement, said first and second bundle rotation assemblies comprising, respectively, a first and a second;
a plurality of bundle rotation rollers disposed in said frame in one or more rows at angles adapted to urge a bundle to simultaneously rotate and advance in a direction of bundle movement toward said third zone;
means for rotating said plurality of bundle rotation rollers at speeds which both urge a bundle to rotate and continue its advance in said direction of bundle movement, said means for rotating adapted to impart different speeds to two or more of said plurality of bundle rotation rollers;
and
means for raising and lowering said plurality of bundle rotation rollers above and below said conveying surface;
and
means for sensing the advance and rotation of a bundle in said second zone adapted to generate bundle rotation signals;
means for controlling said means for centering rotating and discharging bundles, wherein said means for controlling is adapted to receive said bundle rotation signals and send control signals to said means for raising and lowering said first or said second plurality of bundle rotation rollers;
and
power means for operating said conveyor adapted to drive said elongated conveying surface and said means for centering, rotating, discharging and controlling;
whereby either said first or said second plurality of bundle rotation rollers may be engaged to lift, rotate and advance a bundle above said conveying surface, and thereafter lower said bundle to said conveying surface;
and
whereby bundles may be manipulated and organized into one of a plurality of predetermined bundle patterns in said third zone and discharged therefrom.

13 more elements

A pattern forming conveyor for conveying bundles from a manufacturing line to a point of discharge, comprising:

a frame;
an elongated conveying surface disposed in said frame for continuously advancing bundles in a direction of bundle movement;
said conveying surface comprising first, second and third zones further comprising, respectively, means for centering bundles, means for rotating bundles, and means for discharging bundles;
wherein said means for rotating bundles comprises:
first and second bundle rotation assemblies adapted to rotate bundles clockwise or counterclockwise, respectively, relative to said direction of bundle movement, wherein:
said first bundle rotation assembly comprises:
a first plurality of bundle rotation rollers disposed in said frame in one or more rows at angles adapted to urge a bundle to both rotate and advance in a direction of bundle movement;
first means for rotating said first plurality of bundle rotation rollers at speeds which both urge a bundle to rotate and continue its advance in said direction of bundle movement;
and
first means for raising and lowering said first plurality of bundle rotation rollers above and below said conveying surface, wherein said first means for raising and lowering said first plurality of bundle rotation rollers comprises:
a first plurality of shafts slidably and vertically disposed in said frame, said first plurality of shafts adapted for mounting ones of said first plurality of bundle rotation rollers thereon;
means for sliding said first plurality of shafts comprising:
one or more third axles disposed in said frame, adapted to rotate in an arc;
a plurality of first lever arms attached to said one or more third axles adapted to displace respective ones of said first plurality of shafts upon rotation of said third axles in an arc;
and
means for rotating said one or more third axles in concert comprising a third cylinder, a first flat gear assembly and a first gear disposed on the end of each of said one or more third axles, said first gear engaged in said first flat gear assembly;
and
a first plurality of idler pulley pairs, ones of said idler pulley pairs engaged in each of said first bundle rotation rollers and adapted to facilitate raising and lowering said first bundle rotation rollers;
and
said second bundle rotation assembly comprises:
a second plurality of bundle rotation rollers disposed in said frame in one or more rows at angles adapted to urge a bundle to both rotate and advance in a direction of bundle movement;
second means for rotating said second plurality of bundle rotation rollers at speeds which both urge a bundle to rotate and continue its advance in said direction of bundle movement;
and
second means for raising and lowering said second plurality of bundle rotation rollers above and below said conveying surface, wherein said second means for raising and lowering said second plurality of bundle rotation rollers comprises:
a second plurality of shafts slidably disposed in said frame, said second plurality of shafts adapted for mounting ones of said second plurality of bundle rotation rollers thereon;
means for sliding said second plurality of shafts comprising:
one or more fourth axles disposed in said frame, adapted to rotate in an arc;
a plurality of second lever arms attached to said one or more fourth axles adapted to displace respective ones of said second plurality of shafts upon rotation of said fourth axles in an arc;
and
means for rotating said one or more fourth axles in concert comprising a fourth cylinder, a second flat gear assembly and a second gear disposed on the end of each of said one or more fourth axles, said second gear engaged in said second flat gear assembly;
and
a second plurality of idler pulley pairs, ones of said idler pulley pairs engaged in each of said second bundle rotation rollers and adapted to facilitate raising and lowering said second bundle rotation rollers,
means for sensing the advance and rotation of a bundle in said second zone adapted to generate bundle rotation signals;
and
means for controlling said means for centering, rotating and discharging bundles, wherein said means for controlling is adapted to receive said bundle rotation signals and send control signals to said means for raising and lowering said first or said second plurality of bundle rotation rollers, whereby either said first or said second plurality of bundle rotation rollers may be engaged to lift, rotate and advance a bundle above said conveying surface, and thereafter lower said bundle to said conveying surface;
power means for operating said conveyor adapted to drive said elongated conveying surface and said means for centering, rotating, discharging and controlling;
whereby bundles may be manipulated and organized into one of a plurality of predetermined bundle patterns in said third zone and discharged therefrom.

34 more elements

A pattern forming conveyor for conveying bundles from a manufacturing line to a point of discharge, comprising:

a frame;
a plurality of parallel rollers rotatably disposed in said frame substantially forming an elongated conveying surface for continuously advancing bundles in a direction of bundle movement;
said conveying surface comprising first, second and third zones further comprising, respectively, means for centering bundles, means for rotating bundles, and means for discharging bundles;
means for controlling said conveyor adapted for organizing one or more bundles in a pattern for shipping;
and
power means for operating said conveyor adapted to drive said parallel rollers, said means for centering bundles, said means for rotating bundles, said means for discharging bundles and said means for controlling;
wherein said means for centering bundles comprises:
a plurality of centering rollers spaced between said parallel rollers and forming a portion of said conveying surface;
means for rotating each of said centering rollers about an axis of rotation;
means for adjusting said axes of rotation of said centering rollers in and out of alignment with said parallel rollers;
means for sensing the location of a bundle disposed on said conveying surface in said first zone, said means for sensing adapted to generate bundle location signals;
and
wherein said means for rotating bundles comprises:
first and second bundle rotation assemblies adapted to rotate bundles clockwise and counterclockwise, respectively, relative to said direction of bundle movement, said first and second bundle rotation assemblies each comprising, respectively, a first or second:
plurality of bundle rotation rollers disposed in said frame between said parallel rollers at angles adapted to urge a bundle to both rotate and advance in a direction of bundle movement;
means for rotating said plurality of bundle rotation rollers at speeds which both urge a bundle to rotate and continue its advance in said direction of bundle movement;
and
means for raising and lowering said plurality of bundle rotation rollers above and below said conveying surface;
means for sensing the advance and rotation of a bundle in said second zone adapted to generate bundle rotation signals;
wherein said means for discharging bundles comprises
a stop plate adapted to stop the advance of said bundles in said direction of bundle movement;
a sub-frame;
a pusher plate supported by said sub-frame;
means for wiping said pusher plate across said conveying surface transverse to said direction of bundle movement attached to said sub-frame;
two or more lift fingers supported by said sub-frame and adapted to lift at least one of said bundle patterns above said conveying surface;
means for raising said two or more lift fingers above said conveying surface;
wherein said means for controlling is further adapted for receiving bundle location signals and sending responsive control signals to said means for adjusting said centering rollers;
receiving bundle rotation signals and sending responsive control signals to said means for raising and lowering said bundle rotation rollers;
and triggering said means for discharging when a bundle pattern is completed;
whereby a series of bundles conveyed from a manufacturing line are manipulated and organized into at least one of a plurality of predetermined bundle patterns in said third zone, and discharged therefrom.

27 more elements

automatically adjusting a bundle laterally to one of a plurality of positions in either direction on the conveyor while said bundle simultaneously advances in a direction of bundle movement substantially without rotation;
automatically rotating said bundle as necessary in one of opposite first and second directions of bundle rotation for insertion in said one of said plurality of bundle patterns while said bundle simultaneously advances in said direction of bundle movement;
and
automatically accumulating said bundle against a stop plate, interrupting said direction of bundle movement until a complete bundle pattern is established against said stop plate;
said steps of automatically adjusting and automatically rotating being variably performed for each bundle in said group as required to completely establish said one of a plurality of bundle patterns;
and
automatically discharging said bundle pattern from said conveyor.

4 more elements

Dependencies are inferred from the claim text.

Pattern forming conveyor

Life of this patent

Abstract

Claims32

Pattern forming conveyor

Life of this patent

Abstract

Claims32