Brief Description of the Drawings
FIG. 1 is a schematic plan view of a portion of a conveyor belt in accordance with the present invention, illustrating the belt passing around a lateral curve;
FIG. 2 is a schematic plan view of the conveyor belt of FIG. 1, illustrating the belt traveling in a straight line direction;
FIG. 3 is a plan view of an inside portion of the conveyor belt in accordance with an embodiment of the present invention;
FIG. 4 is a sectional view taken generally along line IV--IV of FIG. 3;
FIG. 5 is a plan view of an improved U-shaped link having a work-hardened, curved bearing surface and modified leg portions;
FIG. 6 is a side view of the link illustrated in FIG. 5;
FIG. 7 is a side view of a dual pitch link in accordance with the present invention;
FIG. 8 is a sectional view taken generally along the line VIII--VIII of FIG. 7;
FIG. 9 is a sectional view taken generally along line IX--IX of FIG. 7;
FIG. 10 is a schematic side view, illustrating another embodiment of dual pitch links pivoting from a first pitch to a second greater pitch;
FIG. 11 is a schematic side view similar to FIG. 10, illustrating the dual pitch links pivoting from the second greater pitch to the first shorter pitch;
FIG. 12 is an end view, partially in section, illustrating a guide track for receiving a rod end;
FIG. 13 is a side view of a support link in accordance with an embodiment of the present invention;
FIG. 14 is a front edge view of the support link illustrated in FIG. 13;
FIG. 15 is a top plan view of the support link illustrated in FIG. 13;
FIG. 16 is a schematic vertical sectional view illustrating the inside edge of a pair of stacked tiers of a conveyor belt with the support links disposed along this inside edge of the belt;
FIG. 17 is a top plan view of portions of the conveyor belt;
FIG. 18 is a side view taken generally along line XVIII--XVIII of FIG. 17;
FIG. 19 is a schematic drawing of a conveyor system in accordance with the present invention wherein the belt conveys about a helical path and is driven by a frictional drive mechanism;
FIG. 20 is a schematic drawing of another embodiment of a conveyor system in accordance with the present invention wherein the conveyor belt conveys about a helical path and is driven by a positive drive mechanism; and
FIG. 21 is a schematic top plan view illustrating a conveyor belt designed to travel in both lateral directions with dual pitch links on both transverse edges of the belt.
Detailed Description of the Invention
Referring to the Figures wherein like numerals indicate like elements, a portion of a conveyor belt 10 is shown in FIGS. 1 and 2. FIG. 3 illustrates the left or inside concave edge of belt 10. Conveyor belt 10 is formed of a plurality of rods 12, single pitch links 14 along one edge of belt 10 and dual pitch links 16 along the opposite edge of belt 10. Rods 12 extend transversely of the length of belt 10 and they have enlarged or upset ends. Links 14 and 16 couple adjacent rods 12 to one another to form a length of belt 10.
Single pitch links 14 can be conventional U-shaped links having apertures for receiving the inside ends of a pair of rods 12. The apertures in links 14 are slightly oversized with respect to the cross-sectional dimension of rods 12 to permit cleaning, nevertheless, links 14 hold the ends of rods 12 to substantially a constant or single pitch.
Links 16 are dual pitch links designed to change the pitch of rods 12 (spacing between adjacent rods 12) along the edge at which they are disposed between a first pitch and a second greater pitch. The first pitch is substantially equal to the pitch at which links 14 hold the inside ends of rods 12 during straight line motion as shown in FIG. 2. When belt 10 proceeds around a lateral curve, as shown in FIG. 1, dual pitch links 16 move the outside ends of the rods to which they are coupled to the second greater pitch along the outside convex edge 32 of the lateral curve, while links 14 hold the inside ends of the rods to which they are attached to the first pitch along the inside concave edge 30 of the lateral curve.
As shown in FIGS. 3 and 4, U-shaped links 14 have leg portions 120 which extend generally in the lengthwise direction of belt 10, and connecting portions 122 which join leg portions 120. Leg portions 120 have a pair of spaced holes 124, 125 for receiving the inside ends of a pair of rods 12. Holes 124, at the trailing end of link 14, are slightly oversized with respect to the cross-sectional dimension of rod 12 to permit cleaning of the belt. Holes 125, at the leading end of links 14, are in the form of a slot of oversized width, likewise for the purpose of permitting cleaning. Holes 124 and 125 are located and shaped so that the inside ends of rods 12 are kept at a first pitch (center to center spacing between adjacent rods 12) when the belt is under tractive load. Also, links 14 and rods 12, which are approximately along the inside concave edge of belt 10, remain under tractive load both during straight line motion and lateral curved motion. As will be explained, the inside portions of rods 12 are kept at substantially the first pitch and under tractive load in both straight line motion and lateral curved motion of belt 10 by the specific design of the combination of single pitch links 14 and dual pitch links 16, which form a link mechanism for belt 10.
U-shaped single pitch link 14 leg portions 120 can be substantially straight and diverge outwardly from opposite ends of connecting portion 122. Alternatively, the inside links can be configured as the U-shaped links 14' illustrated in FIGS. 5 and 6. Link 14' has a connecting portion 122' similar to connecting portion 122, however, leg portions 120' are formed different from leg portions 120. Each leg portion 120' includes an inner section 142 extending generally perpendicularly from connecting portion 122', a middle section 144 diverging outwardly from inner section 142, and an outer or end section 146 extending from middle section 144 in a direction generally parallel to inner section 142.
Each link 14, 14' can be formed of a substantially flat piece of metal. The flat piece of metal has a first thickness T.sub.1 along the top and bottom areas of connecting portions 122, 122' and along leg portions 120, 120'. A curved bearing surface 126, 126' is formed in the inner surface of connecting portions 122, 122', while the outer surface remains substantially flat. Bearing surface 126, 126' is formed by a coining process wherein the material of connecting portions 122, 122' is compressed to a maximum reduced thickness T.sub.2. The compressed, reduced thickness area, thus, becomes a work-hardened area of connecting portions 122, 122'. The maximum reduced thickness T.sub.2 is at least 90% of thickness T.sub.1 and not less than preferably 70%. A typical example being T.sub.1 of 0.105 inch reduced to T.sub.2 of 0.80 inch. The curved bearing surface substantially mates with the outer surface of rod 12, i.e. has substantially the same radius of curvature. Links 16 can also include a work-hardened bearing surface. However, this is not necessary since links 16 are designed not to take any significant tractive load.
FIG. 7 illustrates the structural details of one embodiment of a dual pitch link 16. Link 16 is preferably formed as a single integral body 18 which has a generally triangular shape or perimeter. A pivot aperture 20 and an elongate pitch changing slot 22 are formed through body 18 of dual pitch link 16. As further illustrated in FIGS. 8 and 9, body 18 can be formed of two thicknesses of material, i.e., a thick portion 24 extending around a substantial portion of aperture 20 and slot 22, and a thinner web portion 26 filling in and extending around the border of thicker portion 24. A two thickness configuration of body 18 is particularly suitable for a body 18 formed of a molded plastic material wherein a sturdy border is provided for aperture 20 and slot 22, while the thinner web portions 26 form an easy to handle, structurally sound and material saving configuration for the integral body 18.
FIGS. 10 and 11 illustrate an alternate, simplified configuration for the body of dual pitch links 16, identified as body 18'. As seen therein, body 18' is formed of a flat piece of material containing aperture 20 and slot 22. The shape of body 18' is particularly suitable for links 16 made from machined metal.
Referring to FIGS. 1, 2, 10 and 11, an operation of belt 10 will be explained. FIG. 2 illustrates belt 10 proceeding in a straight line direction indicated by arrow A. As seen therein, the pitch is the same at both edges of belt 10. Links 14 are single pitch links which hold adjacent rods at this constant pitch. The position of adjacent rods in straight line conveying is illustrated in FIG. 10 by the left-most pair of rods 12, and the three right-most rods in FIG. 11. Referring to FIG. 10, a first rod 12 is received in pivot aperture 20 of the left-most dual pitch link 16 and an adjacent rod 12 is received in pitch changing slot 22 of this link 16. The last-mentioned rod 12 is located in a first pitch area 28 of slot 22 which is located adjacent rods 12 at substantially the same pitch as links 14 locate the adjacent rods. This pitch is the shortest pitch allowed by link 16. In this condition, tractive load can be shared between the U-shaped single pitch links 14 and the dual pitch links 16. Links 14 and 16 can be dimensioned, however, so that the relative amounts of tractive load can be shared unevenly. For example, when dual pitch links 16 are formed of a plastic material, it is desirable to have single pitch links 14, which are generally formed of metal, carry more of the tractive load.
The orientation of rods 12, when belt 10 proceeds around a lateral curve, as shown by arrow B, is illustrated in FIG. 1. As seen therein, the inside concave edge 30 of belt 10 remains at the same first pitch as in straight line motion, while the outside convex edge 32 of belt 10 has been moved to a greater pitch by dual pitch links 16. FIG. 10 illustrates the pivoting motion of links 16 that moves the outside ends of rods 12 along the outside edge 32 to the second greater pitch. As seen therein, a cam surface or the like 34 for pivoting the dual pitch links is located adjacent outside edge 32 of belt 10 in alignment with links 16. As belt 10 proceeds in the direction of arrow C, an upper edge of links 16 contacts cam surface 34 which causes links 16 to pivot in a counterclockwise direction. The pivoting motion of links 16 causes the ends of rods 12 received in the pitch changing slot 22 to slide from the first pitch area 28, wherein adjacent rods 12 are close to one another, to a second pitch area 36 where the spacing between adjacent rods 12 is greater. The pitch changing slot second pitch area forwardmost end surface is 37. See also, FIG. 7. As seen in FIG. 10, cam surface 34 can cause link 16 to pivot 90.degree. and locate rod 12 carried in slot 22 at the furthest end of slot 22 to contact the second pitch area 36 end surface 37. The length and orientation of pitch changing slot 22 is selected to accommodate the greatest pitch along outside curve edge 32 for a given system. Of course, if smaller pitches are required within the same system, cam surface 34 can be designed to pivot dual pitch links 16 to a lesser degree, thereby locating the end of rod 12 received in slot 22 within an intermediate position in second pitch area 36.
FIG. 11 illustrates the manner in which links 16 are pivoted to return rods 12 from the second pitch used in lateral curved motion to the first pitch used in straight line conveying. As shown therein, belt 10 proceeds in the direction of arrow D and links 16 contact a cam surface or the like 38, which pivots links 16 in a clockwise direction. The clockwise pivoting motion of links 16 moves the ends of transverse rods 12 from the second pitch area 36 to the first pitch area 28 of pitch changing slots 22.
As seen in FIG. 12, an elongate guide block 40, having a guide slot 42, can be located adjacent the belt outer edge 32 in the transition area where cam surfaces 34 and 38 cause pivoting motion of links 16. The outermost end of rods 12 are carried within guide slot 42 to keep the ends of rods 12 within the plane of conveying motion of belt 10 during pivoting of links 16. As further seen in FIG. 12, the ends of rods 12 received within slot 42 preferably have a double struck upset head, which assures that the end of transverse rod 12 remains within guide slot 42 even after wear occurs. Guide slot 42 can be eliminated at curves where smooth travel of the belt is not required, for example, on return portions of the conveyor where no ware is being transported, or on a loaded portion of the conveyor if a slight momentary humping of the conveyor surface will not disarrange the ware.
FIGS. 16, 17, and 18 illustrate an embodiment of the invention wherein the conveyor belt 10' is used in a conveying system in which belt 10' travels along a helical path comprised of a number of superimposed helically extending tiers. FIG. 17 also illustrates the combination of a support link with dual pitch links. The conveyor belt of this embodiment will be designated 10', with elements of belt 10' which are similar to belt 10 indicated by like primed numerals.
FIGS. 13, 14 and 15 illustrate details of an inside support link 140 used with belt 10'. Support links 140 can include a longitudinal portion 148 and tab portions 150. Longitudinal portion 148 is formed in two sections, i.e., a lower section 149 and an upper section 151. Lower section 149 contains a pair of holes 155 for receiving ends of adjacent rods 12' and tab portions 150 extend in opposite transverse directions from an upper end of upper section 151. Upper section 151 extends both upward and longitudinally in two directions from lower section 149. As best seen in FIG. 18, a first support link 140A is coupled to a first pair of adjacent rods 12A', while the next support link 140B is coupled to the next separate pair of adjacent rods 12B'. Lower sections 149 are held in alignment with the direction of travel of belt 10' by outer or end sections 146 of U-shaped links 14'. Upper sections 151 of support links 140 are angularly offset by approximately four degrees from the respective lower sections 149 in order to allow the longitudinal ends of adjacent longitudinal portions 148 to overlap. One end of longitudinal portions 148 include dimples 153 which keep the overlapping portions of adjacent support links 140 out of contact to permit cleaning.
Each tab portion 150 has a width which is sufficient to contact and support links 14' disposed in a tier above it. Also, the length of each tab portion 150 is set so that belt 10' can proceed around reverse bends without adjacent tab portions 150 coming into contact with one another.
As seen in FIG. 16, as the belt proceeds around a helical path, the inside edge of belt 10' is supported on a rotating base (not shown) and successive tiers of the helical path created by belt 10' are supported one upon another by means of support links 140. To accomplish this self-supporting feature, the vertical distance which tab portions 150 are located above rods 12' is selected to accommodate the particular helical path and the ware to be supported on belt 10'. Belt 10' is driven by an internal rotating cage which includes a plurality of vertically extending driving members 70.
Conveyor belt 10 with single pitch links 14 and dual pitch links 16 can be used in a conveying system embodiment wherein belt 10 will travel about lateral curves in a single direction and the lateral curves have a predetermined maximum curvature, i.e., the radius of curvature of the tightest lateral curve in the system will not be below a predetermined value. Single pitch links 14 and dual pitch links 16 will have predetermined spacing between the forwardmost and rearwardmost surfaces of the holes or slots in the links which are correlated to the predetermined maximum curvature of the belt travel and to one another. This correlation of spacing is set to assure that the portions of rods 12 along the inside edge of the belt remain at substantially the first pitch, and that at least one of the single pitch links 14, 14' continues to bear a tractive load while the belt proceeds around lateral curves up to the predetermined maximum curvature.
Conveyor belt 10 is driven along its inside edge in a conventional manner by a drive sprocket or drive cage engaging the inside edge of the belt. As the belt travels in a straight line direction, the tractive load is normally shared by all the single pitch links 14, and the inside ends of the rods are kept at the first pitch. The use of at least two inside U-shaped links helps assure that rods 12 extend substantially parallel during straight line motion under tractive load.
As belt 10 travels about a lateral curve, the outside ends of rods 12 expand in the pitch changing slots 22 of the dual pitch links 16. The rod actually expands from the slot first pitch area 28 to the second pitch area 36. Also, the tractive load gradually shifts to one of the two single pitch links which is farthest from the inside edge of the belt. Single pitch links 14 have a first predetermined spacing between the forwardmost and rearwardmost end surfaces of their holes 125 and 124. Dual pitch links 16 have a second, greater predetermined spacing between the rearwardmost end surfaces 21 of their pivot apertures 20 and the forwardmost surfaces 37 of their elongate pitch changing slot second pitch areas 36. The first and second predetermined spacings are correlated to one another and to the predetermined maximum curvature of the belt so that dual pitch links 16 assume only a minimal amount of the tractive load during travel about a lateral curve of the predetermined maximum curvature. Preferably, this predetermined spacing results in rods 12 contacting a forwardmost end surface 37 of the second pitch area 36 in the dual pitch links 16 without assuming any measurable tractive load so that single pitch links 14 continue to assume substantially all the tractive load. This condition is particularly desirable because then dual pitch links 16 will allow only a negligible amount of play between links 16 and the bearing surfaces of rods 12, thereby assuring smoothness of operation, while also insuring that the single pitch links 14 remain tractive and the inside edge of the belt does not collapse. This is accomplished by setting the ratio of the spacing (P.sub.o ') of the pivot apertures 20 and elongate slots 22 second pitch areas 36 in the dual pitch links 16 to the distance (R.sub.o) from the center of the radius of curvature of the belt to the outermost dual pitch links in the tightest curve only slightly greater than the ratio of the spacing (P.sub.i) of the holes 124, 125 in the single pitch links 14 to the distance (R.sub.i) from the center of the radius of curvature of the belt to the outermost leg 120 of single pitch links 14. Using the equation:
then R.sub.i
P.sub.o '=P.sub.o +0.005 to 0.010 inches. For example, in a system with a four and a half (41/2)foot radius drive cage, two one-inch inside links, and a three (3) foot wide belt: R.sub.i =56 inches; R.sub.o =90 inches; P.sub.i =1.080 inches; and P.sub.o =1.735 inches; then P.sub.o '=1.740 to 1.745 inches. In such a belt, where the tractive load in the helical path could typically be 200 pounds, the single pitch links would continue to assume 150 to 200 pounds of the tractive load in lateral curves of the predetermined maximum curvature.
Referring now to FIG. 19 a spiral low tension helical tier conveying system 100 of the type shown in U.S. Pat. Nos. 4,078,655 and 3,348,659 is illustrated. System 100 can incorporate either of the belts 10 or 10' of the present invention. Since the low tension system is fully described in these patents, which are herein incorporated by reference, only a brief description will be given here. In such a low tension system 100, a cage type driving drum 102 frictionally engages the inner edge of belt 10 (or 10') to drive it with relatively low tension through a helical path around the drum. In addition, a positive sprocket drive 104 engages the belt 10 along a straight portion thereof. A motor 105 drives the drum 102 through gearing 106 and also drives the positive sprocket drive 104 through interconnected gearing 107. The belt 10 travels from the sprocket drive 104, past weighted tension take up roller 110 and idler pulleys 111 to a straight loading portion 108, then in helical loops around the drum 102 to a straight discharge portion 109 and around another idler 111 back to the drive sprocket.
Referring now to FIG. 20 a spiral very low tension helical tier conveying system 200 of the type shown in U.S. Pat. No. 4,741,430, issued on May 3, 1988 to Gerald C. Roinestad is illustrated. System 200 can incorporate either of the belts 10 or 10' of the present invention. Since the very low tension system is fully described in that patent application, which is herein incorporated by reference, only a brief description will be given here. In such a system 200, a cage type driving drum 202 positively engages the inner edge of belt 10 (or 10') to drive it with very low tension through a helical path around the drum. Driving drum 202 functions as the primary drive for the belt moving in the helical path. Secondary drives 204 and 206 are provided adjacent the inlet and outlet of the helical path, however, to maintain a desired fixed length of the belt in the helical path.
Belts 10 and 10' are particularly suited for use in helical tier systems 100 and 200. The maximum curvature of the system is located in the helical path and the spacing between the openings in single pitch links 14 and dual pitch links 16 (and support link 140, if used) is correlated to the radius of curvature of the helical path. This assures non-collapse of the inner edge of the belt within the helical path, while at the same time assuring smooth operation of the belt along its outer edge.
FIG. 21 illustrates an embodiment of the present invention wherein a conveyor system uses dual pitch links 16 disposed along both sides of the belt in order to allow the belt to travel in both the left and right directions as shown by arrows E and F. In such motion, the dual pitch links on the inside edge of the curve would remain at the first pitch position, while the dual pitch links 16 along the outside edge of the curve would be pivoted to the second, greater pitch orientation. FIG. 21 also illustrates belt 10 as part of a conveying system with a conventional conveyor drive mechanism 46, such as a sprocket drive, for moving the conveyor belt 12.
A mesh overlay 48 placed around rods 12 is also illustrated in FIG. 21. Mesh overlay 48 can be of any conventional design, such as wire formed into flattened helicals. The overlay is used to provide support for relatively easily damaged ware. The overlay can be manufactured to a width somewhat wider than its final assembled form on belt 10 so that it provides pressure in the transverse direction against both the inner and outer links to assure that they maintain their transverse position on rods 12, thereby eliminating the need for further welding or the use of mechanical devices to hold the links in place.
This invention has been described in detail in connection with the illustrated preferred embodiments. These embodiments, however, are merely for example only and the invention is not restricted thereto. It will be easily understood by those skilled in the art that other variations and modifications can be easily made within the scope of this invention, as defined by the appended claims.