Decentralized drive system for a conveyor
First Claim
1. A conveyor system for supporting and moving a plurality of objects, said conveyor system comprising:
- a plurality of zones each including a top conveying surface and a bottom surface, wherein the top and bottom surfaces define a space therebetween and wherein the top conveying surface is capable of moving in at least a downstream direction and of supporting one of the objects thereon;
a plurality of electrical motors wherein each of the electrical motors is positioned external to the space between the top and bottom surfaces of a respective one of the plurality of zones and wherein each electrical motor includes a drive shaft operable to drive the top conveying surface; and
a control system operably connected to each of the electrical motors and capable of independently supplying power to each of the electrical motors such that the top conveying surface in one zone, and the object supported thereon, can be moved in the downstream direction independently of the other objects supported within the other zones.
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Accused Products
Abstract
An accumulation conveyor system for supporting and moving a plurality of objects. The conveyor system is divided into a plurality of zones wherein each zone includes a top and bottom conveying surface and wherein a space is defined between the top and bottom surfaces. Each zone also includes its own motor positioned external to the space between the conveying surfaces and coupled to the conveying surfaces via a non-slip connection. A control system is connected to the motor and controls the power to the motor so that the conveying surfaces in each zone can be moved independently. Whenever a sensor detects an empty downstream zone, it signals the control system of the upstream zone to power the motor and move the object to fill the empty zone. The control system may also be configured to allow a soft start wherein motor speed is increased gradually.
34 Citations
39 Claims
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1. A conveyor system for supporting and moving a plurality of objects, said conveyor system comprising:
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a plurality of zones each including a top conveying surface and a bottom surface, wherein the top and bottom surfaces define a space therebetween and wherein the top conveying surface is capable of moving in at least a downstream direction and of supporting one of the objects thereon;
a plurality of electrical motors wherein each of the electrical motors is positioned external to the space between the top and bottom surfaces of a respective one of the plurality of zones and wherein each electrical motor includes a drive shaft operable to drive the top conveying surface; and
a control system operably connected to each of the electrical motors and capable of independently supplying power to each of the electrical motors such that the top conveying surface in one zone, and the object supported thereon, can be moved in the downstream direction independently of the other objects supported within the other zones. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21)
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22. A conveyor system for supporting and moving a plurality of objects, said conveyor system comprising:
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a frame including a pair of laterally spaced support members extending in a machine direction;
a plurality of zones separating the laterally spaced support members into discrete portions, wherein each zone includes a conveying surface extending between, and moveably supported by, the discrete portions of the support members of the zone and wherein one of the rollers in each zone is a drive roller slaved to the other rollers in the zone via a chain and sprocket assembly;
a plurality of electrical motors wherein each of the electrical motors includes a drive shaft operably connected to the conveying surface of a respective one of the zones via a non-slip coupling and wherein each of the motors is supported by one of the support member portions on a side of the support member portion opposite the conveying surface; and
a control system operably connected to each of the electrical motors and capable of independently controlling electrical power supplied to each of the electrical motors such that the conveying surface, and any one of the objects supported thereon, can be moved in the machine direction independently of other objects supported on the conveying surfaces within the other zones. - View Dependent Claims (23, 24, 25, 26)
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27. A method of supporting and conveying a plurality of objects using an accumulation conveyor having a plurality of zones, said conveying method comprising:
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supporting the objects on a top conveying surface of the accumulation conveyor;
sensing an empty one of a plurality of zones subdividing the top conveying surface not supporting one of the objects;
moving the conveying surface of an adjacent one of the zones upstream of the empty zone by energizing an electrical motor and transmitting torque from the motor to the conveying surface with negligible slip; and
controlling electrical power supplied to the motor by causing the electrical power to gradually increase so as to move, in a downstream direction, the top conveying surface of the zone upstream, and adjacent to, the empty zone so as to gradually accelerate and move an object from the upstream zone into the empty zone. - View Dependent Claims (28, 29)
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30. A control system for distributing power to a plurality of motors each positioned in a respective one of a plurality of zones of an accumulation conveyor supporting a plurality of objects thereon, said control system comprising:
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a plurality of sensors, wherein each of the sensors is positioned in a respective one of the zones and wherein each of the sensors is configured to detect one of the objects supported by the conveyor in the zone;
a plurality of logic modules, wherein each of the logic modules is positioned in a respective one of each of the zones and is coupled in communication with the sensor in an adjacent, downstream one of the zones; and
a plurality of power controllers, wherein each of the power controllers is coupled in communication with the logic module in its respective zone and is configured to activate the motor in its respective zone so as to move any one of the objects in its zone into the downstream, adjacent zone. - View Dependent Claims (31, 32, 33, 34, 35, 36)
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37. A conveyor system for supporting and moving a plurality of objects, said conveyor system comprising:
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a plurality of zones each including a top conveying surface and wherein the top conveying surface is capable of moving in at least a downstream direction and of supporting one of the objects thereon;
a drive system capable of independently supplying power to each of the zones such that the top conveying surface in one zone, and the object supported thereon, can be moved in the downstream direction independently of the other objects supported within the other zones; and
wherein the drive system generates a noise level of less than 18 dbA in excess of a background noise level. - View Dependent Claims (38, 39)
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Specification