Independent discharge sorting conveyor

• US 8,807,320 B2
• Filed: 06/21/2012
• Issued: 08/19/2014
• Est. Priority Date: 06/21/2012
• Status: Active Grant

• Current Assignee: Manitssa Corporation
• Original Assignee: Mantissa Corporation
• Inventors: Fortenbery, J. David, Erceg, David Patrick, Sotelo, Gonzalo, Howell, Charles P. III, Kissel, Gregory P., Weckerle, Daniel H., Winkler, LeRoy A. III
• Primary Examiner(s): Burgess, Ramya
• Assistant Examiner(s): Randazzo, Thomas
• Application Number:
  US13/529,584
• Publication Number:
  US 20130341157A1
• Time in Patent Office: 789 Days
• Field of Search: 198/370.03, 198/370.04, 414/339, 414/343, 414/346, 104/290, 104/292
• US Class Current: 198/370.04
• CPC Class Codes: B65G 17/12 comprising a series of individual load-carriers fixed, or normally fixed, relative to traction element
• CPC Class Codes: B65G 2201/0264 Luggage
• CPC Class Codes: B65G 47/38 by dumping, tripping, or releasing load carriers by flexing or tilting travelling structures B65G47/94
• CPC Class Codes: B65G 47/962 tilting about an axis substantially parallel to the conveying direction

Abstract

A sorting conveyor for transporting objects and unloading objects at one or more unloading stations adjacent the conveyor. The sorting conveyor includes a conveyor track and a train of conveyor carts connected end-to-end. At least one of the conveyor carts may include a frame base for engaging the conveyer track; a carrying tray for holding the objects; and a support for supporting the carrying tray above the frame base. A tilting mechanism including at least one gear having at least one cam is adapted for tilting the carrying tray toward at least one side of the conveyor. The present inventions may further include a tilt sensor for determining the direction of tilt of the tray. In addition, a drive motor and a driven member attached to the frame base may be included for moving the conveyor carts around the track.

Claims

1. A sorting conveyor for transporting objects and unloading objects at one or more unloading stations adjacent the conveyor, said sorting conveyor comprising:

(a) a conveyor track;

(b) a train of conveyor carts connected end-to-end; and

(c) at least one of said conveyor carts including

(i) a frame base for engaging said conveyer track,

(ii) a carrying tray for holding the objects,

(iii) a support for supporting said carrying tray above said frame base,

(iv) a tilting mechanism including at least one gear having at least one cam for tilting said carrying tray toward at least one side of the conveyor, and

(v) a self-tensioning adjustment assembly including;

a drive clamp plate connected to said lower base portion, a lever connected to said self-tensioning adjustment assembly and adapted to adjust said pivot block assemblies, and

wherein said lever is adapted so that movement of each pivot block assembly mirrors movement of the other pivot block assembly, and said self-tensioning adjustment assembly includes a self-tensioning clamp plate for supporting said lever, and the clamp plate includes a mounting bracket connecting the proximate end of the lever to the clamp plate;

a lever retainer affixed to said self-tensioning clamp plate to retain a distal handling end of said lever in an operating position;

a coupling arm connecting said lever and said connecting roller link;

a spring assembly between said coupling arm and said connecting roller link; and

said second link is a motor adjustment link.

2. The apparatus according to claim 1, wherein said self-tensioning adjustment assembly includes a self-tensioning clamp plate for supporting said lever.

3. The apparatus according to claim 2, wherein said self-tensioning clamp plate includes a mounting bracket connecting a proximate end of said lever to said self-tensioning clamp plate.

4. The apparatus according to claim 2, including a lever retainer affixed to said self-tensioning clamp plate to retain a distal handling end of said lever in an operating position.

5. The apparatus according to claim 4, including a coupling arm connecting said lever and said connecting roller link.

6. The apparatus according to claim 5, further including a spring assembly between said coupling arm and said connecting roller link.

7. The apparatus according to claim 1, including a rotary motor and a drive belt connecting said motor and said drive roller, wherein said drive roller includes a frictional surface for receiving said drive belt.

8. The apparatus according to claim 1, wherein an opposing surface is adjacent to another surface of said driven member for off-setting the mechanical load of said drive roller in a second drive roller assembly.

9. The apparatus according to claim 8, wherein said second drive roller assembly further includes a second motor assembly.

10. A sorting conveyor for transporting objects and unloading objects at one or more unloading stations adjacent the conveyor, said sorting conveyor comprising:

(a) a conveyor track;

(b) a train of conveyor carts connected end-to-end;

(c) at least one of said conveyor carts including

(i) a frame base for engaging said conveyer track,

(ii) a carrying tray for holding the objects,

(iii) a support for supporting said carrying tray above said frame base,

(iv) a tilting mechanism including at least one gear having at least one cam for tilting said carrying tray toward at least one side of the conveyor,

(v) a self-tensioning adjustment assembly including;

a drive clamp plate connected to said lower base portion, a lever connected to said self-tensioning adjustment assembly and adapted to adjust said pivot block assemblies, and

wherein said lever is adapted so that movement of each pivot block assembly mirrors movement of the other pivot block assembly, and said self-tensioning adjustment assembly includes a self-tensioning clamp plate for supporting said lever, and the clamp plate includes a mounting bracket connecting the proximate end of the lever to the clamp plate;

a lever retainer affixed to said self-tensioning clamp plate to retain a distal handling end of said lever in an operating position;

a coupling atm connecting said lever and said connecting roller link;

a spring assembly between said coupling arm and said connecting roller link; and

said second link is a motor adjustment link, and

(vi) a tilt sensor for determining the direction of tilt of said tray; and

(d) a drive motor and a driven member attached to said frame base for moving said conveyor carts around said track.

11. The apparatus according to claim 10, including a lever retainer to retain a distal handling end of said lever in an operating position.

12. The apparatus according to claim 11, including a coupling arm connecting said lever and said connecting roller link.

13. The apparatus according to claim 12, further including a spring assembly between said coupling arm and said connecting roller link.

14. The apparatus according to claim 10, including a drive roller assembly having a generally cylindrical roller having an outer elastomeric surface for frictionally engaging said driven member.

15. The apparatus according to claim 14, wherein said elastomeric surface is a polyurethane.

16. The apparatus according to claim 15, wherein said polyurethane has a Shore A hardness between 70 and 80.

17. The apparatus according to claim 10, including a rotary motor and a drive belt connecting said motor and said drive roller, wherein said drive roller includes a frictional surface for receiving said drive belt.

18. The apparatus according to claim 10, wherein an opposing surface is adjacent to another surface of said driven member for off-setting the mechanical load of said drive roller in a second drive roller assembly.

19. The apparatus according to claim 18, wherein said second drive roller assembly further includes a second motor assembly.

20. The apparatus according to claim 10, wherein said driven member of said frame base comprises a fin moved in the conveyor line of travel by said opposed roller motor assembly.

21. The apparatus according to claim 20, wherein said opposed roller motor assembly and said fin are both vertically oriented beneath said trailer frame base.

22. The apparatus according to claim 20, wherein said fin is generally parallelogram-shaped with rearwardly angled front and rear edges.

23. The apparatus according to claim 10, wherein said tilt sensor includes a direction indicator.

24. The apparatus according to claim 23, wherein said direction indicator is configured to sense a reference area on said at least one gear.

25. The apparatus according to claim 24, wherein said tilt sensor is a dual sensor.

26. The apparatus according to claim 10, wherein said tilt sensor includes a positioning indicator.

27. The apparatus according to claim 26, wherein said positioning indicator is configured to sense a reference area on said at least one gear.

28. The apparatus according to claim 27, wherein said positioning indicator includes a dual sensor.

29. The apparatus according to claim 10, wherein said at least one cam is rotatable around an axis of rotation of said at least one gear between 0 degrees and 360 degrees.

30. The apparatus according to claim 29, wherein said at least one cam travels between 0 degrees and 140 degrees around said axis of rotation.

31. The apparatus according to claim 29, wherein said cam moves toward 0 degrees in response to said tilt sensor.

32. The apparatus according to claim 29, wherein rotation of said at least one cam in a first direction around an axis of rotation of said at least one gear tilts said tray in a direction toward one side of said conveyer.

33. The apparatus according to claim 10, wherein said tilting mechanism further includes a second gear having a second cam.

34. The apparatus according to claim 33, wherein each cam movement responds to said tilt sensor and whereby said tilt sensor monitors a reference area on said gears.

35. The apparatus according to claim 34, wherein at least one cam actuates said tray toward a neutral position when said tilt sensor determines a not home signal on at least one said gear.

36. The apparatus according to claim 33, wherein said support is a tiltable support having an incremental tilting response to rotation of said first and second cams about an axis of rotation.

37. The apparatus according to claim 36, wherein said tiltable support includes at least one camway for housing said first cam and said second cam.

38. The apparatus according to claim 37, wherein said cams are rotatable substantially between 0 degrees and 25 degrees about an axis of rotation of each gear respectively.

39. The apparatus according to claim 37, wherein one of said cams is housed within a camway within said tiltable support and the other cam is outside of said camway within said tiltable support when said cams are rotated substantially between 25 degrees and 135 degrees about an axis of rotation of each gear respectively.

40. The apparatus according to claim 37, wherein said tiltable support tilts about between 40 degrees and 50 degrees around the axis of tilt when said first cam and said second cam are rotated between 120 degrees and 140 degrees around said axis of rotation of each gear respectively.

41. The apparatus according to claim 33, wherein said axis of rotation of said first gear and said second gear is between 0 degrees and 360 degrees.

42. The apparatus according to claim 41, wherein said first cam and said second cam travel between 0 degrees and 140 degrees around said respective axis of rotation.

43. The apparatus according to claim 42, wherein said first cam rotates between 0 and 140 degrees around said axis of rotation of said first gear and said second cam rotates between 0 and 140 degrees around said axis of rotation of said second gear.

44. The apparatus according to claim 43, wherein rotation of said first cam in a first direction around an axis of rotation tilts said tray in a direction toward one side of said conveyer and wherein rotation of said second cam in a second direction around an axis of rotation tilts said tray toward an opposite side of said conveyer than said one side.

45. The apparatus according to claim 44, wherein said first cam and said second cam each rotate about an independent axis of rotation.

46. The apparatus according to claim 33, wherein rotation of said cams in a clockwise or counterclockwise direction is opposite the tilt of said tilt tray in a clockwise or counterclockwise direction.

47. The apparatus according to claim 10, further including at least one drive for actuating said tilting mechanism.

48. The apparatus according to claim 47, wherein said drive is a gear drive for interacting with at least said first gear.

49. The apparatus according to claim 10, wherein said tilting mechanism is adapted so that each tray is independently dischargeable from said other trays in said conveyor train.