Independent discharge sorting conveyor

• US 9,422,119 B1
• Filed: 07/14/2014
• Issued: 08/23/2016
• Est. Priority Date: 06/21/2012
• Status: Active Grant

• Current Assignee: Mantissa 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): Randazzo, Thomas
• Application Number:
  US14/330,611
• Time in Patent Office: 771 Days
• US Class Current: 1/1
• 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, wherein said tilting mechanism includes a second gear wheel having a second cam, said first cam rotating about a first axis of rotation and said second cam rotating about a second axis of rotation, wherein the first axis of rotation and the second axis of rotation are independent and set apart from each other, and

(v) a drive motor and a driven member attached to said frame base for moving said conveyor carts around said track, and having an opposed roller motor assembly for moving said conveyor carts on said conveyor track.

2. The apparatus according to claim 1, including a self-tensioning adjustment assembly including (i) at least one motor adjustment link affixed to one of said pivot block assemblies, (ii) a second link affixed to said other pivot block assembly, and (iii) a connecting roller link coupling said at least one motor adjustment link and said second link.

3. The apparatus according to claim 2, wherein said second link is a motor adjustment link.

4. The apparatus according to claim 2, wherein said frame base includes a lower base portion attached to said conveyor track and said self-tensioning adjustment assembly.

5. The apparatus according to claim 4, wherein said self-tensioning adjustment assembly includes a drive clamp plate connected to said lower base portion.

6. The apparatus according to claim 2, including a lever connected to said self-tensioning adjustment assembly and adapted to adjust said pivot block assemblies.

7. The apparatus according to claim 6, wherein said lever is adapted so that movement of each pivot block assembly mirrors movement of the other pivot block assembly.

8. The apparatus according to claim 1, wherein said pivot block assemblies are coupled together and adapted so that movement of each pivot block assembly mirrors movement of the other pivot block assembly.

9. The apparatus according to claim 8, wherein said driven member of said frame base comprises a fin moved in the conveyor line of travel by said opposed roller motor assembly.

10. The apparatus according to claim 9, wherein said opposed roller motor assembly and said fin are both vertically oriented beneath said trailer frame base.

11. The apparatus according to claim 9, wherein said fin is generally parallelogram-shaped with rearwardly angled front and rear edges.

12. The apparatus according to claim 8, wherein said drive roller assembly includes a generally cylindrical roller having an outer elastomeric surface for frictionally engaging said driven member.

13. The apparatus according to claim 12, wherein said elastomeric surface is a polyurethane.

14. The apparatus according to claim 13, wherein said polyurethane has a Shore A hardness between about 70 and about 80.

15. In a sorting conveyor for transporting objects and unloading objects at one or more unloading stations adjacent the conveyor, said sorting conveyor having a conveyor track and a train of conveyor carts connected end-to-end, at least one of said conveyor carts comprising:

(a) a frame base for engaging said conveyer track;

(b) a carrying tray for holding the objects;

(c) a support for supporting said carrying tray above said frame base;

(d) a tilting mechanism including at least one gear wheel having at least one cam for tilting said carrying tray toward at least one side of the conveyor, wherein said tilting mechanism includes a second gear wheel having a second cam, said first cam rotating about a first axis of rotation and said second cam rotating about a second axis of rotation, wherein the first axis of rotation and the second axis of rotation are independent and set apart from each other; and

(e) a tilt sensor for determining the direction of tilt of said tray.

16. The apparatus according to claim 15, wherein said tilting mechanism is adapted so that each tray is independently dischargeable from said other trays in said conveyor train.

17. The apparatus according to claim 15, wherein said tilt sensor includes a direction indicator.

18. The apparatus according to claim 17, wherein said direction indicator is configured to sense a reference area on said at least one gear.

19. The apparatus according to claim 18, wherein said tilt sensor is a dual sensor.

20. The apparatus according to claim 15, wherein said tilt sensor includes a positioning indicator.

21. The apparatus according to claim 20, wherein said positioning indicator is configured to sense a reference area on said at least one gear.

22. The apparatus according to claim 21, wherein said positioning indicator includes a dual sensor.

23. The apparatus according to claim 15, wherein said at least one cam is rotatable around an axis of rotation of said at least one gear between about 0 degrees and about 360 degrees.

24. The apparatus according to claim 23, wherein said at least one cam travels between about 0 degrees and about 140 degrees around said axis of rotation.

25. The apparatus according to claim 23, wherein said cam moves toward about 0 degrees in response to said tilt sensor.

26. The apparatus according to claim 23, 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.

27. The apparatus according to claim 26, wherein rotation of said first cam in a first direction around the first 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 the second axis of rotation tilts said tray toward an opposite side of said conveyer than said one side.

28. The apparatus according to claim 26, 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.

29. The apparatus according to claim 15, wherein each cam movement responds to said tilt sensor and whereby said tilt sensor monitors a reference area on said gears.

30. The apparatus according to claim 29, 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.

31. The apparatus according to claim 15, 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.

32. The apparatus according to claim 31, wherein said tiltable support includes at least one camway for housing said first cam and said second cam.

33. The apparatus according to claim 32, 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 about 25 degrees and about 135 degrees about an axis of rotation of each gear respectively.

34. The apparatus according to claim 32, wherein said tiltable support tilts about between about 40 degrees and about 50 degrees around the axis of tilt when said first cam and said second cam are rotated between about 120 degrees and about 140 degrees around said axis of rotation of each gear respectively.

35. The apparatus according to claim 32, wherein said cams are rotatable substantially between about 0 degrees and about 25 degrees about an axis of rotation of each gear respectively.

36. The apparatus according to claim 15, wherein said axis of rotation of said first gear and said second gear is between about 0 degrees and about 360 degrees.

37. The apparatus according to claim 36, wherein said first cam and said second cam travel between about 0 degrees and 140 degrees around said respective axis of rotation.

38. The apparatus according to claim 37, wherein said first cam rotates about between 0 and 140 degrees around said axis of rotation of said first gear and said second cam rotates about between 0 and 140 degrees around said axis of rotation of said second gear.

39. The apparatus according to claim 15, further including at least one drive for actuating said tilting mechanism.

40. The apparatus according to claim 39, wherein said drive is a gear drive for interacting with at least said first gear.

41. 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, wherein said tilting mechanism includes a second gear wheel having a second cam, said first cam rotating about a first axis of rotation and said second cam rotating about a second axis of rotation, wherein the first axis of rotation and the second axis of rotation are independent and set apart from each other, and

(v) 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, and wherein said drive motor further includes an opposed roller motor assembly for moving said conveyor carts on said conveyor track, said opposed roller motor assembly including a cantilevered, drive roller connected to one pivot block assembly and another pivot block assembly adapted for positioning said drive roller, wherein said pivot block assemblies are coupled together and adapted so that movement of each pivot block assembly mirrors movement of the other pivot block assembly, and wherein said pivot block assemblies are coupled together.