Spiral conveyor apparatus with automatic flow control

• US 6,298,971 B2
• Filed: 02/05/2001
• Issued: 10/09/2001
• Est. Priority Date: 08/19/1997
• Status: Expired due to Term

• Current Assignee: Donald F. Belz, Duane L. Glass
• Original Assignee: Donald F. Belz, Duane L. Glass
• Inventors: Belz, Donald F., Glass, Duane L.
• Primary Examiner(s): Bidwell, James R.
• Application Number:
  US09/775,665
• Publication Number:
  US 20010004958A1
• Time in Patent Office: 246 Days
• Field of Search: 198/778, 198/781.05, 198/781.06, 198/781.1, 198/347.1, 198/347.3, 198/783, 198/780, 193/35.S, 193/35.A
• US Class Current: 193/35.00S
• CPC Class Codes: B65G 1/08 the articles being fed by gravity braking arrangements for roller-ways B65G13/075; separating or stopping elements B65G47/88
• CPC Class Codes: B65G 13/08 of curved form; with branch-offs
• CPC Class Codes: B65G 13/11 Roller frames
• CPC Class Codes: B65G 2207/24 Helical or spiral conveying path
• CPC Class Codes: B65G 43/08 Control devices operated by article or material being fed, conveyed or discharged and controlling the discharging devices B65G47/42
• CPC Class Codes: B65G 47/261 Accumulating articles

Abstract

A spiral conveyor with automatic flow control includes a plurality of curved segments connected to form a spiral for the flow by gravity of articles from an upper level to a lower level. Each of the segments includes freely rotating skate wheels forming a conveying surface and a controlled, powered cylindrical roller. A sensor mounted in each segment senses the presence of an article in the segment. A controller receives the signals from the sensors and activates the associated roller for transport mode to assist articles through the conveyor if the path is clear, or if the downstream portion of the conveyor is blocked, to reverse the roller for accumulate mode to hold articles in the segment until the path is cleared.

Claims

1. A conveyor apparatus for moving articles, the conveyor comprising:

a plurality of conveyor segments arranged as a spiral having an entry point and an exit point;

a plurality of freely rotating nondriven roller devices mounted in each conveyor segment;

a plurality of driven powered roller devices, each driven powered roller device is individually controllable to selectively rotate in a transport mode for moving articles from the entry point to the exit point without accumulating the articles and to rotate in a mode other than the transport mode;

a plurality of sensors, at least one of the plurality of sensors disposed in a respective one of the conveyor segments; and

a control unit connected to each of the driven powered roller devices and to each of the sensors.

2. The conveyor apparatus of claim 1, wherein at least one of the plurality of driven powered roller devices is mounted in a respective one of the conveyor segments.

3. The conveyor apparatus of claim 1, further comprising an entry conveyor segment at a first level and an exit conveyor segment at a second level, the first level higher than the second level.

4. The conveyor apparatus of claim 1, wherein the plurality of freely rotating roller devices form a conveying surface.

5. The apparatus as claimed in claim 1, wherein the sensors are photocell devices.

6. The apparatus as claimed in claim 1, wherein each conveyor segment defines an arc of at least 45°

.

7. The apparatus as claimed in claim 6, wherein each conveyor segment defines an arc of at least 90°

.

8. The conveyor apparatus of claim 1, in which the control unit receives a signal from the plurality of sensors, processes the signals, and controls communication of signals to the plurality of driven powered roller devices.

9. The conveyor apparatus of claim 1, in which the control unit receives a signal from the plurality of sensors, processes the signals, and sends actuation signals to the plurality of driven powered roller devices.

10. A conveyor apparatus for moving articles, the conveyor comprising:

a plurality of conveyor segments arranged as a spiral having an entry point and an exit point;

a plurality of freely rotating nondriven roller devices mounted in each conveyor segment;

a plurality of driven powered roller devices, the driven powered roller device is individually controllable to selectively rotate in a transport mode for moving articles from the entry point to the exit point without accumulating the articles and to rotate in a mode other than the transport mode;

a plurality of sensors, at least one of the plurality of sensors disposed in a respective one of the conveyor segments; and

a control unit connected to the driven powered roller devices and to the sensors.

11. The conveyor apparatus of claim 10, wherein at least one of the plurality of driven powered roller devices is mounted in a respective one of the conveyor segments.

12. The conveyor apparatus of claim 10, further comprising an entry conveyor segment at a first level and an exit conveyor segment at a second level, the first level higher than the second level.

13. The conveyor apparatus of claim 10, wherein the plurality of freely rotating roller devices form a conveying surface.

14. The apparatus as claimed in claim 10, wherein the sensors are photocell devices.

15. The apparatus as claimed in claim 10, wherein each conveyor segment defines an arc of at least 45°

.

16. The apparatus as claimed in claim 15, wherein each conveyor segment defines an arc of at least 90°

.

17. The conveyor apparatus of claim 10, in which the control unit receives a signal from the plurality of sensors, processes the signals, and controls communication of signals to the plurality of driven powered roller devices.

18. The conveyor apparatus of claim 10, in which the control unit receives a signal from the plurality of sensors, processes the signals, and sends actuation signals to the plurality of driven powered roller devices.

19. A conveyor apparatus for moving articles, the conveyor comprising:

a frame forming a conveyor path from an entry point at a first level to an exit point at a second level that is lower than the first level;

a plurality of freely rotatable nondriven roller devices mounted to the frame;

a plurality of driven powered roller devices collocated and mounted to the frame at predetermined distance intervals along the conveyor path, each driven powered roller device is individually controllable to selectively rotate in a transport mode for moving articles from the entry point to the exit point without accumulating the articles and in a mode other than the transport mode;

a plurality of sensors, each sensor adjacent to and upstream to a respective one of the driven powered roller devices; and

a control unit connected to each of the driven powered roller devices and to each of the sensors.

20. The conveyor apparatus as in claim 19, wherein the mode other than the transport mode is an accumulate mode.

21. The conveyor apparatus as in claim 19, wherein the mode other than the transport mode is a mode wherein the driven powered roller device is not driven.

22. A conveyor apparatus for moving articles, the conveyor comprising:

a plurality of conveyor segments arranged as a spiral having an entry point and an exit point;

a plurality of freely rotating nondriven roller devices mounted in each conveyor segment;

a plurality of driven powered roller devices, each driven powered roller device is individually controllable to selectively rotate in a transport mode for moving articles from the entry point to the exit point without accumulating the articles and to rotate in a mode other than the transport mode;

a plurality of sensors, at least one of the plurality of sensors disposed in a respective one of the conveyor segments; and

a control unit connected to each of the driven powered roller devices and to each of the sensors,

wherein at least a first of the plurality of powered roller devices is collocated with at least a second of the plurality of powered roller devices.

23. The conveyor apparatus of claim 22, wherein at least one of the plurality of driven powered roller devices is mounted in a respective one of the conveyor segments.

24. The conveyor apparatus of claim 22, further comprising an entry conveyor segment at a first level and an exit conveyor segment at a second level, the first level higher than the second level.

25. The conveyor apparatus of claim 22, wherein the plurality of freely rotating roller devices form a conveying surface.

26. The apparatus as claimed in claim 22, wherein the sensors are photocell devices.

27. The apparatus as claimed in claim 22, wherein each conveyor segment defines an arc of at least 45°

.

28. The apparatus as claimed in claim 27, wherein each conveyor segment defines an arc of at least 90°

.

29. The conveyor apparatus of claim 22, in which the control unit receives a signal from the plurality of sensors, processes the signals, and controls commnunication of signals to the plurality of driven powered roller devices.

30. The conveyor apparatus of claim 22, in which the control unit receives a signal from the plurality of sensors, processes the signals, and sends actuation signals to the plurality of driven powered roller devices.

31. A conveyor apparatus for moving articles, the conveyor comprising:

a frame forming a conveyor path from an entry point at a first level to an exit point at a second level that is lower than the first level;

a plurality of freely rotatable nondriven roller devices mounted to the frame;

a plurality of driven powered roller devices collocated and mounted to the frame at predetermined distance intervals along the conveyor path, each driven powered roller device is controllable to selectively rotate at a first transport speed for moving articles from the entry point to the exit point and at a transport speed other than the first transport speed;

a plurality of sensors, each sensor adjacent to and upstream to a respective one of the driven powered roller devices; and

a control unit connected to each of the driven powered roller devices and to each of the sensors.

32. A method for operating a conveyor apparatus having a plurality of conveyor segments, each conveyor segment comprising a plurality of freely rotatable roller devices and a driven powered roller device, the conveyor segments mounted to assist and control transport of articles, comprising the steps of:

monitoring each conveyor segment for the presence of an article;

controlling a driven powered roller device in one of the conveyor segments to transport an article when the article is sensed in the one conveyor segment and a next one of the plurality of conveyor segments immediately downstream of the one conveyor segment is sensed as clear for transport; and

controlling a driven powered roller device in one conveyor segment to accumulate an article when the article is sensed in the one conveyor segment and a next one of the conveyor segments immediately downstream of the one conveyor segment is sensed as blocked.

33. The method as claimed in claim 32, wherein a conveyor segment is sensed as blocked if an article is sensed in the conveyor segment for at least a predetermined time duration.

34. The method as claimed in claim 32, wherein a conveyor segment is sensed as clear for transport if no article is sensed in the conveyor segment for more than a predetermined time duration.

35. The method as claimed in claim 32, further comprising the steps of sensing an article in an exit conveyor segment for at least a predetermined time duration and controlling an exit conveyor segment driven powered roller device to accumulate.

36. The method as claimed in claim 35, further comprising the steps of sensing that a takeaway conveyor, the takeaway conveyor positioned at the discharge point of the exit conveyor segment, is clear for transport and controlling the exit conveyor segment driven powered roller device to transport the article.

37. A method for operating a conveyor apparatus having a plurality of conveyor segments, each conveyor segment comprising a plurality of freely rotatable roller devices and a plurality of driven powered roller device, the conveyor segments mounted to assist and control transport of articles, comprising the steps of:

monitoring each conveyor segment for the presence of an article; and

controlling a driven powered roller device in at least one of the conveyor segments in a transport mode when an article is sensed in the one conveyor segment and a next one of the conveyor segments immediately downstream is sensed as clear for transport; and

controlling a driven powered roller device in at least one of the conveyor segments in a mode other than transport mode when an article is sensed in the one conveyor segment and a next one of the conveyor segments immediately downstream is sensed as blocked.

38. The method as claimed in claim 37, wherein a conveyor segment is sensed as blocked if an article is sensed in the conveyor segment for at least a predetermined time duration.

39. The method as claimed in claim 37, wherein a conveyor segment is sensed as clear for transport if no article is sensed in the conveyor segment for more than a predetermined time duration.

40. The method as claimed in claim 37, ether comprising the steps of sensing an article in an exit conveyor segment for at least a predetermined time duration and controlling an exit conveyor segment driven powered roller device in other than the transport mode.

41. The method as claimed in claim 37, further comprising the steps of sensing that a takeaway conveyor, the takeaway conveyor positioned at the discharge point of the exit conveyor segment, is clear for transport and changing the exit conveyor segment driven powered roller device to the transport mode from other than the transport mode.

42. The method as in claim 37, wherein the mode other than the transport mode is accumulate mode.

43. The method as in claim 37, wherein the mode other than the transport mode is a reverse rotation.

44. The method as in claim 37, wherein the mode other than the transport mode is driving a powered roller device in a reverse direction.

45. A conveyor apparatus for moving articles, the conveyor comprising:

a plurality of conveyor segments arranged as a spiral having an entry point and an exit point;

a plurality of freely rotating nondriven roller devices mounted in each conveyor segment;

a driven roller device mounted in at least one of the plurality of conveyor segments, the driven roller device individually controllable to selectively rotate in a transport mode for moving articles from the entry point to the exit point without accumulating the articles and to rotate in a mode other than the transport mode;

a plurality of sensors, each sensor in a respective one of the conveyor segments; and

a control unit connected to each of the driven roller devices and to each of the sensors.

46. A spiral conveyor apparatus, comprising:

a plurality of conveyor segments arranged as a spiral, including at least an entry segment at a first level and an exit segment at a second level, each conveyor segment having a plurality of freely rotatable roller devices forming a conveying surface;

at least one powered roller mounted in at least one segment, the powered roller being individually powered and individually controllable for selected rotation;

a sensor for sensing a conveyed article in each conveyor segment; and

a controller for receiving signals from the sensing means and responsively controlling the at least one powered roller in a transport mode for transport of articles and in an accumulate mode for accumulation of articles.

47. A spiral conveyor apparatus, comprising:

a plurality of conveyor segments arranged as a spiral, including at least an entry segment at a first level and an exit segment at a second level, each conveyor segment having a plurality of freely rotatable roller devices forming a conveying surface;

at least one powered roller mounted in at least one segment, the powered roller being individually powered and individually controllable for selectively conveying or not conveying articles along the conveying surface;

a sensor for sensing a conveyed article in each conveyor segment; and

a controller for receiving signals from the sensing means and responsively controlling the at least one powered roller in a transport mode for transport of articles and in an accumulate mode for accumulation of articles.

48. A spiral conveyor apparatus, comprising:

a plurality of conveyor segments arranged as a spiral, including at least an entry segment at a first level and an exit segment at a second level, each conveyor segment having a plurality of freely rotatable roller devices;

at least one of a plurality of powered rollers mounted in each segment, each one of the plurality of powered rollers being individually powered and individually controllable for selected rotation; and

a sensor for sensing a conveyed article in each conveyor segment,

wherein one of the plurality of powered rollers is positioned in one of a plurality of zones to form, with the freely rotatable roller devices, a conveying surface, and wherein the powered roller is individually powered by a motor internal to the powered roller and controlled by a control circuit, the control circuit comprising at least one of a plurality of signal controllers.

49. The spiral conveyor of claim 48, wherein, in a transport mode, at least the one of the plurality of powered rollers operates to assist conveyance of items along a first direction of the conveying surface and

wherein, in an accumulate mode, at least as one of the plurality of powered rollers operates to prevent conveyance of items along the first direction of the conveying surface.

50. A conveyor apparatus for moving articles, the conveyor comprising:

a frame forming a conveyor path from an entry point at a first level to an exit point at a second level that is lower than the first level;

a plurality of freely rotatable nondriven roller devices mounted to the frame;

a plurality of driven roller devices collocated and mounted to the frame at predetermined distance intervals along the conveyor path, each driven roller device is controllable to selectively rotate in at least a first transport speed for moving articles from the entry point to the exit point and in a transport speed other than the first transport speed;

a plurality of sensors, each sensor adjacent to and upstream to a respective one of the driven roller devices; and

a control unit connected to each of the driven roller devices and to each of the sensors.

51. A conveyor apparatus for moving articles, the conveyor comprising:

a frame forming a conveyor path from an entry point at a first level to an exit point at a second level that is lower than the first level;

a plurality of freely rotatable nondriven roller devices mounted to the frame;

a plurality of driven roller devices collocated and mounted to the frame at predetermined distance intervals along the conveyor path, the driven roller device is controllable to selectively rotate in at least a first transport speed for moving articles from the entry point to the exit point and in a transport speed other than the first transport speed;

a plurality of sensors, each sensor adjacent to and upstream to a respective one of the driven roller devices; and

a control unit connected to the driven roller devices and to the sensors.

52. A method for operating a conveyor apparatus having a plurality of conveyor segments, each conveyor segment comprising a plurality of freely rotatable roller devices and a driven roller device, the conveyor segments mounted to assist and control transport of articles, comprising the steps of:

monitoring each conveyor segment for the presence of an article;

controlling a driven roller device in one of the conveyor segments for transport rotation when an article is sensed in the one conveyor segment and a next one of the conveyor segments immediately downstream of the one conveyor segment is sensed as clear for transport; and

controlling a driven roller device in a one conveyor segment for accumulate rotation when an article is sensed in the one conveyor segment and a next one of the conveyor segments immediately downstream of the one conveyor segment is sensed as blocked.

53. The method as claimed in claim 52, wherein one of the plurality of conveyor segments is sensed as blocked in an article is sensed in the one conveyor segment for at least a predetermined time duration.

54. The method as claimed in claim 52, wherein one of the plurality of conveyor segments is sensed as clear for transport if no article is sensed in the one conveyor segment for more than a predetermined time duration.

55. A method for operating a conveyor apparatus having a plurality of conveyor segments, each conveyor segment comprising a plurality of freely rotatable roller devices and a plurality of driven roller devices, the conveyor segments mounted to assist and control transport of articles, comprising the steps of:

monitoring each conveyor segment for the presence of an article; and

controlling a driven roller device in one of the conveyor segments in a transportation rotation mode when an article is sensed in the one conveyor segment and a next one of the conveyor segments immediately downstream is sensed as clear for transport; and

controlling a driven roller device in a one of the conveyor segments in a mode other than that for transportation rotation mode when an article is sensed in the one conveyor segment and a next one of the conveyor segments immediately downstream is sensed as blocked.