CA2254171A1 - Easy-mount roller blocks for conveyor transfer assembly - Google Patents

Abstract

A conveyor system having an improved easy-mount/release conveyor transfer assembly is provided for transferring articles from the end of a first conveyor to the start of a second, in-line conveyor. The conveying surface of the transfer assembly is formed by rollers driven by a magnetic coupling assembly that delivers power from an independent power source. This coupling system is formed of first and second opposed magnets, each having tapered drive faces that mate, thereby causing the magnets to self-align and self-lock in driving engagement. The rollers are detachably secured in a pan forming the framework of the transfer assembly by split mounting block assemblies. This allows for easy removal for servicing or replacing the rollers.

Description

CA 022~4171 1998-11-16 EASY-MOUNT ROLLER BLOCKS FOR
CONVEYOR TRANSFER ASSEMBLY

Technical Field The present invention relates generally to conveyors, and more particularly, to an improvement in roller mounting in a conveyor transfer assembly that is positioned between the end of a first conveyor and the start of a second conveyor.

Backaround of the Invention In a conveyor system, it is common to have two or more conveyors strategically positioned in an end-to-end relationship so as to move articles along a feed path. Such systems are especially beneficial in the food processing or packaging industries, where it is often necessary to provide various lengths and sizes of conveyors that interface to perform a desired function.
As is known in the art, a conveyor transfer assembly is placed between the conveyors to assist in the feeding of articles from one conveyor to the next. However, a prevalent problem in end-to-end conveyor systems is providing a transfer assembly that can be easily lifted and released in the event of an article jam.
One conveyor transfer assembly meeting these requirements is disclosed in Applicant's U.S. Patent No. 5,584,373, issued May 26, 1995, entitled "Conveyor System With Passive Roller Transfer Assembly." This patent discloses a releasable conveyor transfer assembly that rests between the first and second conveyor and includes a conveying surface which is either passive (i.e.
gravity driven) or active (i.e. positively driven by an independent power source).
While this conveyor transfer assembly, in either the passive or active versions, is already known and proven to be successful, additional improvements in the active version are desirable and have been made. More particularly, a need existed for an improved means for more efficiently driving the rollers CA 022~4171 1998-11-16 that form the conveying surface, while at the same time enhancing the releasability feature of the assembly. Towards these goals, Applicant's co-pending patent application Ser. No. 08/642,030 discloses the use of magnetic coupling assemblies that provide a releasable power connection for driving the rollers. These assemblies are formed of first and second opposed magnets recessed below the surface casings that mate to form the magnetic coupling.
Although such magnetic coupling assemblies provide releasability to the transfer assembly, it was found that it was difficult to realign the first and second casings when mounting the transfer assembly in the operative position. Thus, a magnetic coupling assembly was developed that allows the transfer assembly to be easily mounted in the conveyor system, especially after release caused by an article jam. These coupling assemblies and those for similar applications using the same innovative principles, provide optimum power transfer through the connection, while keeping the assemblies simple and inexpensive to manufacture, easy to install and operate, and reliable in day-to-day operations.
With further reference to Applicant's issued U.S.
Patent No. 5,584,373, the disclosed transfer assembly is provided with a pair of mounting blocks for supporting the ends of the shafts that carry the rollers, which comprise the conveying surface of the transfer assembly. These integral mounting blocks are adapted to be secured to a recessed pan extending under the conveying surface. However, if a roller requires servicing or replacement, the transfer assembly must be entirely removed from the conveyor system, the mounting block detached from the transfer assembly and the roller slipped out of the blocks. This is also true if an article becomes inadvertently jammed between the rollers of the transfer assembly. Of course, it is desirable to remove such an article jam as quickly as possible to avoid serious production downtime.
Accordingly, there is a need for a new and reliable means for detachably mounting or supporting the rollers of the conveyer transfer assembly. As with the releasable power CA 022~4171 1998-11-16 connection, it is important that the means for providing the detachable support be simple and inexpensive to manufacture, yet durable, and easy to install and operate.

Summarv of the Invention Thus, with the aforementioned need in focus, it is a primary object of the present invention to provide an improved conveyor transfer assembly that incorporates the ability for easy and quick pop-up release in the event of an article jam or the like, and also provides for the easy maintenance of the rollers.
Another important, and more specific object of the present invention is to provide a conveyor transfer assembly and a component mounting block assembly wherein the shafts supporting the rollers of the conveying surface may be readily accessed for easy removal.
Additional objects, advantages and other novel features of the invention will be set forth in part in the description that follows and in part will become apparent to those skilled in the art upon examination of the following or may be learned with the practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
To achieve the foregoing and other objects, and in accordance with the purposes of the present invention as described herein, a conveyor transfer assembly with improved mounted blocks is provided for placement downstream of a feeding portion of a first conveyor and upstream of the receiving portion of a second conveyor. The conveyor transfer assembly includes a conveying surface for moving the articles between the conveyors.
More specifically, the conveying surface includes a plurality of rollers to assist articles in making the transition between the conveyors. These rollers are supported on shafts which extend transversely across the transfer assembly and are held in position at opposite ends of the transfer assembly in the mounting blocks.
In accordance with an important aspect of the present CA 022~4171 1998-11-16 invention, these mounting blocks are actually assemblies since they are split to form a base adapted for attachment to the transfer assembly and a cover that is detachably secured to the base. Specifically, in the preferred embodiment the cover is provided with mating protrusions that correspond to mating recesses formed in the base. Each protrusion is provided with an aperture that corresponds to and aligns with an aperture formed opposite each recess in the base. Once aligned, the apertures accept a pin in slidable engagement for securing the cover to the base. The pin is provided with an external grasping portion that allows for removal and replacement. Preferably, the base and cover are molded of a suitable plastic, such as a polyacetal/polyamide/polyolefin or composite thereof.
When the rollers are in need of servicing or replacement, the pins are removed from the mounting block assembly and the cover detached from the base, thereby allowing access to lift and remove the shafts. Advantageously, this operation can be completed very quickly to minimize production downtime.
It should also be appreciated that the conveyor transfer assembly is releasable. In the event of an article jam, such as when an article/foreign object becomes lodged under the transfer assembly or the like, it is easily lifted in a pop-up fashion and thereby released before any appreciable damage to the conveyor or the articles can occur.
To provide releasability, a magnetic coupling assembly is located at one end of each roller. Such a magnetic coupling assembly for driving the rollers provides the capability for releasing this power connection upon the occurrence of an article jam. The magnetic coupling assembly is comprised of first and second opposed casings having mating tapered drive faces.
Specifically, a first casing is provided with a tapered drive face and a magnet. The drive face of the second, or opposed casing includes an inverted tapered recess and an oppositely-poled magnet for attracting the drive face of the first casing.
The tapered drive faces cause the casings to self-align and self-lock in driving engagement when the conveyor transfer assembly is CA 022~4171 1998-11-16 in the operative position. Furthermore, the singular magnets and tapered drive faces of the coupling assembly provide a large contact surface area, thereby increasing the power transfer across the connection.
Still other objects of the present invention will become apparent to those skilled in this art from the following description wherein there is shown and described a preferred embodiment of this invention, simply by way of illustration of one of the modes best suited to carry out the invention. As it will be realized, the invention is capable of other different embodiments and its several details are capable of modification in various, obvious aspects all without departing from the invention. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive.

Brief Description of the Drawinqs The accompanying drawings incorporated in and forming a part of the specification, illustrate several aspects of the present invention and together with the description serves to explain the principles of the invention. In the drawings:
Figure 1 is a perspective view showing a cutaway of the conveyor transfer assembly of the present invention being placed in the operative position in the conveyor system including the magnetic coupling assembly and the side plate of the conveyor system frame upon which the transfer assembly rests;
Figure la is a perspective view showing a similar cutaway of the conveyor transfer assembly in the operative position including the mating of the tapered drive faces of the magnetic coupling assemblies;
Figure 2 is an enlarged cross-sectional view showing the mating of each half of magnetic coupling assembly in the operative position, including the recessed magnets and the roller shafts;
Figure 3 is an enlarged perspective view showing the self-aligning and self-locking tapered drive faces of the magnetic coupling assembly including the single recessed magnets for delivering power to the conveying surface;

CA 022~4171 1998-11-16 Figure 4 is an exploded perspective view showing the preferred embodiment of the split mounting block assembly of the present invention including a cutaway view of the rollers and support shafts that form the conveying surface of the transfer assemblyi and Figure 4a is an enlarged cross-sectional view showing the mating of the base and cover of the split mounting assembly, including a pin having an external bend for detachably securing the cover to the base;
Reference will now be made in detail to the present preferred embodiment of the invention, an example of which is illustrated in the accompanying drawings.

Detailed Description of the Preferred Embodiment Reference is now made to Figure 1 showing a one side of a releasable conveyor transfer assembly 10 to illustrate the environment in which the mounting block assembly of the present invention is utilized. As illustrated, the transfer assembly 10 includes a recessed pan 12 as the overall supporting framework.
A mounting block assembly 14 is provided at each end of the pan 12 for supporting the rollers which form the conveying surface, as will be described in more detail below. At the ends of the recessed pan 12, there are provided two pairs of support tabs 16, 18. Matched with the tabs 16, 18 are respective pairs of notches N on upstanding side plates S of the frame of the conveyor system.
It should be appreciated that a complete description of a releasable conveyor transfer assembly 10 and its operation in a conveyor system are set forth in Applicant's U.S. Patent No.
5,584,373, issued May 26, 1995, entitled "Conveyor System With Passive Roller Transfer Assembly," and further in Applicant's co-pending application Ser. No. 08/642,030, entitled "Conveyor System With Driven Roller Transfer Assembly," the disclosures of which are incorporated herein by reference.
In operation of the conveyor system, when an article jam occurs, the transfer assembly 10 is able to be lifted in a pop-up fashion and released to prevent damage to the conveyor CA 022~4171 1998-11-16 system and the articles being conveyed thereon. It is also important that the transfer assembly 10 is aligned and securely mounted in the conveyor system without significant effort, both during initial mounting and re-mounting after release.
This function is accomplished through a magnetic coupling assembly, generally designated by the reference numeral 20. The magnetic coupling assembly 20 is shown positioned at one end of recessed pan 12, although it should be recognized that a similar magnetic coupling assembly could be positioned at the other end as well. The magnetic coupling assembly 20 serves the purpose of actively driving the rollers 24 from a rotary power source (not shown).
As best shown in Figures 2 and 3, the magnetic coupling assembly 20 includes a plurality of magnetic couplings 28; that is, there is one magnetic coupling 28 provided per roller 24.
More specifically, each magnetic coupling 28 includes an axially aligned and opposed first casing 30 and second casing 32. Each first casing 30 is attached to a drive shaft 34, which is in turn connected to the rotary power source or drive means, such as a belt and pulley arrangement or a sprocket and chain arrangement (not shown). Each second casing 32 is attached to a roller shaft 36 for supporting each roller 24 of the conveying surface.
Each pair of the casings 30, 32 are provided with opposing tapered drive faces 40, 42 that mate to form magnetic coupling 28. Specifically, the drive face 40 of first casing 30 extends outwardly from the body of the casing in a frusto-conical fashion. The second casing 32 is provided with a similar, but inverted, mating drive face 42; i.e. it is recessed below the outer surface of the casing. As can be appreciated, when urged into contact, the corresponding mating tapered drive faces 40, 42 create an interface, generally designated by the reference numeral 44 (see Figure 2). Magnets 46, 48 having opposite poles are contained within casings 30, 32, thereby creating the attracting magnetic force, as shown by the action arrow in Figure 3.
As the casings 30, 32 are drawn together to form interface 44, a secure connection for effecting power transfer CA 022~4171 1998-11-16 between the couplings 28 is formed. The slight recess of the magnets 46, 48 create peripheral edges 50, 52. These edges 50, 52 cause the casings 30, 32 to lock in contact during operation while preventing direct contact between the magnets 46, 48. In addition to providing the self-locking feature, this limited contact surface prevents wear and deterioration of the magnets 46, 48 during extended periods of use.
Referring now to Figures 3 and 4, the improved mounting block assembly 14 for supporting the roller shafts 36 and accompanying rollers 24 which comprise the conveying surface is set forth. In the preferred embodiment, the mounting block assembly 14 is split into a base 60 and a mating cover 62. The bottom of the base is secured to the recessed pan 12. The base 60 is provided with shaft supporting channels 64 separated by recesses 66. Protrusions 68 extend downwardly from the upper surface of the cover 62 to tightly mate with the recesses 66.
Shaft-supporting channels 70 are formed in the cover 62 which correspond with the shaft supporting channels of base 64. Thus, when cover 62 is fitted onto base 60, the corresponding, but opposed, pairs of shaft supporting channels 60, 62 form a substantially circular aperture for tightly holding and supporting each corresponding roller shaft 36. The recesses 66, the protrusions 68 and the channels 70 are all molded directly into the plastic material that forms the base 60 and the cover 62. The channels 70 form the bearing surfaces to allow rotation of the roller supporting shafts 36.
As illustrated, a wall 72 is also integrally formed in the base 60. This wall 72 is provided with apertures 74 that correspond to apertures 76 formed in each protrusion 70 of the cover 62. As is more specifically shown in Figure 4a, each of these mating apertures 74, 76 receives a pin 78 to detachably secure the cover 62 to the base 60. The pins 78 are preferably a force fit in the corresponding apertures 74, 76, such that they do not accidentally become dislodged due to vibrations or the like. Also, in the preferred embodiment, the pin 78 is provided with a substantially z-shaped external bend. These bends provide the advantageous function of allowing the pin to be gripped by CA 022~4171 1998-11-16 pliers, or the like, for removal, to thereby allow the cover to be easily lifted for accessing the roller shafts.
It should now be appreciated that the smooth, molded surfaces of the cover 62 and the base 60 of the mounting block assembly, and the tight mechanical fit between these components and the shafts 36, tend to make the assembly devoid of interstitial spaces wherein small bits of food product, or the like, can become trapped during operation of the conveyor system.
Furthermore, the force fit pins 78 which detachably secure the cover 62 to the base 60, fit, similarly eliminate the tendency for loose food product or the like to become trapped.
Also, in the preferred embodiment, the cover 62 is preferably formed with a low profile such that the height of the base 60 and cover 62, when mated, is lower than the outside diameter of the casings 32 and the inside diameters of the rollers 24. Advantageously, this prevents articles feeding along the conveyor system from stalling atop the mounting block assembly.
Referring again to Figures 1 and la, in operation, the conveyor transfer assembly 10 is mounted in the conveyor system by connecting the opposed casings 30, 32 to form the magnetic couplings 28. Specifically, the transfer assembly 10 is positioned at an angle above the side plate S and the casings 32 extending from the roller shafts 36 are positioned in line with the casings 30. The transfer assembly 10 is then dropped into position, thereby moving the outside tapered drive faces 42 into alignment with the similar, but inverted, drive faces 40. The oppositely-poled magnets 46, 48 are attracted towards one another, while the tapered drive faces 40, 42 urge the magnets into proper alignment. Thus, as is now appreciated, magnetic coupling assemblies are self-aligned and the conveyor transfer assembly is easily and efficiently mounted in the conveyor system and ready for operation.
This easy-mount feature for the transfer assembly 10 is beneficial when the removal of article jams is necessary. More particularly, after the transfer assembly is lifted and released and the article jam cleared, the transfer assembly 10 is returned CA 022~4171 1998-11-16 to the conveyor system using the mounting operation described above. As noted above, the magnets which form the magnetic coupling assemblies easily align and lock in the operative position, thereby allowing for the substantially uninterrupted operation of the conveyors.
Furthermore, if during operation a roller 24 or roller shaft 36 requires servicing or replacing, the split mounting block assembly 14 allows the roller 24 to be easily removed and replaced. Specifically, the pins 78 are simply removed by sliding from the apertures 74, 76. A simple tool, such as pliers, can be used to grip the external bend (see Figure 4a).
After removal of the pins 78, the cover 62 is easily removed from its mated position atop the base 62, thereby allowing access to release the shafts 36.
As the split mounting block assembly supports the roller shafts without the use of bearings or the like, and low cost molded parts are desired, the preferred embodiment of the mounting block assembly is formed of a plastics material, such as from the groups of polyacetal/polyamide/polyamide or composite thereof. A good choice of a material having a high degree of lubricity and excellent wear properties, for these purposes, as well as excellent chemical resistance, is nylon from the polyamide group, although the use of other plastics materials, including composites known in the art, is contemplated.
In summary, it will be realized that an improved conveyor transfer assembly 10 is provided wherein the shafts 36 supporting the rollers 24 are secured in mounting block assemblies 14, each having a detachable cover 62, thereby allowing easy removal for servicing or replacing the rollers 24.
The shafts 36 are driven through the magnetic coupling assembly 20. Thus, when an article jam occurs adjacent to the transfer assembly 10, the individual magnetic couplings 28 between the power source and the rollers are released. The transfer assembly 10, including the rollers 24 secured in the mounting block assembly 14, are bodily lifted by pop-up action to prevent damage to the articles and the rollers. This release feature also allows easy manual removal and reinstallation of the transfer CA 022~4171 1998-11-16 assembly 10 during servicing.
The foregoing description of a preferred embodiment of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiment was chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as is suited to the particular use contemplated.
All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with breadth to which they are fairly, legally and equitably entitled.

Claims (16)

1. A conveyor transfer assembly for moving articles feeding along a conveyor system including a first conveyor having a feeding portion, a second conveyor having a receiving portion, and a frame between the portions, comprising:
a plurality of rollers extending transverse to the frame of the conveyor system;
a shaft supporting each of said rollers;
a pair of split mounting block assemblies, each having a base for supporting said shafts in the transfer assembly, a mating removable cover, and means for detachably securing said cover to said base;
whereby the removable cover allows easy access to lift and remove the shafts during servicing.

2. The conveyor transfer assembly of Claim 1, wherein said cover and said base mate to form a plurality of shaft supporting channels.

3. The conveyor transfer assembly of Claim 2, wherein said cover is provided with a plurality of protrusions for mating with corresponding recesses in said base.

4. The conveyor transfer assembly of Claim 3, wherein at least two of said protrusions are provided with apertures.

5. The conveyor transfer assembly of Claim 4, wherein said base includes a wall adjacent said recesses, said wall having apertures aligning with the apertures in said protrusions.

6. The conveyor transfer assembly of Claim 5, wherein said securing means comprises at least one pin for slidable insertion through said aligned apertures for detachably securing said cover to said base.

7. The conveyor transfer assembly of Claim 6, wherein said pin is a force fit in the mounting block assembly.

8. The conveyor transfer assembly of Claim 7, wherein a bend is formed in the portion of said pin external to said mounting block assembly, whereby said bend aids in gripping and removing said pin from said apertures.

9. The conveyor transfer assembly of Claim 8, wherein said bend is substantially z-shaped.

10. The conveyor transfer assembly of Claim 1, including a recessed pan positioned below said rollers and supported by the frame of the conveyor system.

11. The conveyor transfer assembly of Claim 10, wherein a base of each mounting block assembly is secured to each end of said recessed pan.

12. A mounting block assembly for supporting the roller shafts in a conveyor transfer assembly, comprising:
a base for attachment to the conveyor transfer assembly, said base having a plurality of shaft supporting channels;
a cover for mating with said base, said cover having corresponding shaft supporting channels; and means for detachably securing said cover to said base;
whereby the cover allows easy access to lift and remove the roller shafts.

13. The mounting block assembly of Claim 12, wherein said detachable securing means includes at least two pins extending transversely through corresponding apertures formed in said base and said cover.

14. The mounting block assembly of Claim 13, wherein said pins are a force fit in said mounting block assembly.

15. The mounting block assembly of Claim 14, wherein a bend is formed in a portion of each of said pins external to said mounting block assembly, whereby said bend aids in gripping and removing the pins from said apertures.

16. The mounting block assembly of Claim 12, wherein said cover is provided with protrusions for mating with corresponding recesses formed in said base.