CA3213175A1 - Method and system for conveying articles and an apparatus for doing the same - Google Patents

Abstract

A conveyor for transporting and elevating articles and a method and system for conveying articles up inclines is provided. The conveyor has a conveyor belt and a plurality of support elements extending outward from the article-conveying surface of the conveyor belt advancing upward along the incline. The support elements prevent conveyed articles from sliding down the conveyor belt on the inclined conveyor and carry and hold articles on substantially vertical conveyors. The article-conveying surface of the conveyor belt may provide a low-friction retention surface to articles leaning away from the conveyor belt on the incline. The conveyor may be a vertical, nose-over tire conveyor in some embodiments. A portable stand is also provided and may aid in conveyor transportation and/or assembly.

Description

METHOD AND SYSTEM FOR CONVEYING ARTICLES
AND AN APPARATUS FOR DOING THE SAME
CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of priority from U.S. Provisional Patent Application No. 63/165,533, filed on March 24, 2021, the entire disclosure of which is incorporated by reference herein in its entirety. [Are we including the new matter from 4499-7-CIP-CON-2-CIP-2 in this application? If so, then this should claim priority to that app:
17/380,993 filed 7/20/21 ¨ make sure the PCT Request claims priority to this application.]
[Missing 4499-7-CIP-CON-2-CIP = 16/675,105 filed 11/5/19 and now issued.
Please add: U.S. Patent Application Serial No. 16/675,105, filed on November 5, 2019 (now U.S. Patent No. 11,066,243), which is a Continuation-In-Part Application of and claims the benefit of priority from] This application is related to and incorporates by reference the entire disclosures of the following applications and patents: U.S. Patent Application Serial No. 16/119,804, filed August 31, 2018 (now U.S. Patent No. 10,464,754), which is a Continuation Application of and claims the benefit of priority from U.S.
Patent Application Serial No. 15/673,014, filed on August 9, 2017 (now U.S. Patent No.
10,065,801), which is a Continuation Application of U.S. Patent Application Serial No. 15/041,668, filed on February 11, 2016 (now U.S. Patent No. 9,745,133, issued August 29, 2017), which is a Continuation Application of U.S. Patent Application Serial No. 14/641,126, filed on March 6, 2015 (now U.S. Patent No. 9,260,247, issued February 16, 2016), which is a Continuation in Part Application of U.S. Patent Application Serial No. 14/154,141, filed on January 13, 2014 (now U.S. Patent No. 9,061,830, issued June 23, 2015), which claims priority from U.S. Provisional Patent Application No. 61/751,722, filed on January 11, 2013.
FIELD OF THE INVENTION
The invention relates generally to power-driven conveyors and, more particularly, to belt conveyors advancing on steep inclines to elevate articles, especially tires up substantially vertical inclines.
BACKGROUND OF THE INVENTION
In a tire manufacturing plant, tires molded in rows of tires presses are deposited on a trench conveyor and transported to an inspection, balance, or trim station.
Because trench conveyors are typically positioned below the presses at a relatively low elevation, incline conveyors are used to elevate the tires received from the trench conveyor to the level of the presses or higher for transport to subsequent finishing stations. Belt conveyors, such as modular plastic belt conveyors with high-friction conveying-surface characteristics, work well on shallow inclines. On steeper inclines, however, belts with conveying surfaces textured with inverted cones or other non-skid protrusions work well when new.
As the protrusions wear, tires begin to slide down the conveying surface as the belt advances up a steep incline. Rubber-topped belts are not so susceptible to wear, but the slippery mold-release material used to ease ejection of the tires from the presses coats the rubber conveying surface of the belt, which then loses its effectiveness as a high-friction surface.
Consequently, incline angles are limited to a maximum of about 25 off horizontal. Such shallow inclines have a large footprint, taking up valuable floor space. Even if tires could be prevented from sliding along the conveying surface on steep inclines, there must be provisions to prevent tires from falling away from the belt. A wall or other static structure in sliding contact with high-friction articles, such as tires, being lifted on the incline may damage the articles and will increase the load, requiring an oversized belt and drive system In tire warehouses or stores and service stations stocking large numbers of tires, the tires are usually stacked to great heights. Further, the tires may be stacked on shelves or second levels and thus begin to be stacked at heights over 6 feet. Conveyors may be used to elevate the tires to the level of the tire storage or higher for transport to additional floors.
Traditional conveyors use friction or protrusions to prevent the tires from sliding down the inclined conveyor or from falling off of the side of the conveyor belt.
However, friction and protrusions are not fail-safe methods and tires often fall off of the conveyor causing harm to people and property located near the conveyor.
The tire distribution process often includes transporting large quantities of tires from the plants where they are manufactured to the various facilities where tires are delivered to consumers and/or mounted on vehicles. The processes for transporting tires from these plants to wholesalers, retailers, and service centers typically involve the use of large vessels.
For example, semi-trailers are used for transportation over the road, rail cars are used for transportation via rail, and shipping containers are used for transportation over water.
Further, these vessels often provide storage of tires prior to and after transport.
To minimize the costs associated with such storage and transportation, it is desirable to pack tires into each storage and/or transportation vessel in such a manner as to maximize the density of tires within the vessel, while providing satisfactory stability of the loaded tires and avoiding permanent deformation of the loaded tires. Maintenance of tires under a compressive load has been found to improve the stability of the loaded tires.
However, compression may lead to permanent deformation of tires in some stacking configurations.

2 Additionally, to minimize the costs associated with storing the tires once they arrive at their destination (e.g., facilities where tires are delivered to consumers and/or mounted on vehicles such as warehouses and car repair shops), it is desirable to pack tires into the storage location in such a manner as to maximize the density of tires within the storage location, while providing satisfactory stability of the stored tires to prevent injury and save space and avoiding permanent deformation of the stored tires, which may be stored for months or even years.
When the storage and/or transportation within the vessel is complete, tires are typically manually unloaded from the vessel onto a conveyor or pallet. A
variety of implements exist for such handling of tires. For example, U.S. Pat. No.

3,822,526, issued to Black in 1974 and incorporated herein in its entirety, discloses a device for manipulating tires. However, a device does not exist that sufficiently eliminates the difficulties of manually stacking tires in a storage and/or transportation vessel, and unloading the compressed tires from the same vessel. Moreover, no sufficient device currently exists to eliminate the reliance on the vessel to maintain a compressive load on tires.
Although loaders for tires exist, for example, a machine loader and a loader to create a straight stack of tires, the existing loaders are not designed to stack tires in a herringbone pattern. Further still, the current practice is to rest tires directly against the wall and floor of the trailer or boxcar. As a result, the weight of the stacks is unevenly distributed causing further compression and strain on tires. Thus, a lower-compression system for cradling tires during storage and shipping is desired.
Belt conveyors for tires have been produced to transport tires up to various heights.
See U .S . Pat. Pub. No. 2008/0053796 to DePaso et al. ("DePaso"). The entire disclosure of DePaso is incorporated by reference in its entirety.
Thus, there is a need for an elevating conveyor capable of transporting articles, especially tires and solar panels, up steep inclines. Additionally, there is a need for an elevating conveyor capable of transporting large tires, such as tractor trailer tires and tractor tires, and solar panels.
SUMMARY OF THE INVENTION
Certain embodiments of the present invention relate to a conveyor embodying features that address these needs.
Although many of the embodiments are focused on conveyors for tires, the invention may be used in any application where articles are conveyed to different locations. For example, some embodiments are directed to a conveyor for tires while other embodiments are directed to conveyors for solar panels, boxes, wheels, large spools, large rings, rubber components, etc. Further, some embodiments are directed to a conveyor for traditional car and/or SUV tires while other embodiments are directed to a conveyor for tractor trailer (i.e., eighteen-wheelers, semi trucks, semi trailers, or semis) tires, tractor tires, and/or farm machinery tires. Typically, the size and shape of the tire changes depending upon the use of the tire. For example, tires for small cars and/or light trucks may range from about 24" to about 32" in diameter. Tires for a large trucks and/or semi trailers may range from about 32" to about 48" in diameter. Tires for tractors or other farm machinery may range from about 32" to about 74" in diameter.
One aspect of the present invention is to provide a conveyor to move tires or articles up to different heights. The height and angle of the conveyor may be adjustable in some embodiments.
On a conventional tire inspection line, tires brought on a conveyor or like equipment may be stopped at a midway point where information may be read from the barcode affixed to the tires. This is done to identify the type and size of the tires being inspected and sort them into the tires to be sent to the next process and elsewhere. Therefore, one aspect of the present invention is to provide a tire sorting apparatus capable of reliably reading information from a tire identifier, such as a barcode, formed on the surface of a tire without damaging the tire.
It is also an aspect of the present invention to provide a conveyor system comprising a conveyor belt, support elements to support the articles being conveyed, a support frame for the belt and to raise the conveyor belt upward, and a power source. The conveyor belt may include sections secured together, one or more pieces of belt material, strengthening mechanisms either below or between the one or more pieces of belt material to support the support elements, an upper surface, and an under surface. The power source may comprise electrical components and a motor. Note that the terms "cleat" and "support element" can be used interchangeably herein.
In some embodiments, the conveyor may be specially designed to move passenger car and light truck tires upwardly at incline angles up to 60 degrees. In other embodiments, the conveyor may be specially designed to move semi truck and tractor tires upwardly at incline angles up to 60 degrees. In still other embodiments, the conveyor is designed to convey tires of any size substantially vertically, i.e., at an incline of approximately 90 degrees relative to the horizontal.

4

5 In various embodiments, the features of the conveyor include: a 18" wide 2 ply rubber covered top belt sliding flat at about 60 FPM, one or more 4" high urethane cleats bolted to the belt on approximately 60" centers, a curved cleat pattern to fit tire contour, one up/stop/down switch at the bottom end, a lhp 115V 13 FLA electric motor with speed reducer mounted under bottom end, a thermal overload motor protector, a rubber lagged conveyor belt drive pulley, a plain idler pulley with belt tensioner, a high strength steel tubing truss conveyor frame, and a base plate. In additional embodiments, the conveyor may include: an off switch at the top end, a portable stand with casters to hold the top end at a fixed height, a portable stand with casters with a hand-winch adjustable top end height, up/emergency and stop/down switches at both ends of the conveyor with UL
listing, a 24"
wide belt for tractor trailer size tires, a 6" high single cleat for vertical tire lift installation, straight cleats for handling boxes, bags, and general merchandise, and a smooth or rough top belt for shallow inclines_ In some embodiments, the width of the belt is larger than 24"
and in other embodiments the width of the belt is less than 24".
In various embodiments, the cleats may be attached, secured, or interconnected to the belt using a set of two bolts. Further, the bolts may be 1/4" x 1-1/4" #1 elevator bolts with hardware. The cleats may also include holes for the bolts or other interconnection mechanisms.
In some embodiments, the cleats may flip up when going up the conveyor and flip down when going down the back of the conveyor. In one embodiment, the cleats may be hinged to the belt such that they can flip up and down. Other flip mechanisms may also be contemplated by one skilled in the art. In some embodiments, the cleats are permanently attached to the belt. In other embodiments, the cleats are removable. In one embodiment, the cleats are attached without the use of screws.
In some embodiments, the cleats may be flexible. Thus, each cleat may be constructed entirely from an elastomeric material that provides flexibility.
In one embodiment, the cleat or support element is flexible along the length of cleat such that when a tire or article is positioned on the conveyor belt, the two cleats bend in a direction opposite the direction of belt travel along the conveying path. In other embodiments they may be rigid.
In various embodiments, the cleats or tire support elements have a unique shape to hold tires on a conveyor belt. Thus, the first and second tire support elements each has a front section having an tire-supporting face that has a first curve that is curved along the tire support element's length and toward the direction of belt travel. The tire support element also has a back section with a second curve that is curved along its length and in the direction of belt travel. The second curve is typically greater than the first curve.
Additionally, each of tire engaging support elements has a flat conveyor contacting surface that engages the outer tire-conveying surface of the conveyor belt. The support element may also have a top surface that is positioned at an angle relative to the flat conveyor contacting surface.
In various embodiments, the system may comprise one or more motors, which may be changed out to use motors having different power capabilities. In further embodiments, the motor(s) may be detachable and removable.
In some embodiments, the conveyor is foldable for storage flat on the ground or flat against a wall. In other embodiments, the conveyor may be foldable and stored in the location of use. Therefore, when a user needs to use the conveyer, he or she just has to pull the conveyor down. The pull-down and storage motion may be similar to a Murphy bed in some embodiments Further, the conveyor may be pulled down from a specific rack or other storage area.
In some embodiments, the support elements or cleats are bolted onto the belt.
A
gasket that can be rubber may also be used to increase the strength of the interconnection.
Additionally, bolting the cleats onto the belts reduces the cost of the system.
In various embodiments, the conveyor may have rubber feet to help it stick to the ground/floor. The feet may be made of materials other that rubber in alternate embodiments.
Thus, the bottom of the conveyor may contact the floor in one or more places depending on the embodiment. In other embodiments, the conveyor may be positioned on a rail such that the conveyor can slide along the rail to different storage areas. Thus, in an embodiment, the conveyor moves along the rails in a similar manner as library ladders. One skilled in the art can image a rail system similar to the rail systems described herein.
In various embodiments, the conveyor may include an endless conveyor belt looped around rotating drive elements, such as sprockets, drums, or pulleys, which advance the conveyor belt in a direction of belt travel along a conveying path. The endless conveyor belt may have an outer, article-conveying surface and an inner, drive surface engaged by the drive elements. On a steeply inclined elevating portion of the conveying path, the articles are conveyed vertically or at a steep angle. The articles are maintained in position and blocked from sliding down the outer surface of the conveyor belt on the steeply inclined portion of the conveying path by support elements or cleats that extend outwardly from the outer surface. The support elements are periodically spaced along the length of the conveyor belt to form individual bins for the articles. A steep incline for a given conveyor belt may

6 be defined as a conveying path that is so steep that typical vibrations, jolts, or surges cause conveyed articles supported on support elements to fall from the conveyor belt advancing along the incline. In various embodiments, the conveyor may be inclined up to an angle of 60 degrees relative to the horizontal plane.
In various embodiments, the conveyor may further comprise an adjustable base comprising the support stand, a first tubing extending from the support stand, a threaded bar extending from the first tubing, a second tubing receiving an end of the threaded bar, and a nut. The nut may be configured to adjust a height of the threaded bar such that rotation of the nut in a first direction translates the second tubing away from the support stand and rotation of the nut in a second direction translates the second tubing towards the support stand. The nut may comprise a first nut and the adjustable base may further comprise a second nut, wherein the second nut is positioned between the second tubing and the first nut The adjustable base may comprise four of each of the first tubing, the threaded bar, the second tubing, and the nut.
In some embodiments, the floor-to-floor vertical tire conveyor ("VTC") requires minimal ground floor space next to the mezzanine and is also capable of clearing existing structures, such as fire service lines. Although the term VTC is used herein, the VTCs can convey articles other than tires. In some embodiments, the VTC is substantially straight and a user must remove the tire from the top of the conveyor or the top of the conveyor must be interconnected to a mechanism or machine that removes the tire from the top of the conveyor. One disadvantage of the straight VTC is that a hole is typically cut into the mezzanine floor to accommodate the straight VTC. Having a hole in the mezzanine floor can be dangerous and can interfere with existing fire sprinkler water lines and electric lighting, both of which are typically positioned immediately underneath the mezzanine floor. Another disadvantage of the straight VTC design is that every single article or tire that goes up the conveyor must be removed from the conveyor manually when it arrives at the top end. With the inclined, but not vertical, conveyor, this is not necessarily the case because the articles can fall off of the top of the conveyor onto the floor or another (e.g., horizontal) conveyor.
Thus, a VTC that automatically discharges the articles/tires at the top end of the conveyor may be desired. Accordingly, in other embodiments of the VTC, the top end of the VTC has a nose-over portion that allows for easy unloading (or loading for descent) of tires and keeps the operator clear of both moving conveyor parts and the mezzanine edge.
Here, the base of the conveyor could be positioned outside of the mezzanine structure and

7 within the limited distance between service bays (or other constraints) and the edge of the mezzanine. Additionally, the nose-over VTC could avoid interference with existing fire sprinkler water lines and electric lighting, both of which are typically positioned immediately underneath the mezzanine floor. The cleat interconnected to the belt for the nose-over VTC may be shorter and of a different configuration than the cleat for the straight VTC. However, the same cleat may be used for both conveyors in various embodiments.
As discussed herein, the upper/outward-facing surface of the conveyor belt is typically referred to as the "article-conveying surface" and a forward and upward-oriented portion of the cleat is referred to as the "article-supporting face." This is because on an incline conveyor (i.e., non-vertical conveyor), the belt bears the brunt of the conveyed article's weight and the cleats act as supports to keep the articles (e.g., tires) from sliding backwards down the belt. However, when the conveyor is a vertical conveyor (for example, a VTC) the roles of the belt as an "article-conveying surface" and the cleat as a "article-supporting face" are reversed, meaning that on a VTC the cleat is the primary contact with the article (e.g., tire), but the weight burden is equally shared between the cleat and the belt.
In some embodiments of the VTC and other conveyors described herein, the conveyor frame is constructed of standard commercial quality ("CQ") steel tubing rather than the high strength ("HS") tubing generally used. This is advantageous because the CQ
steel tubing is less expensive than HS tubing and the HS tubing is not necessary for all conveyors. However, some embodiments include HS tubing or a combination of CQ
and HS tubing.
Various embodiments of the VTC and other conveyors described herein include two tubes or rails directly next to each other that are positioned between and substantially perpendicular to the longitudinal frame rails and proximate to a center of the frame length.
The tubes/rails may be square or rectangular shaped such that they extend around the perimeter of the frame. These two rails or tubes permit the conveyor frame to be cut into two pieces, e.g., to facilitate installation, because the frame can be cut between the two tubes/rails and each piece will maintain its shape. Then, the two pieces are U-bolted back together to form one conveyor frame using U-bolts and fastening equipment.
In some embodiments of the VTC and other conveyors described herein, the frame comprises sheet metal paneling on all or a portion of the sides of the frame.
The paneling can extend between about 1 ft. and about 8 ft. along the side of the conveyor from the end (either the top or bottom end). In preferred embodiments, the sheet metal paneling extends about 4 ft. from each end. The sheet metal paneling is typically provided for safety purposes,

8 e.g., to keep people, heads, arms, hands, fingers, legs, feet, etc. out of the portions of the conveyor comprising moving parts and the portions of the conveyor where most injuries occur.
In various embodiments of the VTC and other conveyors described herein, the conveyor comprises a 1/2 hp motor or a 1/4 hp motor. Alternatively, any of the conveyors described herein can be constructed with a motor that is smaller than 1/4 hp or a motor that is larger than 1/2 hp.
In some embodiments of the VTC and other conveyors described herein, the conveyor comprises an 18"-wide rubber top cover belt with a friction-resistant bottom cover. Various embodiments include a 5-7/16" high/tall cleat that attaches to the outer face of the belt. The cleat may be interconnected to the belt via two bolt fasteners, flat washers, lock washers, and nuts, or any other attaching mechanism known in the art The cleats may be urethane or other hard material, e g , plastic, hard rubber, metal, etc In various embodiments of the VTC and other conveyors described herein, the cleat has various shapes and dimensions depending on the specific use by the user, the location of the conveyor, the items being conveyed, and the angle of the conveyor relative to the horizontal ground. In some embodiments, the cleat has a 5" overall height and features for careful handling of tires. For example, the cleat can have an extended radius of curvature opposite the article supporting / carrying surface radius and at the cleat tip (upper end) to deter tires or other articles from falling off. Some cleats have narrow widths and edges with radii of curvature to prevent damage to the tire's inner bead. Further, various cleats described herein are manufactured of a urethane composition. In some embodiments, the VTC cleat has a carrying surface (i.e., article-supporting face) that is more rounded than cleats of prior designs, in order to better fit the tire bead contour.
In some embodiments of the VTC, the conveyor is motor driven at the bottom end of the conveyor, meaning the motor is positioned at the bottom end of the conveyor. In other embodiments, the VTC comprises a motor at the top end of the conveyor.
Various portions of the conveyors described herein can vary depending on the specific use of the conveyor. For example, some conveyors may have tighter frame dimensions and features to facilitate installation within tight clearance restrictions. Further, there is a balance between the conveyor belt width, sufficient traction between the belt and the conveyor belt drive pulley to carry the conveyed article (e.g., tire load), and keeping overall dimensions as tight as possible. The conveyor belt width could be variable, but it has to be countered with the drive pulley diameter for sufficient traction. For example, the

9 conveyor belt can be between about 18" wide and about 10" wide. Further, smaller diameter drive and idle drum pulleys are used in some embodiments.
In some embodiments of the VTC and other conveyors described herein, the conveyor comprises a 10"-wide, 2-ply rubber cover on both sides of the belt.
In this embodiment, the conveyor belt drum drive pulley has rubber lagging wrapped around its circumference and a 4.5" outside diameter (-0.D."). The rubber contact between the belt and the drive pulley provides for maximum traction between the two.
Various embodiments of the VTC and other conveyors described herein have a high-efficiency, helical gearmotor mounted at the top end of the conveyor frame for maximum belt-to-pulley traction. The gearmotor plus the roller chain and sprockets are all enclosed within the conveyor frame for safety and to facilitate installation through tight clearances, in some embodiments.
Some embodiments of the VTC and other conveyors described herein comprise a low-profile, custom-design belt tension take-up adjustment to keep all dimensions of the adjustment below the highest point of the conveyor belt drum idle pulley.
In some embodiments, once the articles are conveyed up the incline, they may be transferred to an outfeed conveyor for transport to downstream finishing stations or other storage sections. Further details of exemplary slide-preventing cleats or pair of cleats may extend outwardly from the outer, article-conveying surface of the conveyor belt. In an embodiment, the cleats may be integrally formed with the belts. In another embodiment, the cleats may be secured to a threaded insert in the belt by a bolt or the like through a bore formed in a block of the cleat.
In some embodiments, the cleats are secured to the conveyor belt. In other embodiments, the cleats are secured to a metal drive belt provided under the conveyor belt.
Thus, the conveyor belt may have apertures in the belt such that the cleats can extend upwardly from the drive belt and above the conveyor belt In alternative embodiments, the cleats are secured to a metal (or other material) support within the conveyor belt (i.e., between two layers of the conveyor belt). The cleats may be secured or interconnected to a belt or other part of the conveyor through the use of screws, pins, rivets, bolts, nails, glue, adhesive, sewing, clamps, bonding, welding, or any other mechanism now known or later conceived.
In various embodiments, the cleats are various sizes and shapes depending on the tire or article to be conveyed. In one embodiment, the conveyor belt may include support elements or cleats of many different sizes. The cleats may fold up in order to support an article to convey or may fold down such that it does not inhibit or interfere with the articles being conveyed. Thus, in this embodiment, the cleats that are of a size not currently being utilized are folded down such that they are substantially flat against or within the belt. In other embodiments, the cleats that are of a size not currently being utilized may be folded into the center of the conveyor belt such that they do not interfere with the articles being conveyed.
In various embodiments, the conveyor belt may be a modular plastic conveyor belt constructed of a series of individual belt modules made of a thermoplastic polymer, such as polypropylene, polyethylene, acetal, or a composite material, in an injection molding process. A threaded metallic insert may be inserted into the module during or after molding to serve as an attachment point for a support element. The details of one such insert and its use are described in U.S. Pat. No. 6,926,134, "Plastic Conveyor Belt Module with Embedded Fasteners," which is incorporated by reference herein in its entirety Of course, other methods may be used to fasten the support elements to the conveyor belt.
In some embodiments, the conveyor belt sections comprising cleats may be interconnected to one another and to other similar belt sections without cleats in a side-by-side orientation and end-to-end by hinge rods through hinge eyes to form an endless conveyor belt.
In one embodiment, the system may comprise two cleats that are spaced apart laterally across the width of the conveyor belt. The cleats may have article-supporting faces defining planes oblique to the direction of belt travel and intersecting at a point on the belt below or behind the cleats on the steep incline. The two cleats provide two points of support for round articles, such as tires, and the space between them allows debris or fluids to drop from the tire and off of the belt.
In one embodiment, the belt is replaced with rollers or a roller array. The rollers provide a low-friction, rolling restraining surface that is especially useful with high-friction articles, such as tires. Further, the conveyor belt described as a plastic conveyor belt may be a flat belt or a flat-top chain in other embodiments. Another embodiment of an elevating belt conveyor embodying features of the present invention may include a roller array to prevent conveyed articles from falling off the belt.
One skilled in the art will appreciate that the conveyor and its features may vary depending upon the combination of elements in various embodiments. In some embodiments, the cleats have a rounded shape such that the curve of the cleat matches the curve of the tire being conveyed or transported. Thus, the curve of the cleat is slightly larger than the curve of the tire so that the tire will sit in and fit into the cleat. In still other embodiments, the cleat may have a different shape. For example, the cleat may not be curved. Rather, the cleat may be flat like a wall or tile. The cleat may also be shaped like a post or rod. Still further, the cleat may be V-shaped or U-shaped and only one cleat may be used to support each tire or conveyed article.
In some embodiments, the cleat may only come up to the midpoint of the side of the tire. In other embodiments the height of the cleat is greater than the height of the tire lying on its side, i.e., the width of the tire. In still further embodiments, the height of the cleat is somewhere between the midpoint of tire's side height and the top of the tire's side when the tire is lying on its side.
In various embodiments, one cleat per tire or conveyed article may be used. In other embodiments, two cleats per tire or conveyed article may be used. In other embodiments, 3 or more cleats per tire or conveyed article may be used Additionally, in some embodiments one cleat may be used for one tire or conveyed article and two or more cleats may be used for another tire or article. Thus, the number of cleats could change throughout the conveyor.
In still more embodiments, the position of the cleats may be varied depending upon the shape and size of the tire or article conveyed. For example, the cleats may be spaced further apart and positioned at less of an angle relative to horizontal if the radius of the tire is large, whereas the cleats may be positioned closer together and at a greater angle relative to horizontal if the radius of the tire is small.
Although the invention has been described with application to tires, the invention also finds application to transporting other articles. For example, boxes, solar panels, windows, construction equipment, car or automobile components, tractor components, pallets of products, etc. may be transported on the conveyors.
In some embodiments, the conveyor may be configured with a conveyor belt, roller bars, and/or any other mechanism for moving tires. The conveyor may be configured to be located at any height above a platform to facilitate access by a worker. In one embodiment, the conveyor may be configured about three feet above the platform. The conveyor may be configured to automatically move tires in one or more directions. For example, in one embodiment, the conveyor may be configured to move tires from a placement station to any desired location, such as, for example, a tire loading system, a tire unloading system, a forklift, a railcar, and/or a tire rack. In another embodiment, the conveyor may be configured to move tires to/from a location such as, for example, a tire unloading system, a forklift, a railcar, a tire rack, a tire storage location or the like to/from the placement station for manual loading of tires into racks or storage areas in the tire load station.
In some embodiments of the conveyor system, humans may load articles or tires onto the conveyor (typically the bottom of the conveyor) and unload articles or tires off of the conveyor (typically the top of the conveyor) as a part of the system. In various embodiments, one or more persons load the tires and a different one or more persons unload the tires or articles. In alternate embodiments, machines or robots may load and unload the articles and tires. In additional embodiments a combination of humans, robots, and machines may be used to load and unload the articles or tires.
Lean manufacturing principles may be applied throughout embodiments of the invention to facilitate efficiency in tire loading, unloading, and/or storage.
For example, in one embodiment, value stream mapping is used to analyze logistics data provided by a company to create Pareto analysis to identify high volume, high turn-over tire SKUs (i e , stock control units). A manufacturing plant analysis is implemented to determine the capacity and production rate of a given customer to determine the size, capacity, number, and/or breadth of tire loading, unloading and/or storage needed to fulfill capacity and production goals. For example, for higher customer inventory levels, fully-automated loading, unloading and/or storage systems may be desired. However, for lower inventory levels, customers may use partially-automated loaders, unloaders, and/or storage systems to maximize efficiency and lower overall costs.
In yet other embodiments, the systems and methods of the present invention are facilitated by one or more human and/or computerized operators. For example, an operator monitors robot loaders and/or unloaders, monitors system settings and/or identifies racks that require replacement or repair. Operators also drive forklifts, load/unload tires, and/or the like to facilitate overall system usage.
One aspect of embodiments of the present invention is to provide a system capable of handling all sizes of vehicle tires, providing maximum compression of tires, and minimizing the manual labor required for loading, unloading, stacking, and/or storing the articles or tires.
In some embodiments of the system, tires are ricked or stacked in a herringbone pattern to facilitate compression and/or space management. The system and method also includes the stacking of tires in any other suitable arrangement that would allow the transport rack to perform similar functions. Moreover, the system and method may include any variation or angle of herringbone patterns that would allow the transport rack to perform similar functions as disclosed herein.
As one with ordinary skill in the art appreciates, the proper alignment of tires in the herringbone pattern depends upon the geometry of tires being stacked. Thus, the system contemplates and accommodates incorporation of an automated system for control of the loader system. The control system automatically senses tire geometry based on sensors located at an upstream position on the conveyor, or alternatively, accommodates the manual input of information. In both cases, however, the control system uses information that is indicative of tire geometry, such as outside diameter, inside diameter, and/or tread width, to determine the rotation and translation of each tire to produce the desired stacking pattern.
With respect to herringbone stacking patterns, the relevant output variables may include the angle of deviation from vertical associated therewith the axis of rotation of tires in successive rows as well as the number of tires in each row and the number of rows in each stack. Furthermore, the control system may determine the appropriate amount of compression to apply to the stacked load, and the corresponding number of rows in the stack, to avoid permanent deformation of tires. The control system may consider a variety of factors in determining the appropriate compressive loads to apply. In one embodiment, these factors include the material properties and/or hardness of tires (usually rubber), tire geometry and stacked orientation, and the time and temperature environment to which compressed tires will be subjected. In addition, empirical data and experience may be incorporated to optimize the control of the system.
As used herein, warehouse racks include any type of rack that is distinct, including for example, pallets, racks such as those manufactured by Ohio Rack, Inc., or the like.
In some embodiments, the conveyor system may comprise one or more scanners to facilitate identifying each tire or article. For example, in one embodiment, the system comprises two scanners configured on both sides of a two-lane conveyor. The scanners may be configured both above and below the conveyor and/or articles to facilitate reading the articles' labels/SKUs. In alternate embodiments, the scanner may be a barcode scanner, a radio-frequency scanner, optical scanners, vision systems and/or any other type of scanner for reading and/or identifying tire or article labels and/or SKUs. The scanner may be configured with a CPU and/or any other computing system or unit. The scanner may also be configured to communicate with the rack loading system, conveyor, and/or any other part of the system or any other system described herein. Alternatively, RFID tags and readers may be used with the system.

In one embodiment, each tire on a conveyor and/or a warehouse storage area is the same type, size, and/or SKU number, or may be designated for the same destination or storage area. Tires may be delivered to storage areas and/or a warehouse rack on a conveyor.
In additional or alterative embodiments, articles and tires may be delivered to storage areas and/or a warehouse rack on two or more conveyors. Further, the tire or article may be scanned and identified then loaded on to the appropriate conveyor for storage in the appropriate area. Thus, one type of tire may be loaded onto one conveyor to be stored in a first area and a different type of tire or article may be loaded onto a second conveyor to be stored in a second area that is different from the first area.
In some embodiments, the conveyor system and the rack loading system may also be configured to stack tires or articles based upon identification information received from the scanner. For example, in one embodiment, the rack loading system may be configured to receive tire identification information from the scanner and to use the tire identification information to determine what tire stacking configuration to use. That is, for smaller diameter tires, the rack loading system may stack tires in layers of five tires, for example.
For larger diameter tires, the rack loading system may stack tires in layers of four tires, for example.
In various embodiments, the one or more conveyors may elevate the tires to a stop position in front of one or more position pick-and-place loaders. The pick-and-place loaders may each comprise a support-mounted actuator system, each of which controls an extendable/ retractable arm that is adapted to seize the tire or article from the conveyor.
In some embodiments, the system is configured to sort and queue tires horizontally.
For example, the system comprises one or more tire transportation devices, such as, access conveyors that connect to one or more sub-conveyors. In an embodiment, an access conveyor may move the tires from the main unloading conveyor to various sub-conveyors.
The sub-conveyors, in turn, may move tires to/from towers. Some conveyors may be configured to be computer-controlled devices to facilitate sorting, queuing and/or routing of the tires. In one embodiment, the tires are loaded randomly and scanners are used to sort, queue and/or route the tires when they are unloaded from towers.
In another embodiment, some conveyors may be configured with one or more scanners to obtain tire identifying information to facilitate sorting and queuing the tires. The scanners may be configured like scanners and communicate with the conveyors to facilitate directing each SKU of tire to a different sub-conveyor for loading into a particular tower.
Each tower is configured to hold between 10 and 30 tires of a single SKU.

In one embodiment, a queuing system may comprise an inbound queue of tires or articles that have been unloaded from a trailer, railcar, forklift and/or other transportation mechanism. For example, a number of tires or articles are queued on each side of the queuing system.
In various embodiments, the system may also be configured with a control panel to facilitate worker operation of the conveyor. For example, the worker may use a panel to raise or lower the conveyor in order to facilitate access to tires, storage areas, and racks. In another embodiment, a load station may be configured with one or more scanners or cameras to detect the height of rack, storage floor, storage area, tires, and the conveyors and raise or lower the conveyor based on whether the height of the racks, tires, storage floor, storage area, or conveyor meets a predetermined height.
The scanner computing unit or any other computing unit used or described herein may be connected with each other via a data communication network The network may be a public network and assumed to be insecure and open to eavesdroppers. In the illustrated implementation, the network is embodied as the Internet. In this context, the computers may or may not be connected to the Internet at all times. For example, the customer computer may employ a modem to occasionally connect to the Internet, whereas the bank computing center might maintain a permanent connection to the Internet. Specific information related to the protocols, standards, and application software utilized in connection with the Internet may not be discussed herein. For further information regarding such details, see, for example, Dilip Naik, "Internet Standards and Protocols" (1998); "Java 2 Complete," various authors (Sybex 1999); Deborah Ray and Eric Ray, "Hosting HTML 4.0" (1997);
Loshin, "TCP/IP Clearly Explained" (1997). All of these texts are incorporated by reference herein in their entireties.
It may be appreciated that many applications of the present invention may be formulated. One skilled in the art may appreciate that a network may include any system for exchanging data or transacting business, such as the Internet, an intranet, an extranet, DSL, WAN, LAN, Ethernet, satellite communications, and/or the like. It is noted that the network may be implemented as other types of networks, such as an interactive television (ITV) network. The users may interact with the system via any input device such as a keyboard, mouse, kiosk, smart phone, e-reader, tablet, laptop, ultrabook'TM, personal digital assistant, handheld computer (e.g., Palm Pilot ), cellular phone, or the like. Similarly, embodiments of the invention could be used in conjunction with any type of personal computer, network computer, workstation, minicomputer, mainframe, smart phone, etc. Moreover, although the invention is frequently described herein as being implemented with TCP/IP
communications protocols, it may be readily understood that the invention may also be implemented using IPX, Appletalk, IP-6, NetBIOS, OSI or any number of existing or future protocols. Moreover, the present invention contemplates the use, sale or distribution of any goods, services or information over any network having similar functionality described herein.
In accordance with various embodiments of the invention, the Internet Information Server, Microsoft Transaction Server, and Microsoft SQL Server, may be used in conjunction with the Microsoft operating system, Microsoft NT web server software, a Microsoft SQL database system, and a Microsoft Commerce Server. Additionally, components such as Access or SQL Server, Oracle, Sybase, Informix MySQL, Interbase, etc., may be used to provide an ADO-compliant database management system. The term "webpage" as it is used herein is not meant to limit the type of documents and applications that might be used to interact with the user. For example, a typical website might include, in addition to standard HTML documents, various forms, Java applets, Javascript, active server pages (ASP), common gateway interface scripts (CGI), extensible markup language (XML), dynamic HTML, cascading style sheets (C SS), helper applications, plug-ins, and/or the like.
A system user may interact with the system via any input device such as, a keypad, keyboard, mouse, kiosk, smart phone, e-reader, tablet, laptop, ultrabookrm, personal digital assistant, handheld computer (e.g., Palm Pilot , Blackberry , iPhonee, iPad , Android ), cellular phone, or the like. Similarly, the invention could be used in conjunction with any type of personal computer, network computer, work station, minicomputer, mainframe, smart phone, tablet, or the like running any operating system such as any version of Windows, MacOS, i0S, OS/2, Be0S, Linux, UNIX, Solaris, MVS, tablet operating system, smart phone operating system, or the like, including any future operating system or similar system.
In one embodiment of the present invention, a tire sorting apparatus that includes a mounting means for mounting a tire in a plane perpendicular to the center axis of the tire, a tire grip means for gripping the inner periphery of the tire and positioning the center axis of the tire, an identifier reading means for reading a tire identification marking formed on the surface of the tire, and a holding means for holding the identifier reading means. The tire grip means may further include three grip arms arranged at the vertexes of a triangle within a plane perpendicular to the center axis of the tire and extending in a direction parallel to the center axis of the tire and an arm opening and closing mechanism for opening the three grip arms concentrically around the circle circumscribing the triangle. The holding means may further include a holding unit for holding the identifier reading means and a rotation drive unit for rotating the holding means around a rotating axis parallel to the center axis of the tire. And the center of the circumscribing circle is aligned with the rotating axis of the holding unit.
Some embodiments of the system of the present invention may further include a tire inside diameter detecting means for detecting a tire inside diameter from positional data or travel distance data of the three grip arms when the grip arms are gripping a tire. This allows not only acquisition of information from a tire identifier of a tire but also accurate measurement of the inside diameter of the tire. Hence, the possibility of rechecking the information on the tire identifier may further improve the accuracy of tire sorting.
Some embodiments of the system of the present invention may include a rotation radius changing means for changing the distance between the identifier reading means and the rotation axis of the holding unit and a detecting position control means for controlling the rotation radius changing means in such a manner as to move the identifier reading means to the position of the tire identifier based on the data of the tire inside diameter detected by the tire inside diameter detecting means. Thus, the rotation radius of the identifier reading means may be changed according to the tire size. Therefore, information may be read from the tire identifier even when there is a change in tire size.
Additional embodiments of the system of the present invention may provide a tire sorting apparatus that has a mounting means having a plurality of rotating bodies rotating in contact with the lower surface of the tire and a through hole through which the three grip arms may be extended toward the inner periphery of the tire.
In some embodiments of the system, devices to help in the compression of the tire stacks may be included. Some tire stacking systems, however, continue to rely heavily upon manual labor to accomplish the stacking of tires. For example, U.S. Pat. No.
5,697,294 issued to Keller et al. on December 16, 1997, ("Keller I") discloses an exemplary tire compression device and US. Pat. No. 5,816,142 issued to Keller et al. on October 6, 1998, ("Keller II") discloses another tire compression device intended for use with a forklift. Both Keller I and Keller II are incorporated by reference herein in their entireties. The Keller I
and Keller II devices allow a preset load to compress a stack of tires as the stack is loaded into a truck trailer. Initially, the forklift elevates and supports the preset load. Then, once tires are stacked beneath the elevated load, the forklift allows the load to be lowered against a stack of tires. As a result, the load exerts a downward pressure on the stack of tires, thereby compressing the tires. Once the initial stack is compressed, additional uncompressed tires are loaded on top of the stack until the stack reaches the ceiling of the truck trailer. Then, the forks of the forklift are raised, partially releasing the pressure applied against the compressed portion of the stack and allowing it to expand, while compressing the previously uncompressed portion until the entire stack is equally compressed. This process is repeated, stack by stack, until the entire trailer is full of stacked, compressed tires.
Other devices exist that load tires into a truck trailer and similarly compress tires within the trailer. In each of these cases, tires are maintained in compression by the storage and/or transportation vessel itself. However, no assurance exists that the vessel was designed or is suitable to maintain such loads. In fact, vessels are frequently damaged as a result of such use.
Various embodiments of the present invention include an apparatus for loading a tire onto a rack The apparatus includes an automated tire conveyor, one or more scanners, and one or more robots to pick the tires off of the conveyor. The system may additionally include an apparatus for unloading a rack of tires, which includes a load station configured with a lift. The lift raises a rack of tires to a platform, where an unloader may manually or automatically move tires from the rack to a conveyor.
Further, some embodiments of the present invention include methods and systems for sorting and unloading tires into a store or warehouse for storage and sale as well. For example, the systems for sorting and unloading tires may include one or more automated conveyors, scanners, and storage structures. For example, in the sorting system, the scanner may read information off of incoming tires and communicate the tire information to a system of conveyors, which in turn directs each tire to a specific storage structure based upon the tire information (e.g., size, type, etc.).
In various embodiments, drive-in storage may also be included in the conveyor system configured with one or more computing systems, such as those described herein, to communicate with other loading or unloading systems of the system disclosed herein. For example, an unloading system within the system disclosed herein may communicate with drive-in storage when a first rack, which is being unloaded, is all or partially-empty such that a second rack may be delivered from the drive-in storage to the unloader.
In another embodiment, an unloader or loader communicates with the drive-in storage when daily customer orders show that there is additional demand for a specific tire SKU
(i.e., stock control unit). The rack may then be pulled from the drive-in-storage using, for example, a pull system applying lean manufacturing principles.

In some embodiments, the conveyor system may also include a system for loading, sorting, or unloading tires. The system may be automated or computer controlled. The system may be used in a plant that manufactures tires, and sorts and stores tires coming off the assembly line, and then dispenses tires in a desired order for shipment.
Further, the system may also be used for loading and unloading articles or tires at a final destination, such as a tire shop or warehouse, where tires may be stored.
One aspect of the invention is a method for conveying articles up steep inclines. In one embodiment, the method for conveying articles up steep inclines comprises:
(a) conveying articles on the conveying surface of an endless conveyor belt along a steep incline in a direction of belt travel; (b) blocking conveyed articles from sliding down the conveying surface of the conveyor belt on the steep incline; and (c) restraining conveyed articles leaning away from the conveying surface with a restraining surface moving in the direction of belt travel to prevent the leaning articles from falling away from the conveying surface of the conveyor belt on the steep incline.
The present invention includes a method of packing tires that includes placing one or more rows of tires against a bottom frame, adding an intermediate frame on top of the one or more rows of tires, compressing the tires, and attaching a vertical member to the intermediate frame. The method additionally includes adding one or more additional rows of tires on top of the intermediate frame, adding a top frame, compressing the one or more additional rows of tires, and attaching a vertical member to the top frame.
By way of providing additional background, context, and to further satisfy the written description requirements of 35 U.S.C. 112, the following references are incorporated by reference in their entireties for the express purpose of explaining the nature of conveyors and to further describe the various tools, pieces, and other apparatuses commonly associated therewith:
US. Pat. Pub. No. 2012/0325903 to Takahashi describes a tire sorting apparatus for reliably reading information from a tire identifier, such as a barcode, formed on the surface of a tire without damaging the tire. Placed under a tire-mounting table is a tire grip that has three grip arms arranged circularly in a plane perpendicular to the tire center axis and link mechanisms for spreading the grip arms. Placed above the mounting table is a barcode reader rotating means for rotating a barcode reader held by a barcode reader holder. The rotation axis of the barcode reader is aligned with the center of the circle formed by the grip arms of the tire grip.

U.S. Pat. Pub. No. 2009/0148260 to Leimbach et al., which is incorporated herein by reference in its entirety, discloses a tire loading apparatus and method of packing tires that includes placing the tires in a rack, compressing the tires, and assembling the rack. The apparatus includes one or more conveyors, scanners, and robots that load tires from a conveyor to a rack. A tire unloading apparatus is also disclosed. The unloading apparatus includes a scissor mechanism to rise and lower tire racks to an unloading platform. The unloading apparatus additionally includes one or more unloaders and conveyors.
The sorting and unloading of tires is accomplished with one or more automated conveyors, scanners, and storage structures for reading information from incoming tires and using the tire information to sort and store the tires. A rack to improve compression and support of tires during storage and shipment is also disclosed.
U.S. Pat. No. 6,97,499, issued to Leimbach, et al. on March 4, 2003, ("Leimbach") discloses an example of a tire loading system The unloading system and method described herein may include features or steps (which may be in any order) described in Leimbach, which is incorporated by reference in its entirety.
U.S. Pat. Pub. No. 2010/004399 to Terazono discloses bead core and a bead filler and is incorporated by reference in its entirety.
U.S. Pat. Pub. No. 2012/0092149 to Fujisawa discloses an inspection apparatus arranged with a plurality of cameras located at relatively displaced circumferential positions and set for the respective shooting positions different from each other in the axial direction of the tire. Thus the images of the inner circumferential surface of the tire are shot by the plurality of cameras as the tire is rotated circumferentially relative to the plurality of cameras. Fujisawa is incorporated herein by reference in its entirety.
U.S. Pat. Pub. No. 2011/0013177 to Crim discloses an apparatus and method for verifying a laser etch on a rubber sample. In one embodiment, the apparatus includes a tire production line, a sample holding device, a laser haying a diode, and a servo-assembly. The laser of the apparatus is configured to etch indicia on a sidewall of a tire on the tire production line and is further configured to etch at least one line in a rubber sample on the sample holding device. Crim is incorporated herein by reference in its entirety.
U.S. Pat. No. 7,249,496, issued to Kunitake, et al. on July 31, 2007, ("Kunitake") discloses an uniformity inspection line with a decision-only line having first UF machines exclusive for the measurement of the uniformity of a tire sorted and distributed on an automatic sorting line and a correction-only line haying second UF machines for the correction and re-measurement of the uniformity characteristics of a tire having uniformity characteristics outside specific values measured on the above decision-only line. Kunitake is incorporated herein by reference in its entirety.
U.S. Pat. No. 7,340,946, issued to Gotou, et al. on March 11, 2008, and U.S.
Pat.
Pub. No. 2007/0084275 to Gotou, et al. disclose a method and a device for inspecting a tire, the method comprising the steps of, in a rim assembly station separated from an inspection station having a tire inspector installed thereon, forming a rim/tire assembly in a setup by assembling one side and the other side rims and with an inspected tire and, when an inspection is performed, transforming the rim/tire assembly from the rim assembly station to the tire inspector on the inspection station, whereby a preparatory operation time in the tire inspector can be shortened to shorten a cycle time. The Gotou patent and Gotou publication are incorporated herein by reference in their entireties.
U.S. Pat. No. 7,487,814, issued to Mizota on Feb. 10, 2009, discloses an object to provide a tire reinforcing layer forming device which can form, by a single device, plural reinforcing layers whose cord directions intersect one another. A reinforcing material piece, which is distributed to an upper conveying path, is affixed from a left end side of a drum toward a right side, while the drum is rotated in a direction of arrow CW.
Mizota is incorporated herein by reference in its entirety.
U.S. Pat. No. 7,347,317, issued to Aizawa, et al. on March 25, 2008, discloses methods and devices for measuring elongation, wear, and internal temperature of a conveyor belt to catch signs of conveyor belt failure such as breakage by detecting a magnetic field from a magnetic body by using a magnesium sensor, as well as a rubber magnet sheet as a magnetic body and a method of producing the sheet, the rubber magnet sheet being able to be used while it is embedded in the conveyor belt. Aizawa is incorporated herein by reference in its entirety.
U.S. Pat. No. 7,543,698, issued to Haskell on June 9, 2009, and discloses an article elevator for moving lightweight open ended containers from a first level to a second level vertically spaced from the first level and is incorporated herein by reference in its entirety.
The article elevator includes an input section at the first level for receiving container bodies.
An elevator section is positioned for receiving container bodies from the input section. A
discharge section is located at the second level for receiving container bodies from the elevator section. A plurality of arms is movably mounted above the input section, the elevator section, and the discharge section. Each of the arms moves a group of container bodies from the input section over the elevator section to the discharge section so that successive groups of container bodies are moved to the discharge section from the input section.
U.S. Pat. No. 3,910,405, issued to Couperus, et al. on Oct. 7, 1975, and discloses a belt elevator for elevating loose bulk material from one level to another. The belt elevator comprises a pair of cooperating endless belt conveyors whose forward runs are juxtaposed to face one another with an edge of one in sealing engagement with the other, the material being retained therebetween. A first belt conveyor is provided with raised edges which engage and seal with the edges of the other. The first conveyor is also provided with generally evenly spaced transversely positioned cleats or raised portions which, together with the raised edges, forms pockets to contain material being elevated. The stiffness of the first belt conveyor is greater than that of the second belt conveyor. The second belt conveyor is troughed at the entry portion for receiving the material to be elevated which material is discharged from the first belt conveyor at a discharge point at the higher level The belts are maintained in tension to insure edge engagement and the retention of material therebetween.
Couperus is incorporated herein by reference in its entirety.
Receiving hoppers and varying numbers of cleats may be used to convey loose material such as dirt, stones, etc. Additionally, the cleats may be about 20 to 30 inches apart in the direction of belt travel, or preferably 24 inches apart. In an alternate embodiment, the cleats may be about 50 to 70 inches apart in the direction of belt travel, or preferably 60 inches apart. If an article is conveyed, the cleats may be spaced apart between about 1.0 and about 2.0 times the length of the article conveyed, or preferably between about 1.25 and about 1.75 times the length of the article conveyed, or more preferably about 1.5 times the length of the article conveyed.
The conveyor may include handles and a dolly with wheels to promote movability of the conveyor. The handles can be any size, shape, or material known in the art. For example, the handles may be metal or metal with rubber coatings. The handles may be bar-like, round, or square. The dolly can contain one or more wheels and will have at least one leg or axel.
Different numbers of cleats or support elements can be used together to convey an article. Typically, the taller the cleat is, the fewer cleats need to be used.
For example, one tall (8.0 inch) cleat can be used to convey an article, where as two or three short (1.25 inch) cleats may be needed to convey an article.
U.S. Pat. Pub. No. 2007/0135960, to Shibao et al., discloses a production evaluation managing system in a factory including facilities in a plurality of production processes from materials to products and a means for evaluating the products based on at least one of inspection and testing characterized by comprising a network connecting the facilities in respective production processes with the evaluating means, and a means for collecting through the network field data of the facility in a production process pertaining to the production of a product corresponding to the information of evaluation results, based on the information of evaluation results of the products outputted from the evaluating means. By this, when a nonconformity is found from the information of evaluation results based on at least one of inspection and testing of the product, field data of the facility in a production process pertaining to production of a product corresponding to the information of evaluation results can be collected and analyzed immediately and the problem with the production process can be investigated immediately in a short time. Shibao is incorporated herein by reference in its entirety.
US Pat Pub Na 2007/0289847 to Nakamura is incorporated herein by reference in its entirety and discloses a rubber member conveying device and a rubber member supplying system. The device and the system rapidly promote the shrinkage of the rubber member, thereby avoiding the length variation of the rubber member in the processing step for the rubber member. A rubber member supplying system comprises a belt conveyor which supplies a to-be-cut material having an internal strain, a cutter which cuts the to-be-cut material supplied by the belt conveyor to form a rubber member, and a rubber member conveying part which conveys the rubber members. The rubber member conveying part comprises an endless belt, and rollers supported by supporting parts that are provided at the endless belt. The rubber member is conveyed on the rollers while exposed to vibrations.
Accordingly, the shrinkage in the rubber member caused by the internal strain thereof is substantially completed in the conveying operation.
U.S. Pat. No. 4,534,461, issued to Silverthorn, et al. on Aug. 13, 1985, and discloses a conveyor construction for conveying materials, such as grain, to an elevated location. The conveyor construction comprises a base or supporting structure and an auger conveyor is mounted horizontally on the base. Grain is fed into a hopper at one end of the auger and the discharge end of the auger is provided with a pair of kicker paddles which propel the grain laterally into the lower end of a vertical endless belt conveyor. The endless belt conveyor includes a plurality of integrally molded cleats that convey the grain upwardly within a vertical passage in the conveyor housing and the grain is discharged from the upper end of the housing. The vertical conveyor is mounted for pivoting movement relative to the auger conveyor to adjust the angularity of the vertical conveyor. Silverthorn is incorporated herein by reference in its entirety.
U.S. Pat. No. 4,727,419, issued to Yamada, et al. on Feb. 23, 1988, and is incorporated herein by reference in its entirety. Yamada discloses a system in case of detecting tire information marks engraved in a side wall portion of tire in the form of protrusion or recess, width and inner diameter of tire are detected to provide a tire size signal, after a first camera head is driven into a given position in accordance with the tire side signal, an identification mark engraved in the size wall portion of tire is optically detected by the first camera head to derive a position signal, and after a second camera head is driven into a given position in accordance with the position signal, the tire information marks are optically detected by the second camera head to derive a tire information signal.
In this manner, the tire information marks can be detected in a rapid and accurate manner.
US. Pat. No. 4,700,078, issued to Mizuno, et al. on Oct. 13, 1987, and discloses a method and system for detecting tire information marks. Tire information marks for denoting tire kind, tire size, etc. formed in a surface of side wall of a tire as a protrusion or groove having a triangular cross section are optically detected by illuminating the surface of side wall of the tire from a first direction substantially perpendicular to the surface of the side wall of the tire and a second direction inclined with respect to the surface of the side wall of the tire, and picking up an image of the surface of the side wall of the tire thus illuminated from the two different directions to derive an image signal. The image signal thus derived is converted into a bivalent signal, and is thinned to produce a mark pattern.
Then the mark pattern is compared with a thick standard mark pattern. When a substantial part of the detected mark pattern is included in the standard mark pattern, the detected mark pattern is recognized to be identical with the standard mark pattern. Mizuno is incorporated herein by reference in its entirety.
U.S. Pat. No. 5,092,946, issued to Okuyama, et al. on Mar. 3, 1992, U.S. Pat.
No.
5,415,217, issued to Okuyama, et al. on May 16, 1995, and U.S. Pat. No.
5,194,107, issued to Okuyama, et al. on Mar. 16, 1993. The Okuyama patents disclose a method and an apparatus for sticking a belt-like member, wherein a belt-like member prepared by cutting a raw material of the belt-like member on a conveyor at two front and rear locations, is conveyed by the conveyor, wrapped around a cylindrical drum and stuck to the drum. The inclination angle of the cut line at the leading end of the belt-like member is measured at the time of cutting, the inclination angle of the cut line at the trailing end is measured at the time of cutting, and by comparing the inclination of the cut line at the trailing end with the inclination angle at the leading end, an amount of connection for the inclination angle is calculated. The three Okuyama patents are incorporated by reference herein in their entireties.
In one embodiment, the conveyor comprises an endless conveyor belt having an outer article-conveying surface. The conveyor belt advances in a direction of belt travel along a conveying path that includes a steeply inclined portion. The conveying belt also includes support elements that extend outward from the outer article-conveying surface of the conveyor belt at periodically spaced positions and retention means are disposed along the steeply inclined portion proximate the support elements prevent conveyed articles from falling away from the conveyor belt on the steeply inclined portion.
In various embodiments, the conveyor system comprises an endless conveyor belt having an outer article-conveying surface. The conveyor belt advances in a direction of belt travel along a conveying path that includes a steeply inclined portion The conveying belt further includes support elements that extend outward from the outer article-conveying surface of the conveyor belt. An article-restraining surface facing the article-conveying surface of the conveyor belt is positioned outward of the support elements across gaps along the steeply inclined portion of the conveying path. The article-restraining surface engages outwardly leaning conveyed articles moving upward on the steeply inclined portion of the conveying path in low-friction contact. The article-restraining surface may be the outer surface of a belt advancing in the direction of belt travel or the outer surfaces of an array of rollers rotating in the direction of belt travel on contact with outwardly leaning conveyed articles.
In one embodiment, the conveyor for conveying articles up inclines comprises:
an endless conveyor belt having an outer article-conveying surface and advancing in a direction of belt travel along a conveying path including an inclined portion; a plurality of support elements extending outwardly from the outer article-conveying surface of the conveyor belt and spaced apart at an increment approximately equal to about 1.5 times a length of the article conveyed, where the plurality of support elements comprises pairs of two support elements and each support element in the pair is positioned proximate to the other support element in the pair and with a space between the two support elements, where each support element comprises: curved section having an article-supporting face, which is curved at a first radius of curvature and is positioned in the direction of belt travel, and a back side opposite the article-supporting face, the back side is curved with a second radius of curvature, where the first radius of curvature is smaller than the second radius of curvature;

a block-like bottom section with a flat bottom that engages the outer article-conveying surface of the conveyor belt; and a top opposite the bottom, where the top is positioned at an angle relative to the flat bottom; two securing mechanisms for each support element to secure the support elements on the conveyor belt; a support frame with a support stand positioned proximate to a floor surface and support bars; a drive pulley interconnected to the support frame and positioned at the top of the support frame, where an underside of the conveyor belt engages an outer surface of the drive pulley; an idle pulley interconnected to the support frame and positioned at the bottom of the support frame, where an underside of the conveyor belt engages an outer surface of the idle pulley; and a motor for moving the conveyor belt around the drive pulley and idle pulley.
In a further embodiment, a first support element in one pair of support elements has an article-supporting face defining a first plane oblique to the direction of belt travel and a second support element in the pair of support elements has an article-supporting face defining a second plane oblique to the direction of belt travel. The first plane and the second plane intersect at a point on the conveyor belt below the first support element and the second support element. In another embodiment, the support elements are contoured in shape to mate with the conveyed article. In one embodiment, the support elements are made of an elastomeric material that conforms to the shape of a conveyed article on the inclined portion of the conveying path. In additional embodiments, the conveyor further comprising a retention mechanism for preventing the conveyed articles from falling off of the conveyor belt, said retention mechanism positioned along the inclined portion of the conveying path.
The conveyor may alternatively comprise an article-restraining surface positioned above and facing the article-conveying surface of the conveyor belt, where the article-restraining surface is spaced away from the support elements, and where the article-restraining surface engages outwardly leaning conveyed articles moving upward on the inclined portion of the conveying path in low-friction contact. In one embodiment, the inclined portion of the conveying path is approximately 60 degrees as measured from a horizontal plane. In some embodiments, the inclined portion of the conveying path is approximately 90 degrees as measured from a horizontal plane. The conveyor may be positioned at an inclined angle relative to the horizontal ground, i.e., between about 50 and substantially vertical or about 85 to 95 or the conveyor can be relative to the horizontal ground.
In one embodiment, a conveyor for conveying articles up inclines is provided, the conveyor comprising: an endless conveyor belt having an outer article-conveying surface and advancing in a direction of belt travel along a conveying path including an inclined portion; a plurality of support elements extending outwardly from the outer article-conveying surface of the conveyor belt and spaced apart at least a distance between about 1.0 and 2.0 times a length of the article conveyed on said conveyor belt, wherein each support element comprises: a upright section having an upper portion and an article-supporting face generally positioned in the direction of belt travel; a block-like bottom section with at least one hole and a flat bottom, wherein the bottom engages the outer article-conveying surface of the conveyor belt, and wherein the at least one hole is positioned proximate a leading edge of the support element; and a top positioned at the upper portion of the upright section and opposite the bottom, wherein the top has a flat surface substantially parallel to the flat bottom of the block-like bottom section; at least one securing mechanism for each support element to secure the support elements on the conveyor belt, wherein a portion of the securing mechanism is positioned in the hole of the block-like bottom section of the support element; a support frame with a support stand positioned proximate to a floor surface and support bars; a drive pulley interconnected to the support frame and positioned at the top of the support frame, wherein an underside of the conveyor belt engages an outer surface of the drive pulley; and an idle pulley interconnected to the support frame and positioned at the bottom of the support frame, wherein an underside of the conveyor belt engages an outer surface of the idle pulley.
In further embodiments, the inclined portion of the conveying path is approximately 90 degrees as measured from a horizontal plane. In some embodiments, the support frame comprises a substantially vertical portion connected on a top end to a curved portion, which is connected to a horizontal portion, and/or the conveyor further comprises a solid belt-carrying anti-friction surface positioned at the curved portion of the support frame. In some embodiments, the conveyor further comprises four separate return wheels to carry the conveyor belt over a return curved portion and back to a bottom of the support frame.
In one embodiment, a method for conveying articles up steep inclines is provided, the method comprising: providing a conveyor for conveying articles up an incline, said conveyor comprising: an endless conveyor belt having a lateral extent and a longitudinal extent, and an outer article-conveying surface that is designed to advance in a direction of belt travel along a conveying path including an inclined portion; a plurality of support elements, with each support element having a same width (w), length (1), and height (h), wherein each support element of said plurality of support elements is interconnected to said outer conveying surface by two independent fasteners that penetrate through said outer article-conveying surface, wherein each of said support elements has a front section having an article-supporting face that is oriented in the direction of belt travel, each of said support elements having a conveyor contacting surface that engages the outer article-conveying surface of the conveyor belt, each of said support elements constructed of urethane material that provides strength along the supporting elements, wherein a second support element in the plurality of support elements is spaced apart from a first support element in the plurality of support elements by a predetermined distance; a support frame with a support stand, said support frame having two, longitudinally extending side bar supports extending parallel to each other and connected to each other by a plurality of support struts; at least one pulley operably connected to said support frame that engages said conveyor belt; a motor operably connected to said at least one pulley; moving said endless conveyor belt in the direction of belt travel using the motor, the drive pulley, and the idle pulley; conveying articles on the outer article-conveying surface of the conveyor belt; advancing the conveyed articles in the direction of belt travel along a conveying path including the inclined portion; blocking conveyed articles from sliding down the conveying surface of the conveyor belt on the inclined portion by using said plurality of support elements; and removing the conveyed articles from the conveyor belt.
In some embodiments, the predetermined distance is between about 1.25 and 1.75 times a length of an article conveyed on said conveyor belt. In various embodiments, the conveyed articles are tires and/or the inclined portion of the conveying path is approximately 90 degrees as measured from a horizontal plane.
In some embodiments, a conveyor for conveying articles up inclines may comprise:
an endless conveyor belt having an outer article-conveying surface and advancing in a direction of belt travel along a conveying path; a plurality of support elements extending outwardly from the outer article-conveying surface of the conveyor belt and spaced apart at least a distance between about 1.0 and 2.0 times a length of the article conveyed on said conveyor belt, wherein each support element comprises: a support frame with a support stand and an H-stand, the support stand positioned proximate to a first floor surface and support bars and the H-stand positioned proximate to a second floor surface above the first floor surface; an idle pulley interconnected to the support frame and positioned at the bottom of the support frame, wherein an underside of the conveyor belt engages an outer surface of the idle pulley; and a drive pulley interconnected to the support frame and positioned at the top of the support frame, wherein an underside of the conveyor belt engages an outer surface of the drive pulley.

A first portion of the conveying path may be approximately 90 degrees as measured from a horizontal plane and a second portion of the conveying path may be approximately parallel to the horizontal plane. The support frame may comprise a substantially vertical portion connected on a top end to a curved portion, which may be connected to a horizontal portion. The support stand may be positioned at an end of the substantially vertical portion and the H-stand may be configured to support the horizontal portion.
In various embodiments, a method for conveying articles up steep inclines may comprise: providing a conveyor for conveying articles up an incline, said conveyor comprising: an endless conveyor belt having a lateral extent and a longitudinal extent, and an outer article-conveying surface that is designed to advance in a direction of belt travel along a conveying path including an inclined portion; a plurality of support elements, with each support element having a same width (w), length (1), and height (h), wherein each support element of said plurality of support elements is interconnected to said outer conveying surface by two independent fasteners that penetrate through said outer article-conveying surface, a support frame with a support stand and an H-stand, the support stand positioned proximate to a first floor surface and support bars and the H-stand positioned proximate to a second floor surface above the first floor surface; at least one pulley operably connected to said support frame that engages said conveyor belt; a motor operably connected to said at least one pulley; moving said endless conveyor belt in the direction of belt travel using the motor and the at least one pulley; conveying articles on the outer article-conveying surface of the conveyor belt; advancing the conveyed articles in the direction of belt travel along the conveying path including the inclined portion; blocking conveyed articles from sliding down the conveying surface of the conveyor belt on the inclined portion by using said plurality of support elements; and removing the conveyed articles from the conveyor belt.
A first portion of the conveying path may be approximately 90 degrees as measured from a horizontal plane and a second portion of the conveying path may be approximately parallel to the horizontal plane. The support frame may comprise a substantially vertical portion connected on a top end to a curved portion, which may be connected to a horizontal portion. The support stand may be positioned at an end of the substantially vertical portion and the H-stand may be configured to support the horizontal portion.
In various embodiments, a portable conveyor system for conveying articles up inclines may comprise: a conveyor comprising: a conveyor frame; a first pin disposed at an end of the conveyor frame; a pair of pulleys disposed at opposite ends of the conveyor frame;

a belt configured to revolve around the two pulleys; and at least one cleat disposed on an outer surface of the belt and configured to receive and move an object along the conveyor frame; a support arm having two frame members disposed opposite each other and a pair of arm brackets at an end of each of the two frame members, the support arm including a second pin and a third pin, the second pin received by a first arm bracket in the pair of arm brackets and the third pin received by a second arm bracket in the pair of arm brackets, wherein the third pin pivotably connects the support arm to the conveyor frame; and a portable base comprising a base frame, at least one wheel secured to the base frame, a first pair of brackets secured to the base frame, and a second pair of brackets secured to the base frame and opposite the first pair of brackets, the first pair of brackets configured to receive the first pin thereby pivotably coupling the conveyor to the portable base and the second pair of brackets configured to receive the second pin thereby pivotably connecting the support arm to the portable base The at least one wheel may be rotatable 360 degrees. The base frame may comprise at least one hollow tube configured to receive a fork of a forklift. The conveyor and the support arm may each be configured to move between a first position and a second position.
The support arm may be substantially parallel to the conveyor frame and the conveyor frame may be substantially parallel to the portable base when in the second position. The second pin may be unconnected from the portable base when the support arm is in the second position. The third pin may pivotably couple the support arm to the conveyor frame near a mid-section of the conveyor frame.
In some embodiments, a method for moving a portable conveyor system comprised:

removing a portable conveyor system from a shipping container, the portable conveyor system in a second position, the portable conveyor system comprising a conveyor; a support arm; and a portable base; the conveyor comprising a conveyor frame; a first pin disposed at a first end of the conveyor frame; a pair of pulleys disposed at the first end and a second end opposite the first end of the conveyor frame; a belt configured to revolve around the two pulleys; and at least one cleat disposed on an outer surface of the belt and configured to receive and move an object along the conveyor frame; the support arm comprising two frame members disposed opposite each other and a pair of arm brackets at the end of each of the two frame members; the support arm including a second pin and a third pin; the second pin received by a first arm bracket in the pair of arm brackets and the third pin received by a second arm bracket in the pair of arm brackets, wherein the third pin pivotably connects the support arm to the conveyor frame, and the portable base comprising a base frame; at least one wheel secured to the base frame; a first pair of brackets secured to the base frame;
and a second pair of brackets secured to the frame and opposite the first pair of brackets; the first pair of brackets configured to receive the first pin thereby pivotably coupling the conveyor to the portable base and the second pair of brackets; locking the at least one wheel to prevent movement of the portable base; lifting the conveyor, thereby pivoting the conveyor upwards from the portable base at the first pin and causing the support arm to pivot downwards from the conveyor at the third pin; removing the second pin;
aligning the second pair of brackets and one of the pair of arm brackets of the frame members; inserting the second pin through the second pair of brackets and the first bracket in the pair of arm brackets of the frame members; and securing the second pin to secure the portable conveyor system in a first position.
The pin may be secured using one or more cotter pins. The at least one wheel may be rotatable 360 degrees The base frame may comprise at least one hollow tube configured to receive a fork of a forklift. The support arm may be substantially parallel to the conveyor frame and the conveyor frame may be substantially parallel to the portable base when in the second position. The second pin may be unconnected from the portable base when the support arm is in the second position. The third pin may pivotably couple the support arm to the conveyor frame near a mid-section of the conveyor frame.
In various embodiments, a portable stand comprises: a support arm having two frame members disposed opposite each other and a pair of arm brackets at an end of each of the two frame members, the support arm including a second pin and a third pin, the second pin received by a first arm bracket in the pair of arm brackets and the third pin received by a second bracket in the pair of arm brackets, wherein the third pin pivotably connects the support arm to a conveyor frame of a conveyor; and a portable base having a base frame, at least one wheel secured to the base frame, a first pair of brackets secured to the base frame and a second pair of brackets secured to the base frame and opposite the first pair of brackets, the first pair of brackets configured to receive the first pin thereby pivotably coupling the conveyor to the portable base and the second pair of brackets configured to receive the second pin thereby pivotably connecting the support arm to the portable base.
The at least one wheel may be rotatable 360 degrees. The support arm may be configured to move between a first position and a second position. The support arm may be substantially parallel to a conveyor frame when in the second position. The second pin may be unconnected from the portable base when the support arm is in the second position. The third pin may pivotably couple the support arm to a conveyor frame near a mid-section of a conveyor frame.
While various configurations of the conveyor are herein specified, this description is only exemplary and is not intended to limit or otherwise narrow the invention. The conveyor may include any number of components in any potential combination thereof as desired for achieving the desired function for desired article shape and size and incline.
One or ordinary skill in the art will appreciate that embodiments of the present invention may be constructed of materials known to provide, or predictably manufactured to provide the various aspects of the present invention. For example, materials used in the support structure of the conveyor may include, for example, metal, composites, plastics, and other synthetic and natural materials. Further, the belt of the conveyor may be comprised of rubber, latex, synthetic rubber, synthetic materials, polymers, and natural materials.
As used herein, the term "a" or an entity refers to one or more of that entity As such, the terms "a" (or "an"), one or more and "at least one can be used interchangeably herein. It is also to be noted that the terms "comprising", "including", and "having" can be used interchangeably.
As used herein, "at least one, one or more, and "and/or" are open-ended expressions that are both conjunctive and disjunctive in operation. For example, each of the expressions "at least one of A, B and C", "at least one of A, B, or C", "one or more of A, B, and C", "one or more of A, B, or C" and "A, B, and/or C" means A alone, B
alone, C alone, A and B together, A and C together, B and C together, or A, B and C together.
The phrases "device", "apparatus", "conveyor", "conveyor apparatus", and "conveyor device" are used herein to indicate the invention device.
The phrase "removably attached", "removable", and/or "detachable" is used herein to indicate an attachment or connection of any sort that is readily releasable or disconnected.
This Summary of the Invention is neither intended nor should it be construed as being representative of the full extent and scope of the present invention.
The present invention is set forth in various levels of detail in the Summary of the Invention as well as in the attached drawings and the Detailed Description, and no limitation as to the scope of the present invention is intended by either the inclusion or non-inclusion of elements, components, etc. in this Summary of the Invention. Additional aspects of the present invention will become more readily apparent from the Detailed Description, particularly when taken together with the drawings.

The above-described benefits, embodiments, and/or characterizations are not necessarily complete or exhaustive, and in particular, as to the patentable subject matter disclosed herein. Other benefits, embodiments, and/or characterizations of the present disclosure are possible utilizing, alone or in combination, as set forth above and/or described in the accompanying figures and/or in the description herein below. However, the Detailed Description, the drawing figures, and the claims set forth herein, taken in conjunction with this Summary of the Invention, define the invention.
BRIEF DESCRIPTION OF THE DRAWINGS
Those of skill in the art will recognize that the following description is merely illustrative of the principles of the invention, which may be applied in various ways to provide many different alternative embodiments. This description is made for illustrating the general principles of the teachings of this invention and is not meant to limit the inventive concepts disclosed herein The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention and together with the general description of the disclosure given above and the Detailed Description of the drawings given below, serve to explain the principles of the disclosures.
Fig. 1 shows one embodiment of a nose-over vertical tire conveyor;
Figs. 2A and 2B show another embodiment of a nose-over vertical tire conveyor;
Fig. 3 shows the nose-over vertical tire conveyor of Figs. 2A-B conveying tires and with a stand and ramp on the second floor;
Fig. 4 shows the top end of the nose-over vertical tire conveyor of Figs. 2A-3 without the belt;
Fig. 5 shows the bottom end of the nose-over vertical tire conveyor of Figs.

without the belt;
Fig. 6 shows an embodiment of a nose-over vertical tire conveyor;
Fig. 7 shows an embodiment of a nose-over vertical tire conveyor;
Figs. 8A, 8B, 8C, and 8D show an embodiment of a cleat for a vertical tire conveyor according to embodiments of the present invention;
Fig. 9 is a front perspective view of a vertical tire conveyor according to embodiments of the present invention;
Fig. 10 is a front perspective view of the conveyor of Fig. 9 shown without the belt guard;

Fig. 11 is a front perspective view of the conveyor of Fig. 10 shown conveying tires;
Fig. 12A is a front perspective view of the conveyor of Fig. 10 shown without the conveyor belt;
Fig. 12B is a zoomed in view of the upper or top end of the conveyor of Fig.
12A;
Fig. 13 is a front perspective view of the conveyor of Fig. 12A shown with the solid belt-carrying anti-friction surface removed to show the belt return carrying surface;
Figs. 14A and 14B are rear perspective views of the conveyor of Fig. 10 shown without the conveyor belt such that the mechanism by which the belt returns inside the conveyor frame can be seen;
Figs. 15A and 15B show the standalone return wheel assembly;
Fig. 16 shows a belt tracking aid called a belt liner;
Figs 17A, 17B, 17C, and 17D show a cleat for a vertical tire conveyor according to embodiments of the present disclosure;
Fig. 18 is a front perspective view of a nose-over vertical tire conveyor according to embodiments of the present disclosure;
Fig. 19 is a zoomed in view of a first end of the conveyor of Fig. 18;
Fig. 20 is a zoomed in view of a second end of the conveyor of Fig. 18;
Fig. 21 is another zoomed in view of the second end of the conveyor of Fig.
18;
Fig. 22A is front perspective view of a conveyor on a portable stand in a first position according to at least one embodiment of the present disclosure;
Fig. 22B is another front perspective view of the conveyor on the portable stand of Fig. 22A;
Fig. 23A is a front perspective view of the conveyor on the portable stand of Fig.
22A in a second position;
Fig. 23B is a side view of the conveyor on the portable stand of Fig. 22A in the second position;
Fig. 24A is a front perspective view of the portable stand of Fig. 22A; and Fig. 24B is a side view of the portable stand of Fig. 22A.
It should be understood that the drawings are not necessarily to scale, and various dimensions may be altered. In certain instances, details that are not necessary for an understanding of the invention or that render other details difficult to perceive may have been omitted. It should be understood, of course, that the invention is not necessarily limited to the particular embodiments illustrated herein.

DETAILED DESCRIPTION
The invention described herein relates to a conveyor used in any application where an article (such as a tire) may need to be transported or lifted more than five feet. Such applications include moving tires and articles during manufacture, after manufacture to be shipped, loading tires and articles on the shipping vessels, unloading the tires and articles off of the shipping vessels, and moving the tires and articles within stores and warehouses to their final storage place.
It should be appreciated that the particular implementations and embodiments shown and described herein are illustrative of the invention and are not intended to otherwise limit the scope of the present invention in any way. Indeed, for the sake of brevity, trivial and conventional features and aspects of the present invention are not described in extensive detail herein. It should be understood that the legal scope of the description is defined by the words of the claims set forth at the end of this disclosure The detailed description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible.
Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims. Furthermore, the connecting lines shown in the various figures shown herein are intended to represent exemplary functional relationships and/or physical couplings between the various elements of the system. It should be noted that many alternative or additional functional relationships or physical connections may be present in a practical conveyor apparatus, conveying system, conveying method, tire sorting system, and tire loading system.
Figure 1 shows one embodiment of a nose-over vertical tire conveyor 100. The nose-over vertical tire conveyor 100 is very compact with a small footprint and suitable for retrofitting spaces such as tire service areas. Such conveyors may be used to move, for example, tires bottom to top or top to bottom of the conveyor. In other words, the conveyor may be used to move tires from a first floor to a second floor or from the second floor to the first floor. The VTC 100 includes a frame 106 with a stand 104, which may be a base plate bolted-down to the ground floor 102, at the bottom end 108. The frame 106 may be comprised of high-strength steel tubing on approximately 60" centers, in some embodiments. The VTC 100 extends from the ground floor 102 to the mezzanine (or second) floor 110. The height H1 between the ground floor 102 and mezzanine floor 110 can vary, but the embodiment shown contemplates a height H1 of about 10.0 ft, or between about 8.0 ft. and 14.0 ft.
The VTC 100 has a belt (not visible in this view) with cleats 112 interconnected thereto, a belt take-up adjuster, belt take-up adjustment frames 114, a motor 116, and an H-stand 120. The belt can be between about 10" and about 20" wide. In a preferred embodiment, the belt is about 18" wide. The cleats 112 can be any known cleats 112, but are preferably between about 4" tall and 7" tall. In a preferred embodiment, the cleats are 6"
high/tall urethane cleats that are bolted onto the belt.
The motor 116 can be any known motor, but is a 15V motor in some embodiments.
The motor 116 may be interconnected to one or more roller chains, sprockets, and safety guards. The roller chains may be speed reducer roller chains in some embodiments. Thus, the roller chain transfers power between the speed reducer and the drive shaft positioned through the drive pulley, via sprockets In some embodiments, the nose-over VTC
100 has a right-angle speed reducer that is mounted under the conveyor frame at the top end 122. In other embodiments, the nose-over VTC 100 has an in-line motor and speed reducer mounted under the conveyor frame. However, either of these motors and speed reducers could be used in any conveyor described herein.
The H-stand 120 positions the top end 122 of the conveyor 100 at the desired height H2 above the mezzanine floor 110. In some embodiments, this height H2 is between about 2.0 ft. and about 5.0 ft. In a preferred embodiment, the height is about 4.0 ft. or about 4 ft.
1 in. The conveyor 100 extends a length L2 horizontally along the mezzanine floor 110. In some embodiments, this length L2 is between about 4 ft. and 7 ft. In a preferred embodiment, this length L2 is between about 5 ft. and about 6 ft. In a more preferred embodiment, this length L2 is about 5.5 ft.
The depth or length Li of the conveyor can vary. In some embodiments, the length Li is between about 10" and about 14". In a preferred embodiment, the length Li is about 11-1/8". The conveyor 100 needs more floor space than the length Li because it must accommodate the articles being conveyed and any hand rails added to the frame to protect and enclose the articles being conveyed. Thus, the length L3 is the amount of floor space needed by the VTC 100. In some embodiments, the length L3 is between about 2 ft. and about 4 ft. In a preferred embodiment, the length L3 is about 30- (2.5 ft.).
If an opening in the mezzanine floor 110 is necessary for the conveyor 100 to extend from the ground floor 102 to the mezzanine floor 110, then¨assuming the hole has a rectangular shape¨the opening should extend the length L3 in one direction and should be a few inches larger than the diameter of the largest conveyed tire or article in the other direction.
The perimeter of an opening in the mezzanine floor 110 should have a hand rail extending around the entire perimeter for safety reasons.
Similar to other conveyors described herein, the conveyor 100 can be comprised of two sections bolted together at a double rail or double square portion 118, which could be positioned at either location shown in Fig. 1. Having the conveyor frame 106 be comprised of two pieces makes installation and transportation of the conveyor easier.
Figures 2A-B show another embodiment of a nose-over vertical conveyor 200.
Fig.
2A is a perspective view and Fig. 2B is a side view of the conveyor 200. The conveyor 200 comprises a frame 206 and belt 224 with cleats 212. The bottom end 208 is the idle end and the upper end 210 is the drive end in this embodiment because the motor 216 is positioned at the top drive end 210. The motor 216 is interconnected to the drive pulley via a roller chain or drive belt (not visible in this view) and sprockets Thus, proximate the motor 216 and covering the roller chain and sprockets is a guard 202. The motor 216 can be an electric motor and include a speed reducer in some embodiments. The motor can be positioned at the bottom end 208 in other embodiments. The bottom end 208 includes a stand 204 that can be bolted to the floor. The idle pulley 228 is positioned at the bottom idle end 208 with the belt tension adjustment mechanism 218.
The nose over conveyor 200 also includes one or more belt return rollers 226 to direct and guide the belt 224 in the proper direction, i.e., around the 90 bend. In these views, the returning belt 224A (i.e., the portion of the belt not conveying articles and moving from the drive end to the idle end) and the returning cleats 212A (i.e., the cleats not conveying articles and moving from the upper end 210 to the bottom end 208) can be seen.

Additionally, the horizontal portion 214 of the conveyor 200 is typically the portion positioned on the second floor or mezzanine. The horizontal portion 214 may have the belt 224 positioned at a downward angle relative to the horizontal plane in order to eject or drop conveyed articles (e.g., tires) off of the conveyor without a person having to take the article off of the conveyor 200.
Figure 3 shows the nose-over vertical tire conveyor 200 of Figs. 2A-B
conveying tires 300 and with an H-stand 308 and a ramp 302 on the second floor 304. The ramp 302 may be a plurality of gravity rollers at the top discharge end 210 to assist in removing the tires 300 from the conveyor 200. The bottom idle end 208 is positioned on the ground 306.
Figure 4 shows the top end of the nose-over vertical tire conveyor of Figs. 2A-without the belt and Fig. 5 shows the bottom end of the nose-over vertical tire conveyor of Figs. 2A-3 without the belt. In Figs. 4 and 5 the idle pulley 228 and the drive pulley 232 are visible. Additionally, the belt return rollers 226 can be seen.
Figure 6 is a perspective view of the nose-over vertical tire conveyor of Figs. 2A-5 with the ramp 302 at the end of the discharge end 210. Here the ramp 302 is shown with gravity rollers or bars 310 to slide the tires 300 or articles off of the conveyor 200 and onto the mezzanine floor 304. One advantage of the nose-over vertical tire conveyor 200 is that minimal ground floor clearance is required.
Figure 7 shows another embodiment of a nose-over vertical tire conveyor 700.
The conveyor 700 has a frame 706 with a stand or base 704 on the bottom idle end 708. The conveyor 700 also has a conveyor belt 724 with cleats 712 interconnected to the belt 724.
The top drive end 710 has a motor 716 and a guard 702 covering the drive belt or chain and sprocket. The embodiment shown also includes a ramp (also called a "staging platform"
herein) 736 at the end of the conveyor's top or discharge end 710_ The ramp 736 can have gravity rollers or bars 4807 to slide the tires 4400 or articles off of the conveyor 700 and onto the mezzanine floor 734. The conveyor 700 includes an H-stand at the discharge end 710 to position the discharge end 710 at the proper height above the mezzanine floor 734 and to support the discharge end 710. The staging platform 736 may not extend all the way down to the mezzanine floor 734 and, instead, may have a second stand 4874 on the end of the staging platform 736 opposite the conveyor 700. The staging platform 736 can vary in length L5 depending on the end user's needs. For example, the length L5 of the staging platform 736 is between about 2.0 ft and about 5.0 ft. in some embodiments. In a preferred embodiment, the length L5 of the staging platform 736 is about 36" (3 ft.).
One advantage of the staging platform 736 is that it provides for safe unloading of articles and safe loading of articles (i.e., loading for descent). The staging platform 736 also keeps operators clear of moving drive parts in the drive end 710 and away from the mezzanine edge.
The height H1 of the mezzanine floor 734 above the ground floor varies depending on the installation location and the conveyor 700 can vary as well. However, in the embodiment shown the height H1 is between about 6.0 ft. and about 12.0 ft. In one embodiment, the height H1 of the mezzanine floor 734 above the ground floor is about 8.0 ft.
Another advantage of the nose-over VTC 700 is that it has a small base footprint and can be confined within a distance L4 of the mezzanine's edge, which means it is clear of bay work areas and is positioned around fire sprinkler water lines 738 and other electrical lines. In some embodiments, the distance L4 of the edge of the base stand 704 to the mezzanine edge is between about 12" and about 36". In a preferred embodiment, the distance L4 of the edge of the base stand 704 to the mezzanine edge is about 24". On the ground level, the conveyor 700 has easy and clear access to the loading face of the conveyor 700.
In some embodiments, the conveyor 700 has controls on both ends 708, 710 of the conveyor, e.g., up, down, and emergency stop. In various embodiments, the motor 716 is a 115 VAC motor with a speed reducer and safety guards 702. Thus, the conveyor requires minimal ground floor clearance next to the mezzanine and is also capable of clearing existing structures such as fire service lines and electrical lines.
The top-end nose over allows for easy unloading (or loading for descent) of tires or other articles and keeps the operator clear of moving conveyor parts and the mezzanine edge.
Figures 8A-D show an embodiment of a cleat 800 for a vertical tire conveyor according to embodiments of the present invention Specifically, Fig 8A is a perspective view of the cleat 800, Fig. 8B is a top plan view of the cleat 800, Fig. 8C is a side view of the cleat 800, and Fig. 8D is a rear view of the cleat 800. In some embodiments, the cleat shown is for a nose-over vertical tire conveyor; however, the cleat can be used with other vertical and incline or non-vertical conveyors.
In some embodiments, the cleat 800 is a 4.0" tall cleat. In other embodiments, the cleat 800 is a 2.0" cleat, a 5.0" cleat, a 6.0" cleat, an 8.0" cleat, or any height between 3.0"
and 8.0". The cleat 800 may also include holes 802 for bolts or other attachment or interconnection mechanisms. In one embodiment, the holes 802 have a diameter between about 1/8" and 1". In a preferred embodiment, the holes 802 have a diameter of about 0.28".
The cleat 800 can have a flat lower area 804 (also called a "block" herein) or a curved block 804. In one embodiment, the under surface 806 of the block 804 has a radius of curvature R6 between about 4" and about 8" and the block 804 has a width W1 between about 1.5"
and about 3.5". In a preferred embodiment the under surface 806 of the block 804 has a radius of curvature R6 of about 6.0" and the block 804 has a width of 2.5".
The block can have a flat or a curved upper surface 808. In one embodiment, the height H2 of the block 804 (i.e., from the under surface 806 to the upper surface 808) is between about 1/2" and about 1.0". In a preferred embodiment, the height H2 of the block 804 (i.e., from the under surface 806 to the upper surface 808) is about 3/4-. The outer edge of the block 804 can have a square corner or a rounded corner. In one embodiment, the radius of curvature R5 of the corner of the block 804 is between about 1/16" and about 1/2". In a preferred embodiment, the radius of curvature R5 of the corner of the block 804 is about 1/4".

In some embodiments, the cleat 800 also has a curved section 810. The curved section 810 has a back side 812 (i.e., the side facing away from the article conveyed) and an article-supporting face (also called a "carrying surface") 814 positioned opposite the back side 812. In one embodiment, the article-supporting face 814 has a larger radius of curvature R7 than the radius of curvature R8 of the back side 812. Thus, the radius of curvature R7 of the article-supporting face 814 may be between about 5.0" and about 12.0" and the radius of curvature R8 of the back side 812 may be between about 4.0" and about 12.0"
in some embodiments. In a preferred embodiment, the radius of curvature R7 of the article-supporting face 814 is about 9.0" and the radius of curvature R8 of the back side 812 is about 8.0".
The cleat 800 also has atop 816 and sides 818. In one embodiment, the height from the under surface 806 to the top of the top 816 is between about 3.0" and about 6.0".
In a preferred embodiment, the height H1 from the under surface 806 to the top of the top 816 is about 4.0". In one embodiment, the length Li from one side 818 to the other side is between about 2" and about 5". In a preferred embodiment, the length Li from one side 818 to the other side is about 3.25". Additionally, the top 816 may be flat or curved.
In one embodiment, the entire width W2 of the cleat 800 is between about 1.0"
and about 5.0". In a preferred embodiment, the width W2 of the cleat 800 is about 2.98". Further, the holes 802 are positioned a distance W3 from the edge of the block 804, where the distance W3 is between about 0.5" and about 2". In a preferred embodiment, the holes 802 are positioned a distance W3 from the edge of the block 804, where the distance W3 is about 1.13". Additionally, the holes 802 are positioned a distance W4, W5 from the side 810, where the distance W4, W5 is between about 1/4" and about 1". In a preferred embodiment, the holes 802 are positioned a distance W4, W5 from the side 810, where the distance W4, W5 is about 0.56". The cleat 800 can be urethane or any known material in the art. The cleat 800 may have a narrow width Li and radius edges 5150 to prevent damage to the conveyed tires' inner beads.
Figure 9 is a perspective front view of a vertical nose over conveyor 900 according to embodiments of the present invention. Figure 10 is similar to the conveyor of Fig. 9 but without the belt guard 901. The conveyor 900 comprises a conveyor belt 906 that revolves around two pulleys 920 (visible in Fig. 12A), one each at a top end 903 and a bottom end 905. Cleats 904 are secured to the conveyor belt 906 at intervals and are used to carry tires 300 up and down along the conveyor frame 922. Fig. 9 is a "non-use" form with a belt guard 901 placed on the conveyor 900 at the bottom end 905 to prevent personnel from getting entangled with the belt cleats 904. The conveyor belt 906 and conveyor frame 922 are narrower than in previous nose-over designs in order to minimize the conveyor footprint.
The conveyor 900 also includes a motor 950 interconnected to the one of the pulleys 920 pulley via a roller chain or drive belt 924 (visible in Fig. 13) and sprockets 930. Thus, proximate the motor 950 and covering the roller chain and sprockets is a guard 980. The motor 950 can be an electric motor and include a speed reducer in some embodiments. The motor 950 is positioned near the top end. The motor 950 can be positioned at the bottom end 903 in other embodiments. The bottom end 903 includes a stand 912 that can be bolted to the floor. The conveyor 900 also includes a motor cage 972 on which the motor 950 may be positioned. The top end 905 includes an extension 902 of the frame 922. The extension 902 may comprise a pair of U-shaped tubing extending from the frame 922 at the top end 905 to prevent a user from contacting the top end 905 (including cleats 904) In some embodiments the extension 902 may not be U-shaped and may be any shape extending from the top end 905. In some embodiments, the extension 902 may extend from the top end 905 and the motor frame 972. In other embodiments, the conveyor 900 may not include the extension. It will be appreciated that any conveyor described herein may comprise the extension 902.
Figure 11 shows the conveyor of Fig. 10 conveying tires 300.
Figure 12A is a perspective front view of the conveyor of Figs. 10 and 11 shown without the conveyor belt 906. Fig. 12B is a zoomed in view of the top end of the conveyor 900 of Fig. 12A. In this embodiment, the upper rounded part of the conveyor frame 922 has a different belt-carrying surface 926 than other embodiments. Specifically, the conveyor frame 922 has a solid sheet or plate 926 at the curved upper end of the frame 922, whereas the belt-carrying surface on the vertical portion of the conveyor frame is tubular rails 928.
In other embodiments, for example the conveyor frame 206 shown in Fig. 4, the top carrying surface is a continuation of the vertical tubular rails around the curve of the frame 206. The solid belt-carrying surface 926 at the upper curved portion of the frame 922 in Figs. 12A-B
is an anti-friction surface that supports the belt 906 around the curve. The reduced friction at the curve reduces wear on the belt 906 as well as reduces wear on the drive components of the conveyor 900 (e.g., motor, gearbox, roller chain, sprockets, etc.). In one embodiment, the anti-friction surface is UHMW (ultra-high-molecular-weight) polyethylene.
In other embodiments, the anti-friction surface may include other engineered plastics that have a favorable low coefficient of friction and abrasion-resistant properties.

Figure 13 shows the conveyor frame 922 of Fig. 12A with the solid belt-carrying anti-friction surface 926 removed to show the belt return carrying surface that is contained within the conveyor frame 922.
Figure 14A is a rear perspective view of the conveyor 900 of Figs. 9-13 shown without the conveyor belt 906 such that the mechanism by which the belt returns inside the conveyor frame 922 can be seen. In other embodiments, the belt 906 was carried by a series of rollers, where each roller had a shaft that was mounted in plates on both sides of the conveyor frame. In the small footprint, vertical, nose-over conveyor of Figs.
9-14B, the conveyor 900 has four separate return wheels 932 (an additional return wheel is adjacent to the visible return wheels 932) to carry the belt over the conveyor curve and back to the bottom of the conveyor frame. In other embodiments, the conveyor 900 may have less or greater than four wheels. Each return wheel 932 has its own shaft 934, bearing, and base 936, as well as a mounting bracket 938 designed with an important belt tracking feature Figure 14B is an enlarged view of the top of the conveyor of Fig. 14A and shows how the return wheel assembly 932 is mounted inside the conveyor frame 922.
When the return wheel assembly 932 is installed, it rests on a shelf 940 that is a part of the conveyor frame 922 and uses two fasteners (in the embodiment shown, socket head cap screws) to fix the return wheel assembly 932 to the conveyor frame 922. When tightened, the two fasteners oppose each other about a fulcrum 942 (i.e., the bar-shaped feature seen in Fig. 15A), allowing the return wheel assembly 932 to pivot in order to influence the belt motion with the goal of centering the belt 906 within the frame 922. Fig. 14B also shows added nose loops, which help protect personnel from the belt cleat at the top end of the conveyor.
Figures 15A and 15B show the standalone return wheel assembly 932. Fig. 15A is a perspective front view and Fig. 15B is a perspective rear view of the standalone return wheel assembly 932. In some embodiments the standalone return wheel assembly 932 is adjustable so as to adjust a steering of the belt. However, in other embodiments, the standalone return wheel assembly 932 is not adjustable and thus, may comprise less parts. For example, the base 936 may be integrated with the mounting bracket 938.
Figure 16 shows an additional belt tracking aid¨sometimes called a belt liner 944.
The belt liner 944 has three components: a roller 946, a shaft 948, and bracket 951. The three components are shown assembled. The belt liner 5444 places hard limits on the belt's ability to track away from center and is a secondary measure to aid in ideal belt tracking. In other words, the belt liner 944 prevents the belt from moving too far away from an end of the frame 922.

Figures 17A-D show another embodiment of a cleat 904 (also called a support element herein) and an improved version of the cleat shown in Figs. 8A-D. The cleat 904 of Figs. 17A-D fastens to the conveyor belt at the leading edge 906 of the cleat 904. With the cleat 904 fastened in this way, along with its long base 908, the cleat 906 can better support a heavy tire being conveyed vertically without causing the belt 906 to fold back on itself.
This design supports the goal of having a minimally tensioned belt, which increases the life of conveyor components. The cleat 904 is also designed to aid in tire disengagement at the top end of the conveyor 900 by minimizing the tire contact area as the cleat 904 approaches the top belt pulley 920.
Figure 18 shows a perspective front view of another vertical nose over conveyor 1800. The conveyor 1800 is generally the same as or similar to the conveyors 100, 200, 700, 900 described above. The conveyor 1800 comprises a frame 1802 extending from a first end 1804 to a second end 1806, a first pulley (not visible) positioned at the first end 1804, a second pulley (not visible) positioned at the second end 1806, a motor 1808 configured to drive the second pulley, a belt 1810 that rotates around each of the first pulley and the second pulley, and cleats 1812 attached to the belt 1810. As previously described, the conveyor 1800 may be used to move objects, such as tires 300, from the first end 1804 to the second end 1806.
In some embodiments, the conveyor 1800 may comprise a horizontal extender 1814 which may extend the second end 1806 horizontally away from the first end 1804. The horizontal extender 1814 may be, for example, between about lft to 5ft. In other embodiments, the horizontal extender is about 1.0ft, 1.25ft, 1.5ft, 1.75ft, 2.0ft, 2.25ft, 2.5ft, 2.75ft, 3.0ft, 3.25ft, 3.5ft, 3.75ft, 4.0ft, 4.25ft, 4.5ft, 4.75ft, 5.0ft, or any range therebetween.
In other embodiments, the horizontal extender 1814 may be less than lft or greater than 5ft.
In some embodiments, the horizontal extender 1814 enables a middle, vertical portion 1816 of the conveyor 1800 (and thus, also the first end 1804) to be positioned away from the mezzanine floor. In such embodiments, the horizontal extender 1814 may enable space between the middle, vertical portion 1816 and a wall or support for the mezzanine floor such that a user can walk underneath the horizontal extender 1814 and behind the middle, vertical portion 1816. In other embodiments, the horizontal extender 1814 may, for example, position an unloading zone of the second end 1806 away from an edge of the mezzanine and may keep users a safe distance away from the edge.
The conveyor 1800 may also comprise an extension 1818 extending from the second end 1806 of the frame 1802. The extension 1818 may provide clearance for a cleat 1812 as the cleat 1812 rotates around the pulley. The extension 1818 may comprise a pair of U-shaped tubing extending from the frame 1802 at the second end 1806 to prevent a user from contacting the second end 1806 (including cleats 1812). In some embodiments the extension 1818 may not be U-shaped and may be any shape extending from the second end 1806. For example, the extension 1818 may be sized so as to cover a profile of a cleat 1812 rotating around the pulley. In some embodiments, the extension 1818 may extend from the second end 1806 and motor frame 1820. In other embodiments, the conveyor 1800 may not include the extension. It will be appreciated that any conveyor described herein may comprise the extension 1818.
The conveyor 1800 may also comprise one or more panels 1822 coupled to the frame 1802. The one or more panels 1822 may prevent a user from contacting moving parts within the frame 1802 such as the belt 1810, cleats 1812, pulleys, or any other component of the conveyor 1800 In the illustrated embodiment the one or more panels 1822 comprise a side panel 1822, though it will be appreciated that in other embodiments the one or more panels 1822 may comprise more than one panel and may cover any portion of the conveyor 1800.
The one or more panels 1822 may also provide a surface to mount controls, decals (e.g., safety decals, operating decals, etc.), hooks, or any other component thereon.
For example, a control box may be mounted near the first end 1804 or the second end 1806 of the conveyor 1800. The one or more panels 1822 may comprise sheet metal, though the one or more panels 1822 may comprise any other material. The one or more panels 1822 may be welded to the frame 1802, though in other embodiments the one or more panels 1822 Turning to Figure 19, an adjustable base 1824 of the conveyor 1800 is shown in detail. The adjustable base 1824 may comprise a stand 1826 which may be bolted to a floor.
The adjustable base 1824 may also comprise a first tubing 1828 extending from the stand 1826 and a threaded rod 1830 extending from the first tubing 1828. In some embodiments, the threaded rod 1830 and the first tubing 1828 are integrated. In other embodiments, the threaded rod 1830 and the first tubing 1828 are secured to each other by, for example, adhesives, welds, or the like. In some embodiments, a first bore of the first tubing 1828 may be threaded and the rod 1830 may be threaded into the first inner bore. In such embodiments, an adhesive such as Loctite may be used to secure the rod 1830 to the first tubing 1828. A
second end of the threaded rod 1830 may be received by a second inner bore of a second tubing 1836, a first nut 1832, and a second nut 1834. The second inner bore may be smooth such that the rod 1830 freely slides in and out of the second tubing 1836. The first nut 1832 and the second nut 1834 may be, for example, hex nuts, however, the first nut 1832 and the second nut 1834 may be any type of nut. It will be appreciated that the first nut 1832, the second nut 1834, and the second tubing 1836 may be independent of each other.
The second nut 1834 may be positioned between the first nut 1832 and the second tubing 1836 and the second nut 1834 may act as an adjustment nut to adjust a height of the conveyor 1800, described in more detail below. It will be appreciated that in the illustrated embodiment, the adjustable base 1824 comprises four of each of the rod, the first tubing, the second tubing, the first nut, and the second nut. In other embodiments, the adjustable base 1824 may comprise any number of rods, first tubings, second tubings, first nuts, and second nuts.
The adjustable base 1824 may adjust a height of the conveyor 1800. When the second nut 1834 is rotated, the rod 1830 may translate into and out of the second tubing 1836. More specifically, when the second nut 1834 is rotated in a first direction, the rod 1830 translates into the second tubing 1836 and the frame 1802 of the conveyor 1800 moves towards the stand 1826, thus lowering the conveyor 1800 towards the floor.
When the second nut 1834 is rotated in a second direction, the rod 1830 extends from the second tubing 1836 and the frame 1802 of the conveyor 1800 moves away from the stand 1826, thus raising the conveyor 1800 away from the floor. Once a desired height adjustment is reached, the first nut 1832 is used as a jam nut that uses friction to prevent rotation of the second nut 1834. It will be appreciated that in the illustrated embodiment, each of the four rods may be adjusted to different lengths. For example, a first rod may be adjusted to a first length and a second rod may be adjusted to a second length different from the first length.
The adjustable base 1824 provides an adjustment to a height of the conveyor 1800 between about lin to 6in. In a preferred embodiment, the adjustable base 1824 provides an adjustment to the height of the conveyor 1800 between about 2in and 3in. It will be appreciated that in other embodiments, the adjustable base 1824 may provide more than 6in of adjustment or less than lin of adjustment. Such adjustments allow for the stand 1826 to be adjusted to variations in the floor. For example, two of the rods may be adjusted to account for an angle in the floor.
Turning to Figures 20 and 21, a close-up perspective view and a close-up side view of the second end 1806 of the conveyor 1800 are respectively shown. The conveyor 1800 may comprise a motor frame 1820. The motor frame 1820 may act as a stand on, for example, a mezzanine floor and may provide support for the second end 1806 of the conveyor 1800. The motor frame 1820 may also house the motor 1808. The motor may be positioned at an end of the motor frame 1820 opposite the extension 1818 and a back of the motor 1808 may face towards the middle, vertical portion 1816 of the conveyor 1800. Such positioning of the motor 1808 within the motor frame 1820 enables a shortening of a length of the motor frame 1820, thereby reducing a footprint of the motor frame 1820 on the mezzanine floor. Such reduction in the footprint of the motor frame 1820 allows for more floor space for other components outside of the conveyor 1800. More specifically, a length of a conventional motor frame may be 36" and a length of the motor frame 1820 is 30".
During use a tire such as the tire 300 is looped over the cleat 1812 (whether moving tires from the first end 1804 to the second end 1806 or vice versa). When moving tires from the first end 1804 to the second end 1806, each cleat 1812 may be loaded with a tire.
However, when moving tires from the second end 1806 to the first end 1804, a tire may be loaded on every three cleats 1812 so that a user unloading the tire at the first end 1804 is not unloading a tire as a new tire is being lowered. This is because the user needs more time to safely unload tires coming down the conveyor and means that the belt speed does not have to be slowed when moving tires down from the second floor. Alternatively, tires can be loaded on every cleat 1812 when moving tires down the conveyor from the second floor if the belt speed is slowed. In other instances, the tire may be loaded on any cleat 1812 (whether the first, second, third, fourth, or fifth clear).
Figures. 22A-22B show a first and second perspective view, respectively, of a conveyor 2200 on a portable stand 2202 in a first position. The stand 2202 may aid in conveyor transportation and assembly (of which, in some embodiments, assembly may be aided by the use of a forklift). The conveyor 2200 may be a floor-to-floor incline conveyor for conveying objects such as, for example, tires. In other embodiments, the conveyor may be a nose-over vertical tire conveyor such as described above. The stand 2202 may be shipped separately from the conveyor 2200, though the stand 2202 may also be shipped with the conveyor 2200 in other instances. In some embodiments, the stand 2202 may be installed on the conveyor 2200 and the conveyor 2200 and the stand 2202 may be shipped together as one unit. The conveyor 2200 comprises a conveyor belt 2206 that revolves around two pulleys (not visible), one each at the top and bottom ends. Cleats 2204 (which may be the same as or similar to any cleats described herein) are secured to the conveyor belt 2206 at intervals along the belt 2206.
The conveyor 2200 also includes a motor 2250 (visible in Fig. 22B) interconnected to one of the pulley via a roller chain or drive belt and sprockets (not visible). Thus, proximate the motor 2250 and covering the roller chain and sprockets is a guard 2280. The motor 2250 can be an electric motor and include a speed reducer in some embodiments. The motor 2250 can be positioned at the bottom end in some embodiments, as illustrated. The conveyor 2200 may also have a motor frame 2208 which houses the motor 2250, a speed reducer gearbox (not visible), and control switches 2252 (visible in Fig.
22A). A footprint of the motor frame 2208 (and the assembly or configuration of the components housed within the motor frame 2208) may be sized to minimize a footprint of the motor frame 2208 so as to achieve a shipping configuration, shown in Figs. 23A-23B. more specifically, the footprint or volume of the motor frame is sized so as to allow the conveyor 2200 to rest substantially or near parallel to the base 2210 when in the shipping configuration.
The conveyor 2200, as shown in Figures 22A-22B, is mounted to the portable stand 2202. The stand 2202 includes hollow fork tubes or pockets and casters or wheels, which provide mobility in two configurations: a first, upright, or assembled position¨shown in Figures 22A-22B¨and a second, horizontal, or shipping position¨shown in Figures 23A-Turning to Figures 24A-24B, the stand 2202 is shown in a front perspective view and a side view, respectively. The stand 2202 comprises a base 2210 and a support arm 2212. In the illustrated embodiment, the base 2210 includes a frame 2214 shaped as a rectangle, though it will be appreciated that the frame 2214 may be shaped as, for example, a square. The frame 2214 includes a pair of hollow fork tubes 2216 opposite each other. The fork tubes 2216 are configured to receive forks of a forklift, which provides for easy handling and movement of the conveyor 2200 by a forklift. The base 2210 also includes four casters or wheels 2218 that can each rotate 360 degrees so that the base 2210 (and thus, the conveyor 2200) may be moved in any direction. The casters or wheels 2218 may also be locked so as to prevent movement of the base 2210, whether during shipping, use, or otherwise. The casters or wheels 2218 are securely mounted to the frame 2214, whether by nuts and bolts, screws, welding, adhesion, or the like.
As shown, the base 2210 also includes a first pair of brackets 2220 and a second pair of brackets 2222 disposed on opposite sides of the frame 2214. The first pair of brackets 2220 are configured to receive a first pin 2224 of the conveyor 2200 such that the conveyor 2200 is configured to pivot about the first pin 2224 at the base 2210. The first pin 2224 is located near a bottom of the conveyor 2200. The second pair of brackets 2222 is configured to receive a second pin 2226 of the support arm 2212 to secure the support arm 2212 to the base 2210 during installation and use. A third pin 2228 is located near a mid-section of the conveyor 2200 and pivotably connects the support arm 2212 to the conveyor 2200.

Though the support arm 2212 is shown in Figures 24A-24B as separate from the conveyor 2200 and coupled to the base 2210, it will be appreciated that during shipping¨
or when the conveyor 2200 is in the second position¨the support arm 2212 is coupled to the conveyor frame 2221 and is separated from the base 2210, as visible in Figures 23A-23B. The support arm 2212 is shown and described with the base 2210 in Figures for clarity. In the illustrated embodiment, the support arm 2212 includes two frame members 2230 opposite each other. The frame members 2230 may have a pair of brackets 2234 at each end to receive the second pin 2226 and the third pin 2228. The support arm 2212, as shown, is in the shape of a rectangle, though in other embodiments the support arm 2212 may be in the shape of a square or triangle. As previously described, the second pin 2226 pivotably couples the support arm 2212 to the base 2210 and the third pin 2228 pivotably couples the support arm 2212 to the conveyor 2200. The support arm 2212 also includes a cross bar 2232 extending across the two frame members 2230, though in some embodiments the support arm 2212 may not include the cross bar 2232. Though not shown, at least one hook may be coupled to or integrated with the frame members 2230 so as to receive and store, for example, a power cord. The power cord may be, for example 25'. In other embodiments, the power cord may be less than or greater than 25'. It will be appreciated that the at least one hook may be positioned anywhere on the stand 2202.
Though also not shown, a retractable cord may be positioned anywhere on the stand 2202 or positioned anywhere on a conveyor to which the stand 2202 is installed to.
The conveyor 2200 may be shipped in the second position, shown in Figures 23A-23B. In the second position, the support arm 2212 is substantially parallel to the conveyor frame 2221 and the conveyor 2200 is also substantially or near parallel to the base 2210. As shown in Fig. 23B, the conveyor 2200 has a low profile when in the second position, and is easy to ship in such configuration. Further, the conveyor 2200 can be unloaded directly from a trailer in the second position. To move the conveyor 2200 from the second position to the first position, the conveyor 2200 is lifted by, for example, a forklift, such that the conveyor 2200 lifts and pivots away from the base 2210. When the conveyor 2200 is lifted, the support arm 2212 pivots downward and away from the conveyor 2200. While the conveyor 2200 is raised, the second pin 2226 is removed and the brackets 2234 of the two frame members 2230 are aligned with the second pair of brackets 2222 on the base 2210. When the brackets 2234 of the two frame members 2230 and the second pair of brackets 2222 are aligned, the second pin 2226 is reinserted through the second pair of brackets 2222 and the brackets 2234 of the two frame members 2230. The second pin 2226 is then secured to the base 2210, whether by cotter pins or otherwise.
The conveyor 2200 and portable stand 2202 as described above with respect to Figures 22A-24B provides for a mobile conveyor that self-contained, simple to transport, and to install with minimal personnel.
In some embodiments, an incline conveyor may be positioned on a moveable stand to facilitate usage, storage, and/or shipping of the incline conveyor. In other instances, the VTC (straight or nose over) can be positioned on a movable stand to facilitate usage, storage, and/or shipping of the VTC.
While various embodiment of the present invention have been described in detail, it is apparent that modifications and alterations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and alterations are within the scope and spirit of the present disclosure, as set forth in the following claims.
The foregoing discussion of the disclosure has been presented for purposes of illustration and description. The foregoing is not intended to limit the disclosure to the form or forms disclosed herein. In the foregoing Detailed Description for example, various features of the disclosure are grouped together in one or more embodiments for the purpose of streamlining the disclosure. This method of disclosure is not to be interpreted as reflecting an intention that the claimed disclosure requires more features than are expressly recited in each claim. Rather, as the following claims reflect, inventive aspects lie in less than all features of a single foregoing disclosed embodiment. Thus, the following claims are hereby incorporated into this Detailed Description, with each claim standing on its own as a separate preferred embodiment of the disclosure.
Moreover, though the present disclosure has included descriptions of one or more embodiments and certain variations and modifications, other variations and modifications are within the scope of the invention, e.g., as may be within the skill and knowledge of those in the art, after understanding the present disclosure. It is intended to obtain rights which include alternative embodiments to the extent permitted, including alternate, interchangeable and/or equivalent structures, functions, ranges or steps to those claimed, whether or not such alternate, interchangeable and/or equivalent structures, functions, ranges or steps are disclosed herein, and without intending to publicly dedicate any patentable subject matter. Further, the invention(s) described herein is capable of other embodiments and of being practiced or of being carried out in various ways. It is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

Claims (20)

What is claimed is:

1. A conveyor for conveying articles up inclines, the conveyor comprising:
an endless conveyor belt having an outer article-conveying surface and advancing in a direction of belt travel along a conveying path;
a plurality of support elements extending outwardly from the outer article-conveying surface of the conveyor belt and spaced apart at least a distance between about LO and 2.0 times a length of the article conveyed on said conveyor belt, wherein each support element comprises:
a support frame with a support stand and an H-stand, the support stand positioned proximate to a first floor surface and support bars and the H-stand positioned proximate to a second floor surface above the first floor surface;
an idle pulley interconnected to the support frame and positioned at the bottom of the support frame, wherein an underside of the conveyor belt engages an outer surface of the idle pulley; and a drive pulley interconnected to the support frame and positioned at the top of the support frame, wherein an underside of the conveyor belt engages an outer surface of the drive pulley.

2. A conveyor as in claim 1, wherein a first portion of the conveying path is approximately 90 degrees as measured from a horizontal plane and a second portion of the conveying path is approximately parallel to the horizontal plane.

3. A conveyor as in claim 1, wherein the support frame comprises a substantially vertical portion connected on a top end to a curved portion, which is connected to a horizontal portion, the support stand positioned at an end of the substantially vertical portion and the H-stand is configured to support the horizontal portion.

4. A conveyor as in claim 3, further comprising a solid belt-carrying anti-friction surface positioned at the curved portion of the support frame.

5. A conveyor as in claim 1, further comprising four separate return wheels to carry the conveyor belt over a return curved portion and back to a bottom of the support frame.

6. A conveyor as in claim 1, further comprising an adjustable base comprising the support stand, a first tubing extending from the support stand, a threaded bar extending from the first tubing, a second tubing receiving an end of the threaded bar, and a nut.

7. A conveyor as in claim 6, wherein the nut is configured to adjust a height of the second tubing such that rotation of the nut in a first direction translates the second tubing away from the support stand and rotation of the nut in a second direction translates the second tubing towards the support stand.

8. A conveyor as in claim 6, wherein the nut comprises a first nut and the adjustable base further comprises a second nut, wherein the second nut is positioned between the second tubing and the first nut.

9. A conveyor as in claim 6, wherein the adjustable base comprises four of each of the first tubing, the threaded bar, the second tubing, and the nut.

10. A method for conveying articles up steep inclines, the method comprising:
providing a conveyor for conveying articles up an incline, said conveyor comprising:
an endless conveyor belt having a lateral extent and a longitudinal extent, and an outer article-conveying surface that is designed to advance in a direction of belt travel along a conveying path including an inclined portion;
a plurality of support elements, with each support element having a same width (w), length (1), and height (h), wherein each support element of said plurality of support elements is interconnected to said outer conveying surface by two independent fasteners that penetrate through said outer article-conveying surface, a support frame with a support stand and an H-stand, the support stand positioned proximate to a first floor surface and support bars and the H-stand positioned proximate to a second floor surface above the first floor surface;
at least one pulley operably connected to said support frame that engages said conveyor belt;
a motor operably connected to said at least one pulley;
moving said endless conveyor belt in the direction of belt travel using the motor and the at least one pulley;
conveying articles on the outer article-conveying surface of the conveyor belt;
advancing the conveyed articles in the direction of belt travel along the conveying path including the inclined portion;
blocking conveyed articles from sliding down the conveying surface of the conveyor belt on the inclined portion by using said plurality of support elements; and removing the conveyed articles from the conveyor belt.

11. The method for conveying articles up steep inclines of claim 10, wherein the predetermined distance is between about 1.25 and 1.75 times a length of an article conveyed on said conveyor belt.

12. The method for conveying articles up steep inclines of claim 10, wherein the conveyed articles are tires.

13. The method for conveying articles up steep inclines of claim 10, wherein a first portion of the conveying path is approximately 90 degrees as measured from a horizontal plane and a second portion of the conveying path is approximately parallel to the horizontal plane.

14. A portable stand comprising:
a support arm having two frame members disposed opposite each other and a pair of arm brackets at an end of each of the two frame members, the support arm including a second pin and a third pin, the second pin received by a first arm bracket in the pair of arm brackets and the third pin received by a second bracket in the pair of arm brackets, wherein the third pin pivotably connects the support arm to a conveyor frame of a conveyor; and a portable base having a base frame, at least one wheel secured to the base frame, a first pair of brackets secured to the base frame and a second pair of brackets secured to the base frame and opposite the first pair of brackets, the first pair of brackets configured to receive the first pin thereby pivotably coupling the conveyor to the portable base and the second pair of brackets configured to receive the second pin thereby pivotably connecting the support arm to the portable base.

15. The stand of claim 14, wherein the at least one wheel is rotatable 360 degrees.

16. The stand of claim 14, wherein the support arm is configured to move between a first position and a second position.

17. The stand of claim 16, wherein the support arm is substantially parallel to a conveyor frame when in the second position.

18. The stand of claim 16, wherein the second pin is unconnected from the portable base when the support arm is in the second position.

19. The stand of claim 14, wherein the third pin pivotably couples the support arm to a conveyor frame near a mid-section of a conveyor frame.

20. The system of claim 14, wherein the base frame comprises at least one hollow tube configured to receive a fork of a forklift.