GB2208286A

GB2208286A - Multiple conveyor system

Info

Publication number: GB2208286A
Application number: GB8817891A
Authority: GB
Inventors: Dennis Alfred Kirtland
Original assignee: WH Dunn and Son Ltd
Current assignee: WH Dunn and Son Ltd
Priority date: 1987-07-27
Filing date: 1988-07-27
Publication date: 1989-03-22
Anticipated expiration: 2008-07-27
Also published as: GB2208286B; GB8717767D0; GB8817891D0

Abstract

A conveyor system comprises a base structure in the form of opposed side frames (10) mounting a conveyor system selected from a range of conveyor structures (14A-14E) including belt conveyors, roller conveyors and chain conveyors. The conveyor structure is mounted on the frames (10) by means of an appropriate adaptor structure (18A-18E, 19A-19B, 34). The frames (10) have an arrangement of mounting apertures (12) in a first pattern with the adaptor structure having a pattern of mounting apertures corresponding to the apertures (12). The adaptor structure has further mounting patterns for the selected conveyor structure, whereby any of a range of conveyors can be mounted on the same side frames (10) while ensuring that the mounting formations on the conveyor are evenly spaced as required and that the even spacing exists even between mounting formations supported by adjacent adaptors of the appropriate adaptor structure. Fig. 1 indicates several types of conveyors which can be mounted on the same frames (10) by means of adaptor structures respectively. <IMAGE>

Description

Conveyor System The present invention relates to conveyor systems and to methods of forming them.

Conveyor systems are used in a very wide range of situations, and a variety of different types of conveyor have been developed for particular needs. These include belt conveyors having belts supported on slider beds or roller beds which may be horizontal or inclined. Powered roller conveyors are available with a variety of features including zero or low pressure accumulation zones. The diameter and pitching of the rollers will be chosen according to the size of article being conveyed. Power to the rollers can be provided by belt, chain or rope. Chain conveyors may use a simple endless chain of steel or plastic for instance, or the chain may incorporate rollers of various designs.

It is a skilled job to analyse a situation to determine which conveyor type and size is most appropriate to achieve satisfactory performance. The designer of a new conveyor system is required to consider all these possibil ities before selecting the appropriate type and then designing the complete system. The range of possibilities is so wide that it is often found to be uneconomic for a manufacturer to stockpile components for use as required; each conveyor system is normally individually designed and manufactured for the corresponding application. Considerable design and manufacturing costs may therefore be incurred in producing a new conveyor system, but the system may differ only slightly from an existing design (although those differences will be crucial).

There exists a need for a conveyor system and a method of forming conveyor systems which addresses these problems by reducing the design effort required when a conveyor system is to be produced for a new application.

According to the present invention there is provided a conveyor system comprising a base structure which provides mounting formations in a first pattern, a conveyor structure having mounting formations in a second pattern, and an adaptor structure which has first mounting formations arranged to co-operate with the mounting formations on the base structure to be supported thereon and which can be provided with selected second mounting formations arranged to co-operate with the mounting formations on the conveyor structure for supporting the latter, whereby the conveyor structure can be supported on the base structure by means of the adaptor structure.

Preferably the first pattern of mounting formations of the base structure is so selected that each of a range of conveyor structures having respective mounting formation patterns can be supported on the base structure by means of a selected adaptor structure.

Preferably the adaptor structure is chosen from a range of adaptor structures having first mounting formations arranged in a common arrangement and having respectively arranged second mounting formations.

Alternatively, the adaptor may be formed from a blank having the first mounting formations and having a region which may be formed before use to provide the second mounting formations selected to co-operate with the mounting formations of the chosen conveyor.

Preferably the adaptor structure is formed by moulding and may be formed from a mouldable plastics material.

Preferably the base structure comprises two elongate supports extending along respective sides of the conveyor structure and each providing the mounting formations in the first pattern, the conveyor structure being attached to each of the supports by means of a respective one of the adaptor structures. Preferably a plurality of relatively short adaptors are located side by side along each of the elongate supports, and each adaptor may be identical.

Preferably the first and second mounting formations of the selected adaptor are evenly spaced by first and second spacings, the first spacing being so chosen that when the adaptors are installed, second mounting formations on adjacent identical adaptors are separated by a multiple of the second spacing.

Preferably the base structure provides upper and lower patterns of mounting formations to which upper and lower adaptor structures can be attached for supporting the conveyor structure at upper and lower locations.

Preferably the conveyor system forms part of a range of systems including belt conveyors, roller conveyors and chain conveyors.

The invention further provides a method of forming a conveyor system, comprising providing a base structure with mounting formations in a first pattern, a conveyor structure having mounting formations in a second pattern, and providing an adaptor structure with having first mounting formations arranged to co-operate with the mounting formations on the base structure to be supported thereon and with second mounting formations arranged to co-operate with the mounting formations on the conveyor structure for supporting the latter conveyor, and supporting the conveyor structure on the base structure by means of the adaptor structure.

Preferably the method includes selecting the adaptor from a range of adaptor structures having first mounting formations arranged in a common arrangement and having respectively arranged second mounting formations.

Alternatively, the adaptor structure may be formed from a blank having the first mounting formations and a region wherein the second mounting formations can be formed before use to co-operate with the mounting formations of the selected conveyor structure.

The method may include forming the adaptor or the blank by moulding, and forming the adaptor or the blank from a mouldable plastics material.

Preferably the method includes providing a base structure having two elongate supports extending along respective sides of the conveyor structure and each providing the mounting formations in the first pattern, and attaching the conveyor to each support by means of a respective one of the adaptor structures.

Preferably a plurality of relatively short adaptors are located side by side along the elongate supports, and the conveyor is supported thereon at respective locations.

The method preferably includes selecting the first pattern to enable a predetermined range of conveyor structures having respective mounting formation patterns to be supported on the same base structure by means of a selected adaptor structure. The method may include forming the first and second mounting formations to be evenly spaced by first and second spacings, and selecting the first spacing so that when the adaptors are installed, second mounting formations on adjacent identical adaptors are separated by a multiple of the second spacing.

The method preferably includes forming the base structure to provide upper and lower patterns of the mounting formations to which upper and lower adaptor structures may be attached for supporting the conveyor structure at upper and lower locations.

Preferably the conveyor is chosen from a range of systems including belt conveyors, roller conveyors and chain conveyors.

The method preferably includes providing and operating automatic means to determine the adaptor structure design required in dependence on parameters of the chosen conveyor structure. The said parameters may be parameters which determine the said second pattern. The automatic means may comprise a computer.

Embodiments of conveyors according to the present invention and the method of forming them will now be described in more detail, by way of example only and with reference to the accompanying drawings in which Figs. 1 and 2 show partial vertical sections of several types of conveyor system manufactured according to the present invention; Fig. 3 shows side elevations of some adaptors used in the conveyor systems of Figs. 1 and 2; and Fig. 4 shows end and side elevations of the frame member common to each system of Fig. 1 and 2.

The conveyor systems shown in Figs. 1 and 2 each comprise a base structure 10 in the form of a side frame. The frame 10 has mounting formations (apertures) at 12 in a first pattern. A conveyor system 14 has mounting formations 16 in a second pattern. Adaptors 18 have first mounting formations to be described and arranged to co-operate with the mounting formations 12 on the base structure to be supported thereon. The adaptors 18 also have second mounting formations to be described and arranged to co-operate with the mounting formations 16 on the conveyor for supporting the conveyor.The conveyor 14 is thereby supported on the base structure 10 by means of the adaptor 18, and an alternative conveyor system 14 having mounting formations in a third pattern can be supported on the same base structure 10 by means of an adaptor 18 having first mounting formations arranged as aforesaid and having alternatively arranged second mounting formations.

Fig. 1A shows a simple driven roller conveyor 14A comprising an upper roller 20A and lower roller 22A. The lower roller 22A serves to pinch a driven belt 24A between itself and the upper roller 20A so that the upper roller 20A is rotated as the driven belt 24A moves. A line of rollers 20A arranged along the length of the side frame 10 form the conveying surface along which articles are moved as the rollers 20A revolve.

The rollers 20A,22A are mounted on the side frame 10 by means of an upper adaptor 18A and a lower adaptor 19A.

The upper adaptor 18A has a socket for receiving the shaft 16A of the roller 20A. The shaft forms one of the mounting formations of the conveyor. The adaptor 18A is mounted on the side frame 10 by screw or bolt or other suitable attachment means which extends through a mounting aperture 12 in the side frame 10.

The lower roller 22A is similarly mounted on the side frame 10 by means of an adaptor 19A which receives the shaft of the roller 22A and is attached at 12 to the side frame 10, by means of a bolt or screw passing through another mounting aperture in the side frame 10. A similar side frame extends along the other side of the conveyor and supports the other ends of the rollers in like manner.

The adaptors 18A,19A are shown in more detail in Figs.

3A and 3C. The adaptor 18A has a series of notches 26A formed at regular intervals along its upper surface. Each notch 26A has two vertical walls separated by a sloping floor 28. Apertures 30 are formed at regular spacings along the adaptor 18A for receiving bolts or screws which extend through the mounting apertures 12. The size and spacing of the apertures 30 is selected solely to allow the adaptor to be mounted on the side frame 10. The size, shape and spacing of the notches 26A is selected solely to ensure that rollers of the desired diameter and pitch can be accommodated. The notch formation shown in Fig. 3A is for a zero pressure accumulation conveyor system. As articles being conveyed begin to accumulate, rollers under stationery objects can rise up the sloping floor 28, so moving away from the belt 24A and disconnecting themselves from the drive.

For ease of manufacture, the adaptors 18A may be formed as a series of short strips, a number of which are attached side by side along the length of the side frame 10 in order to support a relatively long conveyor.

The lower adaptor 19A has apertures 32 for attachment by bolts or screws to the side frame 10. Notches 34 accommodate rollers 22A which in the examples shown are provided between each pair of rollers 26A. The positions of the apertures 30,32 determines the relative positions of the adaptors 18A,19A when installed. The notches 26A and 34A are located to ensure the correct relationship between the rollers 20A,22A having regard to the relative positions of the adaptors 18A,19A.

The spacing of the apertures 12 in the side frame 10 is preferably chosen so that when a line of identical adaptors 18A,19A are attached to the side frame 10, the end notches 26A,34 on adjacent adaptors 18A,19A are separated by the desired pitch.

An alternative design of adaptor 18A shown in Fig. 3B uses simple parallel sided notches 268 which allow the rollers to rotate but not to move linearly. These rollers are therefore constantly driven rather than forming a zero pressure accumulation zone. It will be understood that adaptors of the types shown in Figs. 3A and 38 could be intermingled to produce a conveyor system having accumulation zones separated by driving zones, but in which the roller diameter and pitch are maintained constant throughout.

Fig. is, and Figs. 3D,3E and 3F show how the same side frame 10 can be used tn support a conveyor 148 of the same type as shown in Fig. 1A, but having different roller sizes and pitches. In the alternative arrangement, upper and lower adaptors 185,198 are again used to support upper and lower rollers 208,22B between which a driven belt 24B is pinched. The adaptors 185,195 are attached to the side frame 10 by using the same mounting apertures 12 used in the embodiment of Fig. 1A. Accordingly, identical apertures 30,32 are provided in the adaptors 188,195. The notches 265,345 are cut to depths chosen to accommodate the larger roller diameter, and at spacings corresponding to the larger pitch required. It can be seen from Fig. 3D and 3F that the apertures 30,32 are formed higher up the adaptors 185,195 than the adaptors 18A,19A, so that the larger rollers 26B can be accommodated without projecting unnecessarily above the side frames 10. Again in this embodiment, alternative adaptors 18B (Fig 3E) can be used to provide zero pressure accumulation zones or constantly driven zones.

Fig. 1C shows another conveyor 14C having upper and lower rollers 20C,22C. The lower roller 22C is pivotally mounted at 36 so that it may press the belt 24C against the upper roller 20C, or swing down thereby to disengage the drive. The upper roller 20C is mounted by a suitably formed adaptor 18C on the side frame 10, again using the same mounting apertures 12. The lower roller 22C is mounted on a bracket 34 attached to the side member 10 at 12, again using the same mounting apertures 12. Accordingly, the bracket 34 is analogous to the adaptors 19A,195.

In each of the arrangements shown in Fig. 1A,1B and 1C, a further return roller 38 supports the belt 24 on its return leg.

Fig. 1D shows a conveyor 14D in which each roller 20D is belt driven from a common shaft 40 which extends the whole length of the conveyor. A drive belt 42 is provided for each roller 20D, to drive from the shaft 40. The rollers 20D are mounted by adaptors 18D which in turn are mounted on the side frame 10 using the mounting apertures 12. The upper mounting apertures 12 are used for the adaptors 18D, but the lower mounting apertures 12 are not used in this arrangement. The shaft 40 is supported on bearings which are mounted on the side frame 10 by means of brackets 44.

Fig. 1E shows a conveyor 14E in which the upper roller 20E is driven by chains 46 and sprocket wheels 48 which are protected by a guard 50. The roller 20E is mounted on the side frame 10 by an adaptor 18E made in two parts as shown in Figs. 3G and 3H. The adaptor 18E comprises a lower portion 52 which has notches 54 for receiving the roller shaft, and also has apertures 56 for mounting the adaptor on the side frame 10. The roller shafts are trapped in position by an upper part 58 held in position by removable pins 60. The apertures 56 are spaced to allow the use of the upper mounting apertures 12 when mounting the adaptor 18E on the side frame 10. Again, the lower mounting apertures 12 are not used in this arrangement.

Fig. 2A shows a belt conveyor. Articles are supported on a belt 62A which is supported on rollers 64A. The roller shafts are supported in adaptors 18F which are mounted to the side frame 10 by the mounting apertures 12. The apertures in the adaptors 18F for receiving screws or bolts through the mounting apertures 12, and the sockets for receiving the shafts of the rollers 64 are formed and positioned to ensure that the belt 62A is at the desired height above the side frame 10. If the roller diameter is changed, appropriate adjustments to these positions and sizes can be made.

Fig. 25 shows a slider bed construction in which the belt 62B rests on a slider bed 64B which is supported on the side frame 10 by means of a bracket 18G analagous to an adaptor and mounted by means of the upper mounting apertures 12. The bracket 18G may extend along the whole or a considerable part of the length of the conveyor or an individual bracket may be used at each mounting aperture 12.

Fig. 2C shows a slider bed conveyor in which the belt 62C is supported directly by a bracket 18H analagous to an adaptor and mounted on the side frame 10 by means of the upper mounting apertures 12. The belt 62C is strengthened at 66 by strengthening means which are sliding'liy supported on a bracket 68 which is in turn supported by the bracket 18H.

Figs. 2D and 2E show two designs of roller top chain conveyor. In each case, the chain conveyor 70A,70B is supported on the side frame 10 by a bracken 72A,725, using the upper mounting apertures 12. The dimensions of the brackets 72A,725 are chosen according to the dimensions of the conveyor 70A,70B to ensure that the top surface is level with or slightly above the top of the side frame 10.

Fig. 4 shows the side frame in more detail. It can be seen from Fig. 4A that the side frame 10 has a generally "S"-shaped profile upper and lower lips 74A,74B for strength. Upper and lower rows of regularly spaced mounting apertures 12 allow the various brackets and adaptors described above to be supported on the frame 10. The spacing of the mounting apertures 12 is carefully selected in the following manner. The range of conveyor types and sizes which the side frame 10 will be required to support is first determined. From this, the spacing of notches or other regularly spaced formations which will be required for supporting the conveyor can be determined. This allows an adaptor to be designed which can be duplicated to allow a line of identical adaptors to be used to support the conveyor.By careful choice of the spacing of the mounting apertures 12, it has been found that the whole range of conveyors can be mounted on the same side frame 10 while ensuring that the mounting formations on the conveyor are evenly spaced as required, and that the even spacing exists even between mounting formations supported by adjacent adaptors. In other words, the mounting formations supported by adjacent adaptors are spaced by a multiple of the mounting formation spacing apart and are preferably one such spacing apart so that the existence of separate adaptors is not apparent from above the conveyor.

The use of adaptors to mount a range of conveyors on identical side frames has further economic advantages. The side frame, which normally represents a significant cost element of the complete conveyor, can be mass produced and stockpiled, because the same design is used for all conveyors. Adaptor blanks can also be mass produced and stockpiled, each blank having apertures for receiving bolts or screws through the mounting apertures 12 but having no formations for supporting a conveyor. Once a conveyor design has been selected, the blanks can then be finished by providing appropriate notches, sockets or other formations for supporting that conveyor. Accordingly, the use of mass produced parts is maximized without prejudicing the range of conveyors available. The flexibility required is provided by the adaptors. The cost savings may be sufficient to allow stockpiling of e range of fully pre-formed adaptors in common sizes and types, rather than only stockpiling blanks.

In a further development, it is envisaged that part of the design process could be computerized. The type and size of conveyor to be chosen is largely determined by parameters of the task to be performed (such as the size of articles to be conveyed). It is therefore envisaged that a computer could be programmed to select conveyor size and type from these details, which in turn determine the required design of adaptor, so that the computer could then produce designs to which the stockpiled blanks can be cut. The computer could directly control manufacturing equipment.

A further advantage is that the normal wear and tear on the support structures for a conveyor is largely avoided, or taken by the adaptors which can quickly and cheaply be replaced. Adaptors can also be replaced without replacing the side frames if the conveyor design is to be changed.

Claims

1. A conveyor system comprising a base structure which provides mounting formations in a first pattern, a conveyor structure having mounting formations in a second pattern, and an adaptor structure which has first mounting formations arranged to co-operate with the mounting formations on the base structure to be supported thereon and which can be provided with selected second mounting formations arranged to co-operate with the mounting formations on the conveyor structure for supporting the latter, whereby the conveyor structure can be supported on, the base structure by means of the adaptor structure.

2. A conveyor system according to Claim 1, wherein the first pattern of mounting formations of the base structure is so selected that each of a range of conveyor structures having respective mounting formation patters can be supported on the base structure by means of a selected adaptor structure.

3. A conveyor system according to Claim 1 or 2, wherein the adaptor structure is chosen from a range of adaptor structures having first mounting formations arranged in a common arrangement and having respectively arranged second mounting formations.

4. A conveyor system according to Claim 1 or 2, wherein the adaptor structure is formed from a blank having the first mounting formations and having a region which may be formed before use to provide the second mounting formations selected to co-operate with the mounting formations of the chosen conveyor structure.

5. A conveyor system according to any of the preceding Claims, wherein the adaptor structure is formed by moulding.

6. A conveyor system according to Claim 5, wherein the adaptor structure is formed from a mouldable plastics material.

7. A conveyor system according to any of the preceding Claims, wherein the base structure comprises two elongate supports extending along respective sides of the conveyor structure and each providing the mounting formations in the first pattern, the conveyor structure being attached to each of the supports by means of a respective one of the adaptor structures.

8. A conveyor system according to Claim 7, wherein the adaptor structure comprises a plurality of relatively short adaptors which are located side by side along each of the elongate supports.

9. A conveyor system according to Claim 8, wherein each adaptor of the selected adaptor structures is identical.

10. A conveyor system according to Claim 9, wherein the first and second mounting formations of the selected adaptors are evenly spaced by first and second spacings, the first spacing being so chosen that when the adaptors are installed, second mounting formations on adjacent identical adaptors are separated by a multiple of the second spacing.

11. A conveyor system according to any of the preceding Claims, wherein the base structure provides upper and lower patterns of mounting formations to which upper and lower adaptor structures can be attached for supporting the conveyor structure at upper and lower locations.

12. A conveyor system according to any of the preceding Claims, wherein the conveyor structure is selected from a range of conveyor structures including belt conveyors, roller conveyors and chain conveyors.

13. A method of constructing a conveyor system, the method providing a base structure with mounting formations in a first pattern, a conveyor structure having mounting formations in a second pattern, providing an adaptor structure with having first mounting formations arranged to co-operate with the mounting formations on the base structure to be supported thereon and nith second mounting formations arranged to co-operate with the mounting formations on the conveyor structure for supporting the latter, and supporting the conveyor structure on the base structure by means of the adaptor structure.

14. A method according to Claim 13, including selecting the first pattern to enable a predetermined range of conveyor structures having respective mounting formation patterns to be supported on the same base structure by means of a selected adaptor structure.

15. A method according to Claim 13 or 14, wherein the adaptor structure is selected from a range of adaptor structures having first mounting formations arranged in a common arrangement and having respectively arranged second mounting formations.

16. A method according to Claim 13 or 14, wherein the adaptor structure is formed from a blank having the first mounting formations and a region whereir the second mounting formations are formed before use to co-cperate with the mounting formations of the selected conveyor structure.

17. A method according to any of Claims 13 to 16, wherein the adaptor structure is formed by moulding.

18. A method according to any of Claims 13 to 17, including forming the base structure of having two elongate supports extending along respective sides of the conveyor structure and each providing the mounting formations in the first pattern, and attaching the conveyor to each support by means of a respective one of the adaptor structures.

19. A method according to any of Claims 13 to 18, wherein the adaptor structure is formed of a plurality of relatively short adaptors which are located side by side along the elongate supports.

20. A method according to Claim 19, including forming the first and second mounting formations to be evenly spaced by first and second spacings, and selecting the first spacing so that when the adaptors are installed, second mounting formations on adjacent identical adaptors are separated by a multiple of the second spacing.

21. A method according to any of Claims 13 to 20, including forming the base structure to provide upper and lower patterns of the mounting formations to which upper and lower adaptor structures may be attached for supporting the conveyor structure at upper and lower locations.

22. A method according to any of Claims 13 to 21, wherein the conveyor structure is selected from a range of conveyor structures including belt conveyors, roller conveyors and chain conveyors.

23. A method according to any of Claims 13 to 22, including providing and operating automatic means to determine the adaptor structure design required in dependence on parameters of the chosen conveyor structure.

24. A method according to Claim 23, wherein the parameters determine the design of the second pattern of mounting formations.

25. A method according to Claim 23 or 24, wherein the automatic means comprises a computer.

26. A method of constructing a conveyor system substantially as hereinbefore described with reference to the accompanying drawings.

27. A conveyor system substantially as hereinbefore described with reference to the accompanying drawings.

28. Any novel subject matter or combination including novel subject matter herein disclosed in the foregoing Specification or Claims and/or shown in the drawings, whether or not within the scope of or relating to the same invention as any of the preceding Claims.