GB2575861A

GB2575861A - Separator

Info

Publication number: GB2575861A
Application number: GB1812214.3A
Authority: GB
Inventors: Simmons Paul; Greenland Ben
Original assignee: Colin Mear Engineering Ltd
Current assignee: Colin Mear Engineering Ltd
Priority date: 2018-07-26
Filing date: 2018-07-26
Publication date: 2020-01-29
Anticipated expiration: 2038-07-26
Also published as: WO2020021264A1; GB2575861B; GB201812214D0

Abstract

A separator 100 for a conveyor system is adapted to separate an item from a batch of similar items on the conveyor. The separator 100 comprises a reserved area (35, figure 7), a first adjustable dimension 10, a second adjustable dimension 30 and engagement apparatus 70 positioned above the reserved area (35, figure 7). The first adjustable dimension 10 is adjustable to accommodate a dimension of said item in the direction of movement of the conveyor to ensure only one item of the batch at a time is received thereon. The second adjustable 70 dimension is adjustable to accommodate a dimension of said item perpendicular to the direction of movement of the conveyor. The height of the engagement apparatus 70 is adjustably positionable to ensure the item, when positioned in the reserved area (35, figure 7), is receivable within the engagement apparatus 70 to secure the item for movement away from the conveyor system 100. The reserved area (35, figure 7) may include a lift which is operable to raise an item received onto the reserved area (35, figure 7) above the level of the remaining items in the batch.

Description

BOX WIDTH ADJUSTMENT

Separator

The present invention is directed to a separator for separating, for individual processing, items in a batch of similar items on a conveyor system, such as a conveyor belt, from other items in the batch.

Conventional conveyor systems are relied upon where a series of functions need to be carried out on an item, with the same series of functions carried out on successive items in a batch of such items having the same dimensions, the functions carried out in the same order, repeatedly. Items are transported between each function on for example a conveyor belt.

This system works very well and means that items can be mass produced economically, however conveyor systems such as conveyor belts do have problems. For example, when items are moving along a conveyor belt they generally bunch together, during the course of their journey along the conveyor belt, even if they are placed on the conveyor at different times. As they bunch together on the conveyor belt it becomes challenging to select individual items for processing.

In addition, most conveyor belts are adapted to handle items of a particular size and shape, and should the need to process items of this size and shape cease, it is not straightforward to adapt the conveyor belt to handle, and process, items of a different size and shape. Conventionally a conveyor belt can be adapted to handle items of a different size and shape but it takes a long time to reconfigure the conveyor so that the items of the new size and shape can be transported between the desired functions, meaning that processing time is lost, resulting in a cost to the manufacturer.

The present invention is directed to overcoming at least some of these disadvantages.

The present invention provides, in accordance with a first aspect, a separator for a conveyor system, the separator adapted to separate an item from a batch of similar items on the conveyor, the separator including a reserved area with a first adjustable dimension, the first adjustable dimension adjustable to accommodate a dimension of the item in the direction of movement of the conveyor to ensure only one item of the batch at a time is received thereon. The separator further includes a second adjustable dimension, the second adjustable dimension adjustable to accommodate a dimension of the item perpendicular to the direction of movement of the conveyor. The separator further includes an engagement apparatus positioned above the reserved area, a height of the engagement apparatus adjustably position-able to ensure the item, when positioned in the reserved area, is receivable within the engagement apparatus to secure the item for movement away from said conveyor system.

Preferably the reserved area includes a lift operative to raise an item received onto the reserved area above the level of the remaining items in the batch and towards the engagement apparatus.

Preferably an item in the batch of items subsequent to the item on the lift is prevented from moving with the conveyor, by the side of the lift.

Preferably the separator includes a stop adjustably positioned proximal the reserved area to stop an item moving too far onto the reserved area.

Preferably the separator includes a sensor adjacent the stop to sense when an item from the batch of items is fully contained on the reserved area but no part of a subsequent item in the batch of items is contained on the reserved area.

Preferably the second dimension includes opposing side panels adjustably separable by a width of the item, wherein the engagement apparatus is mounted on respective side panels.

Preferably the engagement apparatus includes a pair of timing belts on each respective side panel, a first member of each pair adjacent the respective side panel, a second member of each pair adjacent a gap between the side panels.

Preferably the timing belts include flights.

Preferably the flights on a first member of each pair are out of phase with flights on a second member of each pair.

Preferably the flights on respective second members overlap belts of respective first members.

Preferably receiving the item in the engagement apparatus includes flights on one of the members of each pair engaging with a leading edge of the item, and flights on the other of the members of each pair engaging with a trailing edge of the item, to secure the item and provide for the item to be urged away from the conveyor system.

Preferably the width, height and length parameters of the separator are manually adjustable.

Preferably the width height and length parameters of the separator are electronically adjustable.

Preferred embodiments of the present invention will now be described by way of example only and with reference to the accompanying drawings in which

Figure 1 shows a perspective view of a separator in accordance with an embodiment of the invention,

Figure 2 shows a top-down view of the separator of Figure 1,

Figure 3 shows a cross sectional side view of the separator of Figure 1, along lines C - C of Figure 2,

Figure 4 shows side view of the separator, showing ends of the rotary motors,

Figure 5 (a) shows a cross sectional side view, along lines A - A, of a rotary motor operating drive belts of the separator of Figures 1 - 3,

Figure 5 (b) shows a cross sectional side view, along lines B - B, of a rotary motor operating control belts of the separator of Figures 1 - 3,

Figure 6 (a), and (b) show the arrangement of Figures 2 and 4 respectively with an item to be processed in position.

Figure 7 shows a mechanism for adjusting the separator height, additionally showing an item in the separator indicating the height of the item in relation to the other features of the separator.

As items move along a conventional conveyor system, for example a conveyor belt, a first item arrives at a first processing point and movement of the item is slowed or stops altogether. Subsequent items that are not yet ready for processing continue to move with the consequence that the items bunch together while the first item is processed. This continues and is one mechanism underlying the tendency for all the items on the conveyor belt to bunch together after processing starts.

The first processing step may require the item to for example have a label attached thereto, and so it is necessary for a first item of a batch of items to be selected and separated out from the rest of the items and labelled. Alternatively, a different function may be carried out, but for any function the item must be selected from the rest for the action to be carried out. Once the first processing step has been completed for the first item, the second item needs to be selected and processed in turn, and so on until all the items on the conveyor have been processed.

In accordance with the present invention, one way of selecting an item from the bunched batch of items is to for example include a separator 100 in the conveyor system, and a separator in accordance with the present invention is shown in Figure 1. The separator may include for example a lift in the conveyor system, so that when the first item arrives on the lift, the lift can be triggered to rise up above the level of the conveyor so that the item on the lift may be captured for processing.

Once the item is captured for processing, the lift then returns to its original position ready for the next item to arrive thereon, and be raised in turn for individual processing. This can continue until there are no further items in the batch to be processed.

If the process is to proceed efficiently, it is essential that the lift accommodates only one item at a time, and furthermore it essential that no part of a further item is present on the lift platform prior to the lift rising up and separating the first item from the rest. For at least this reason it is necessary to know, for each batch of items to be processed, the dimension of the items in the batch in the direction of travel, referred to herein as the width of the item.

The width of the item is therefore provided to the separator. The width dimension determines the position of an adjustable stop, adjacent the lift, which may be provided to prevent further motion of an item in the batch once the item has arrived safely on the lift. The stop is positioned at a distance less than or equal to the width of the item when measured from the first edge of the lift encountered by the item on the conveyor, so that once movement of the item on the conveyor is stopped by the stop, the item will be substantially present on the lift, and no second item can be present on the lift at the same time.

The separator may also include a sensor positioned proximal the lift so that when the sensor detects the leading edge of an item in the batch of items, the position of the item can be calculated, for example to determine when the item will be fully or substantially on the lift and no part of a subsequent item will be on the lift. This can assist in triggering the lift to rise above the level of the conveyor and begin separation of the item on the lift from the remaining items on the conveyor.

The remaining items on the conveyor are prevented from moving forward due for example to their being urged against the side of the lift platform. As the item on the lift moves away from the lift towards processing, the lift moves back down to the same level as the conveyor and the next item can move along onto the lift and the process can repeat until all the items in the batch have been processed.

As already explained, the position of the stop is adjustable, and the position selected is determined by the width (i.e. the dimension of the item in the direction of travel) of the item to be processed. The position of a sensor, if present, is fixed in relation to the position of the stop.

Once an item is raised above the level of the other items in the batch on the infeed conveyor, it is urged off the lift, meaning separation of the item from the other items is complete. Once separated it can be processed, for example taken for labelling or for some other action.

The mechanism by which the item is conveyed from the lift toward the next step may include for example two pairs of flighted timing belts 70, as seen in Figures 1 and 3. One pair of flighted timing belts 70 are positioned on a first edge panel, 32, on one side of the separator, with the second pair of flighted timing belts are positioned on a second edge panel, 34, on the side of the separator opposite the first edge panel (not shown in Figure 3).

One pair of the flighted timing belts 70, positioned on one of the edge panels, is shown in detail in the cross-sectional view of Figure 3. As can be seen, the belts loop around respective pulleys, 73, 75 extending between the pulleys along a guide 79 on a lower side of the loop, and extending towards and over a tensioner 77 on an upper side of the loop.

As can be seen from Figure 1, each pair of flighted timing belts include a first belt 70a closer to the respective edge panel 32, 34, and a second belt 70b extending into the space between the panels. The height of the flighted timing belts of the separator are adjustable dependent on the height of items in the batch of items to be processed, with all the timing belts adjusted in unison.

Conventionally and practically, the distance the lift travels upwardly and away from the conveyor is fixed, however the height of the flighted timing belts in the separator is adjustable dependent on the height of the items on the lift to be processed. This means that once a batch of items is introduced to the conveyor system, moving along the conveyor until a first member enters onto the lift, the flighted timing belts, adjusted in unison to accommodate the height of the items in the batch, are positioned to engage with each item in the batch once the lift moves it up and away from the conveyor.

In addition, it is important to know the length of the item to be processed, i.e. the dimension of the item in a direction perpendicular to the direction of travel of the item, as this will determine the adjustment introduced into the separator to determine the adjustable distance between the edge panels of the separator

When the dimensions of the item are entered into the separator the position of the stop is determined, the height of the flighted timing belts above the lift are determined, and the distance between the separator edge panels 32, 34 is determined.

Figure 1 shows a perspective view of the separation means of the present invention. The separator includes a linear shaft 10 extending along the direction of travel of items on the conveyor, the linear shaft 10 connected to a handle 20 which may be wound to adjust the position of the stop on the conveyor that is operative to stop the first item in the batch of items from moving any further, for example once the first item on the conveyor is stopped by the stop, the first item will be positioned on the lift and no part of a subsequent item will be present on the lift. In addition, a sensor may be positioned close to the stop, adapted to trigger the lift to move and raise the first item above the conveyor to raise the item above the rest of the items. It is contemplated that the sensor is a fixed distance from the adjustable stop, meaning that the position of the sensor is effectively adjustably movable also, dependent on the width of the item.

Figure 1 also shows further shaft 30 extending from a first edge panel 32 of the separator to a second edge panel 34 of the separator, and flighted timing belts 70a, 70b, positioned on respective edge panels 32, 34. The further shaft 30 is attached to a handle 40 which when actuated can adjust the distance between the edge panels 32, 34, this distance adjustable to match the length of items of the batch of items on the conveyor.

Finally, Figure 1 shows that the separator includes a shaft 50 with a handle 60, the handle operable to adjust the height of the timing belts 70 to correspond with the height of items of the batch of items being processed, and to ensure the items to be processed, when raised on the lift, engage with the timing belts to ensure the item can be moved along to the next stage.

Figure 2 shows a top-down view of the separator of Figure 1, showing the linear shaft 10 and handle 20, with stop 25 at the end of shaft 10.

Figure 3 shows a cross sectional view of the separator along line C - C of Figure 2, with a first item 1 adjacent a second item 2 on the conveyor. The first item 1 has been slightly lifted out of the plane of the conveyor by a lift 35. The second item 2 abuts the side of the lift 35, or is stopped by the stop, and so does not move further while the first item 1 is being lifted.

In addition, Figure 3 shows in more detail a pair of timing belts 70 on one of the edge panels 32, 34. As can be seen, the timing belts are urged to rotate around pulleys 73 and 75 (as shown in Figure 1) by conventional means. The timing belts are guided from a first pulley 73 to a second pulley 75, over tensioner 77 and along a guide shelf 79.

Figure 4 is a side view of the separator of Figure 1, showing handle 40 attached to shaft 30 (not shown), and also handle 20 attached to shaft 10 (not shown). Figure 4 also shows a portion of the timing belts 70, just visible through and over the edge panel 32, 34, and rotary motors 80, 81. Figure 5 (a) is a cross sectional side view of the separator of Figure 4 along lines A-A, showing that the rotary motor 80 operates on the inner drive belts of the drive belt pairs on respective edge panels of the separator of the present invention.

Figure 5(b) is a cross sectional side view of the separator of Figure 4 along lines B - B, showing that the rotary motor 81 operates on the outer drive belts of the drive belt pairs on respective edge panels of the separator of the present invention.

Figure 6 (a) is a view of Figure 2 including an indication as to the positioning of the item to be processed between edge panels 32, 34. For example, the inner of the drive belt pairs is within the length dimension (perpendicular to the direction of motion) of the item, and the outer of the drive belt pairs are outside the length dimension of the item. Each of the inner and outer belts include respective flights 93, 95, extending away from the belt and in the present case adapted to engage with the item to be processed. As seen in Figure 1, the flights 93 of the inner belt extend away from the belt to engage directly with the item whereas the flights 95 of the outer belt extend away from the belt and in addition overlap the inner belt to engage with the item. In this way the flights on for example the inner belt engage with a leading edge of the item and the flights on the outer belt, which overlap with the inner belt, engage with a trailing edge of the item, thereby securing the item between them. Figure 6 (b) is a view of Figure 4 including an indication as to the height of the item within the separator in relation to the features of the separator.

Figure 7 shows more clearly the arrangement of the separator in relation to for example the height of an item in a batch being processed. Figure 7 in particular shows the item in position below and between the drive belts, on the lift.

It is contemplated that the difference in the dimensions of items between respective batches may vary in dimension, for example across the conveyor, in the height of the conveyor and along the direction of motion of the conveyor, between 38.5mm x 20mm x 20mm to 216mm x 135mm x 131mm.

In use, items in a batch of items to be processed in a conveyor system are reviewed and a separator in accordance with the present invention, forming part of the conveyor system, is updated to reflect the width, length and height of the items in the batch. In particular, handle 20 is manipulated to adjust the separator to reflect the width of batch items (i.e. the size of items in the direction of travel on the conveyor), including positioning a stop, 25, a distance less than or equal to the width of the item from the edge of the lift first encountered by an item on the conveyor. A sensor may also be positioned close to the stop such that a leading edge of a first item passing the sensor may be relied upon to trigger the sensor to determine when the item 1 will be positioned fully on a lift 35, with no part of the next item 2 on the lift, so that the lift can then lift the item and thereby enable it to be separated from it from its fellows.

The separator also includes two pairs of timing belts 70, a pair on each respective opposite planar edge 32, 34, the separation of the edges 32, 34 being determined by the length (i.e. the size of the item in a direction perpendicular to the direction of travel on the conveyor) of the items being processed: this can be seen in Figure 1. Once the lift has lifted the first item in an upwardly direction away from the conveyor, for processing, it must be urged off the lift for processing to occur. The separation of the planar edges, and the height dimension of the item as supplied to the separator, is relied upon to ensure that the timing belts are in a position to engage with the item.

As discussed, each timing belt includes flights 93, 95 (as seen on Figures 1 and 3) conventionally positioned at intervals along the belt. The positions of flights on respective inner and outer belts of a pair, in addition to being different sizes, do not match, i.e. they are out of phase to a degree which reflects the width of the item being processed. The flight positions of respective belts are also adjustable. The phase difference between the inner and outer pairs of belts may be achieved by driving the two sets of belts independently, or by driving them together but including a means of adjusting the phase between the drive pulleys 73, 75 to effect a change in gap between the flights that will be positioned at the leading edge of the item, and the flights that will be positioned at the trailing edge of the item.

Figure 1 shows a perspective view of a pair of timing belts on one edge panel of the separator, the timing belt adjacent the edge panel providing the outer belt, forming a pair with the corresponding outer belt on the other edge panel, and the timing belt furthest from the edge panel providing the inner belt, and forming a pair with the corresponding inner belt on the other edge panel. As can be seen from Figure 5, the inner pair of belts are driven by rotary motor 80, and the outer pair of belts are driven by rotary motor 81.

As stated, the position of the flights in the inner belt pair may be out of phase with the position of the flights on the outer belt pair, to more securely control the behaviour of the selected item. For example, a flight on one of the belts, say the outer belt, can engage with a leading edge of the item, and the flight on the other of the belts, say the inner belt, is positioned to engage with the trailing edge of the item, meaning that the two belts between them can secure the item, and operatively control the position of the item. Specifically, the phase difference between the occurrence of flights of the inner and outer belts is adjustable in the separator to match the width of the item. The height and length dimensions of the item are relied upon to ensure the timing belts are positioned accurately to engage with and control the item. To assist in this the flights on the inner belt extend away from the belt to engage with the item, but the flights on the outer belt extend away from the belt and overlap the inner belt to engage with the item. This may be seen in Figures 1, 2, 6 (a) and 7. Overlapping flights are not an essential feature of the design but can be helpful as the minimum length of an item that can be processed can, with overlapping flights, be less than the width of the 4 belts.

Handles 20, 40 and 60 of the separator can be adjusted to determine the width, length and height dimensions of the separator so that an item with a specific width, length and height is lifted by the lift, and engages with the timing belts to be moved along and processed separately from the other items in the batch.

When a batch of items arrives at the conveyor system to be processed, the dimensions of the items in the batch are noted, and if the dimensions of the items in the batch are different from the items in the last batch to be processed, wheels 20, 40, 60 of the separator are manipulated until the separator reflects the dimensions of the items in the batch to be processed. In particular the position of the stop adjacent the lift is adjusted to reflect the width of the items to be processed, and this will also adjust the position of a sensor, if present, for detecting a leading edge of the item once it approaches the lift, to trigger the lift to move the item in an upwards orientation. The height of the items of the batch is also relied upon to adjust the height of the timing belts above the lift, and the length of the items of the batch is also relied upon to adjust the separation of the edge panels on which the timing belts are positioned. Finally, the timing belts themselves are adjusted to co-ordinate the phase of the flights on the inner and outer belts dependent on the width of the items in the batch.

The batch items are then added to the conveyor system, possibly randomly, but tend to bunch together during their journey through the conveyor and may eventually move as a single block of items.

When a first item of the batch arrives at the separator it is stopped by the stop 25 once it has arrived fully on the lift (with no other item present on the lift). The sensor, if present, senses the item on arrival, when it is positioned fully on the lift, triggering the lift to raise the item above the surface of the conveyor. As the lift rises the remaining items on the conveyor cease to move as they are held still by the first item in the lift or the side of the lift itself. The lift rises and, as the height of the timing belts have been adjusted to reflect the height of the item, and the separation of the side panels has been adjusted to reflect the length of the item, the item engages with the timing belts. The phase of flights on respective timing belts has been adjusted so that flights on one of the inner or outer pairs of timing belts engage with the leading edge of the item and the flights on the other of the outer or inner pairs of timing belts engage with the trailing edge of the item to ensure adequate control of the item for transport of the item to the next stage of processing.

The lift can then return to receive the next item in the batch and allow it to be lifted up and separated, and then and conveyed for processing.

An advantage of the present invention is that the separator can be dynamically adjusted, in a short time, to manage successive batches with items that differ in size from items in earlier batches.

For example, once a batch of items has been processed, the separator may be required to process a further batch, but the further batch may include items of different dimensions from the batch just processed, for example the items in the further batch may have different width, height and/or length dimensions to those of the items in the batch whose processing has just completed.

As explained, adapting a separator system to process a second batch of items in which the items have different dimensions to a first batch is conventionally a labour intensive, time intensive process which means that the conveyor system is unavailable, possibly for several shifts, adding to the expense of the system and occupying skilled labour for a period of time.

The present invention avoids this overhead as the separator can be simply adjusted by means of the handles 20, 40, 60 to adjust the dimensions of items that may be processed: the handles may be adjusted quickly, and all adjustments may be completed within a few minutes. In addition, the phase of the flights of respective inner and outer pairs of the timing belts can be adjusted to ensure the items engage with the flights for transportation and processing, once selected.

Once the separator has been adjusted to accommodate items of different dimensions from the items in an earlier batch, the new batch of items may be processed. The new dimensions fed into the separator provides for the separator to separate out individual items of the new batch of items efficiently and effectively, the whole process taking a few minutes only.

The dimensions of the separator can be adjusted to accommodate new batches several times in a shift meaning that the conveyor is versatile and can handle batches in which the items in one batch are different from items in another batch, and both (or all) batches may be processed in a single shift without impacting on the utility of the conveyor.

The invention is not restricted to the details of the foregoing embodiments. For example, the sensor 25 may be positioned at a different position than at the end of the shaft 10, the sensor must be positioned to detect the leading edge of the next item on the lift but can be positioned anywhere provided this is accomplished. Other methods of separating an item from the bunched batch of items are contemplated: the method is not restricted to that of a lift urging an item on the conveyor towards engagement means above the conveyor but may provide for the engagement means moving towards the item on the separator area to engage therewith and move the item away from the conveyor. Handles 20, 40, 60 may be other types of adjusters, for example may be electronic interfaces to electronically adjust the width, length and height dimensions of the separator, or may include other means of controlling the dimensions of the separator. While the size of the items that can be accommodated has been set out above, the sizes of items to be processed may vary from the dimensions given, and in particular are adjustable dependent on the subject conveyor system. In addition, the items are not necessarily of a regular shape, such as a cuboid or other shape, but can be an irregular shape.

Claims

1. A separator for a conveyor system, the separator adapted to separate an item from a batch of similar items on the conveyor, the separator including:

a reserved area with:

a first adjustable dimension, said first adjustable dimension adjustable to accommodate a dimension of said item in the direction of movement of the conveyor to ensure only one item of the batch at a time is received thereon, and a second adjustable dimension, said second adjustable dimension adjustable to accommodate a dimension of said item perpendicular to the direction of movement of the conveyor;

engagement apparatus positioned above the reserved area, a height of said engagement apparatus adjustably position-able to ensure said item, when positioned in said reserved area, is receivable within said engagement apparatus to secure the item for movement away from said conveyor system.

2. The separator of claim 1, wherein said reserved area includes a lift, and wherein said lift is operative to raise an item received onto the reserved area above the level of the remaining items in the batch and towards the engagement apparatus.

3. The separator of claim 2, wherein an item in the batch of items subsequent to the item on the lift is prevented from moving with the conveyor, by the side of the lift.

4. The separator of claim 1, wherein the separator includes a stop adjustably positioned proximal the reserved area to stop an item moving too far onto the reserved area.

5. The separator of claim 4, wherein the separator includes a sensor adjacent the stop to sense when an item from the batch of items is fully contained on the reserved area but no part of a subsequent item in the batch of items is contained on the reserved area.

6. The separator of claim 1, wherein said second dimension includes opposing side panels adjustably separable by a width of said item, wherein said engagement apparatus is mounted on respective side panels.

7. The separator of claim 6, wherein said engagement apparatus includes a pair of timing belts on each respective side panel, a first member of each pair adjacent said respective side panel, a second member of each pair adjacent a gap between said side panels.

8. The separator of claim 7, wherein said timing belts include flights.

9. The separator of claim 8, wherein said flights on a first member of each pair is out of phase with flights on a second member of each pair.

10. The separator of claim 9 wherein said flights on respective second members overlap belts of respective first members.

11. The separator of claim 9 or claim 10, wherein receiving said item in the engagement apparatus includes flights on one of the members of each pair engaging with a leading edge of the item, and flights on the other of the members of each pair engaging with a trailing edge of the item, to secure the item and provide for the item to be urged away from the conveyor system.

12. The separator of claim 1, wherein said width, height and length parameters of the separator are manually adjustable.

13. The separator of claim 1, wherein said width height and length parameters of the separator are electronically adjustable.