MXPA97001971A - Method and apparatus for renovation of ba - Google Patents

Abstract

The apparatus (10) and the method for the renewal of damaged conveyor belt (16). The apparatus (10) includes a frame (11) with a conveyor system (14). A mechanism (12) is attached to the frame (11) to remove a desired amount of the conveyor belt surface (24) as the conveyor belt (16) moves relative to the frame (11) on the conveyor system (1).

Description

METHOD AND APPARATUS FOR BAND RENEWAL Field of the Invention The present invention relates to an apparatus for renewing industrial conveyor belts. In particular, the present invention relates to an apparatus that renews expensive modular conveyor belts for reuse in the food industry.

Background of the Invention In industry, conveyor systems are used to transport products between various industrial processing stations. In particular, conveyor systems of the food industry use conveyor belts to transport the food product during food processing. In the food processing industry, the unprocessed food product is transported on conveyor systems that use modular conveyor belts. The modular conveyor belts are formed from injection molded plastic modules formed universally which generally have smooth and impermeable surfaces. The conveyor belt modules are flexibly connected together to form the desired conveyor belt lengths and widths. The cost of the conveyor belts is very high and increases with the size of the belt. Modular conveyor belts are used in the food processing industry because they meet the regulatory and sanitary requirements of the United States Department of Agriculture (USDA) and others. Food processes are inspected daily by USDA representatives to ensure that procedures are complying with federal regulations. After a period of use, the surface of modular conveyor belts is no longer smooth or waterproof. Modular conveyor belts are damaged by knife strokes and return carriages in the form of cuts and debris on the surface of the belt. Damaged modular belt surfaces no longer meet USDA inspection requirements and federal regulations that damaged surfaces may be susceptible to the buildup of bacteria and other organisms. In the past, the only alternative was to dispose of damaged conveyor belts and replace them at a very high cost.

Brief Description of the Invention The present invention is an apparatus and method for the renewal of conveyor belts. Particularly, the present invention relates to an apparatus and method for the renovation of expensive modular conveyor belts for reuse in the food industry. In one embodiment, the present invention includes an apparatus for renewing conveyor belts having a damaged portion. The apparatus includes a frame and a conveyor system. A mechanism is attached to the frame to remove a desired amount of the conveyor belt as the conveyor belt moves relative to the frame on the conveyor system. The mechanism for removing a desired amount of the conveyor surface may include a generally cylindrically shaped, selectively rotating member having at least one blade extending from a longitudinal surface thereof. The mechanism for removing a desired amount of the conveyor belt can also be obtained by other mechanical means. Electrical or chemical, such as the use of a drum sander. Additionally, the mechanism for removing a desired amount of the conveyor surface may include a mechanism to apply uniform pressure to the surface of the conveyor belt. The mechanism for applying pressure to the surface of the conveyor belt may include a pair of pressure conservation devices located on each side of the apparatus frame. Additionally, the apparatus may include a mechanism for unloading the removed conveyor belt. The conveyor belt renewing apparatus may also include a mechanism for adjusting the vertical position of the conveyor belt surface relative to the mechanism for removing a desired amount of the conveyor belt surface. In a preferred embodiment, the present invention includes a system for modular conveyor belt renewal used on conveyor systems in the food processing industry, the modular conveyor belt having a damaged surface. The renovation system includes a frame with a conveyor bed that passes through the frame. A mechanism is attached to the conveyor bed to selectively move the damaged modular conveyor belt on the conveyor bed relative to the frame. A mechanism is also attached to the frame to remove a desired amount from the damaged surface of the modular conveyor belt as the conveyor belt moves through the frame. In addition, a control mechanism is included to control the amount of surface removed, adjusting the position of the conveyor bed relative to the mechanism for removing the surface of the conveyor belt. In one embodiment, the removal mechanism includes a mechanism for smoothing the surface of the modular conveyor belt having at least one rotating blade.

Alternatively, the removal mechanism may include a drum sander. Additionally, the system may include a mechanism for polishing the conveyor belt after the damaged surface has been removed; a mechanism for selectively imparting a drag force on the modular conveyor belt to assist in the removal of the conveyor belt surface; a mechanism for adjusting the conveyor frame to accommodate different widths and lengths of the conveyor belt; and a mechanism to apply uniform pressure to the surface of the modular conveyor belt. In another embodiment, the present invention may include a control mechanism for varying the speed of movement of the conveyor bed relative to the frame and, a control mechanism for varying the speed of smoothing the surface of the conveyor belt. The present invention renews the modular conveyor belt for reuse, which in the past was discarded and replaced at a high cost. The modular conveyor belt can be renewed a number of times, depending on the amount of conveyor belt removed.

Brief Description of the Drawings The invention will be described with reference to the accompanying drawings in which similar reference numerals refer to similar parts in the different views and where: FIG. 1 is a diagrammatic view of an apparatus for band renewal in accordance with the present invention; Fig. 2A is a plan view of a portion of the damaged modular conveyor belt shown in FIG. 1; Fig 2B is an end view of the damaged modular conveyor portion shown in Fig. 2A; Fig. 2C is an end view of the damaged modular conveyor belt of Figs. 2A and 2 B shown in the alternative position; Fig. 3 is a partial view showing the smoothing of a modular conveyor belt surface in accordance with the web renewal apparatus of the present invention; Fig. 4A is a plan view of a portion of the renewed modular conveyor belt; Fig. 4B is an end view of the portion of the renewed modular conveyor belt shown in FIG. 4A; and Fig. 5 is a control diagram including a graphic representation of the input signals and the output signals according to one embodiment of the present invention.

Detailed Description of the Preferred Modalities The present invention relates generally to an apparatus for renewing the industrial conveyor belt used in conveyor systems. Particularly, the modular conveyor belt used on conveyor systems in the food processing industry that is damaged after a period of use. In the past, when the damaged band no longer meets federal regulations for use, the conveyor belt was discarded and replaced at a high cost. The present invention renews damaged modular conveyor belts to its smooth, waterproof preform, which complies with federal regulations for reuse in the food industry at a fraction of the replacement cost. Fig. 1 shows a web renewal system according to the present invention generally at 10. The web renewal system 10 generally includes a surface removal system 12 and a conveyor system 14. In general, the conveyor system 14 transports the damaged conveyor belt which will be renewed through the surface removal system 12 to remove the damaged conveyor belt surface. The conveyor belt to be renewed is generally shown at 16 on the conveyor system 14. In a preferred fashion, the conveyor belt 16 is a modular conveyor belt that is generally used in the food processing industry. A portion of the modular conveyor belt 16 is shown in Figs. 2A, 2B and 2C. As shown in Fig. 2A, the conveyor belt 16 includes modules 18 that are rotatably connected together. Modules 18 are formed from injection molded plastic material, such as acetal, polyurethane, polyethylene, combinations of acetal polyethylene or similar materials. Modules 18, such as those commonly manufactured by Rexnord, Intralox, Falcon, Cambridge, etc. , are generally formed to fit most conveyor systems in the food industry. The modules 18 include a top surface 20 and hinge extensions 22. The modules are flexibly connected together by passing a pin (not shown) through corresponding hinge extensions 22 and securing the pin in place with a fastener 23. As shown in Fig. 2C, the conveyor belt formed of modules 18 is flexible in the hinge extensions 22. The conveyor belt can be provided in various widths and lengths. The bandwidths vary up to any usable width. Therefore, to obtain larger conveyor belt widths, manufacturers commonly combine a combination of modules 18. The top surface 20 is a molded surface that is generally flat. In the food processing industry, as the modular conveyor belt 16 transports unprocessed feed through the different processing stations, the upper surface 20 of the modular conveyor belt 16 is damaged by the knife strokes and the return carriages in the shape of cuts and debris on the upper surface shown generally at 24. The damaged upper surface 24 may be susceptible to the accumulation of bacteria and other organisms. Food procedures are subjected to daily inspections to meet federal health requirements. In the past, when conveyor belt 16 was damaged to the point that it no longer complied with federal regulations, the only alternative was to dispose of the damaged belt and replace it at a very high cost. The present invention for web renewal 10 removes the damaged portion 24 from the top surface 20. The top surface 20 is smooth again and suitable for use in conveyor systems of the food industry. Referring to Fig. 1, the surface removal system 12 is securely secured to the frame 11. The surface removal system 12 removes the damaged portion 24 from the upper surface 20, renewing the conveyor belt 16 in condition to the re-use In a preferred embodiment shown in Fig. 1, the surface removal system 12 includes a band smoothing system 30. The smoothing system 30 includes a smoothing drum 32 having blades 34, pressure devices 36, channel of relief. discharge of damaged conveyor belt 40, motor 42 and controller 44. The smoothing drum 32 is rotatably connected within the frame 11. The smoothing drum 32 is generally cylindrical with blades 34 extending from the smoothing drum 32 along of its longitudinal surface. The blades 34 are secured within the smoothing drum 32, with the amount of blades 34 extending from the smoothing drum 32 being adjustable. In a preferred embodiment shown in Fig. 1, four blades 34 are equidistanced along the cylindrical surface of the smoothing drum 32. The smoothing drum 32 is mechanically coupled (43) to the motor 42 to rotate at a desired speed as it is indicated by the directional arrow 46. The rotation of the drum 32 is controlled by the controller 44. The controller 44 controls the starting and stopping of the smoothing drum 32. Additionally, the engine 42 may include a variable frequency drive coupled to the drum of smoothing 32, which allows the controller 44 to also control the speed of rotation of the smoothing drum 32. In operation, as the damaged conveyor belt 16 moves past the smoothing drum 32, indicated by the directional arrow 48, a pair of devices of pressure 36 apply uniform pressure to the upper surface of the conveyor belt 16. The pressure devices include pressure conservation bars 50 and pressure plates 52. The pressure plates 52 have a different width that is greater than or equal to the width of the conveyor belt 16. In operation, the pressure plates 52 are in contact with the upper surface of the conveyor belt 16. The pressure conservation bars 50 are located on the pressure plates 52 and secured to the frame 11. Pressure conservation bars 50 adjust the amount of uniform pressure applied to the conveyor belt 16. Pressure devices 36 prevent the conveyor belt 16 from flexing laterally as the conveyor belt 16 passes through the smoothing system 32, and are spaced apart at a distance that is generally less than the width of a module 18. As shown at 54, the blades 34 rotate, extend between the pressure devices 36 to cut the upper surface 20 of the conveyor belt 16. Additionally, the guards 38 are located around the smoothing drum 32. The guards 38 provide safe protection of the blades 34 and also a conduit for the blades 34 for launching the removed conveyor belt material into the damaged conveyor belt discharge area 40. In one embodiment, the damaged conveyor belt discharge 40 is connected to a vacuum to collect the damaged conveyor belt material. in a central location. The damaged conveyor belt byproduct is in a form suitable for recycling. The conveyor belt by-product can be melted and used again for injection molded processes. The present invention provides advantages over previous wasteful industrial practices. In the past, when the damaged conveyor belt no longer met the inspection requirements, it was discarded and was in a very large form for easy recycling. With the advantages of the present invention, the conveyor belt is renewed for reuse, and the damaged conveyor belt byproduct is recyclable for use in other injection molded products. The conveyor system 14 moves the conveyor belt 16 through the frame 1 1 for the removal of the damaged top surface 24 by the surface removal system 24. The conveyor system 14 includes the conveyor bed 60, the conveyor bed surface 62, drive gear 64, engine 66, brake spool 70, conveyor bed length adjustment 71, and surface removal setting 74. The conveyor bed 60 extends through the frame 1 1 and is securely mounted and supported by frame 1 1.

Alternatively, the conveyor bed 60 may extend through the frame 1 1, be located adjacent the frame 1 1 and be supported by the process floor. The conveyor bed 60 has a conveyor bed surface 62. The conveyor bed surface 62 is formed of a material that will not damage the conveyor belt 16 that passes over the conveyor bed surface 62 and, which has a low coefficient of friction between the conveyor bed. conveyor bed surface 62 and conveyor belt 16. In one embodiment, the conveyor bed surface 62 is formed of plastic or a material similar to that of conveyor belt 16. Carrier bed 60 is secured to frame 1 1, indicated at 76. The drive sprocket is located at one end of the conveyor bed 60 and the braking reel 70 is located at an opposite end of the conveyor bed 60. The conveyor belt 16 is loaded onto the conveyor bed 60 and around the drive sprocket 64. and the braking spool 70 as shown in Fig. 1. The drive sprocket 64 pulls the conveyor belt 16 through the surface removal system 12 on the conveyor bed 60. If necessary, the drive sprocket 64 can be easily changed to accommodate a specific type of conveyor belt from the manufacturer, since that the drive sprockets for each type of conveyor belt all have a common universal pin system. The drive sprocket 64 is mechanically coupled (67) to the motor 66 which drives the drive sprocket 64. The controller 68 allows control of the drive sprocket 64, such as the start and stop operations. In one embodiment, the motor 66 includes a variable frequency drive coupled to the drive sprocket 64 to vary the speed of the conveyor belt 16. With the variable frequency drive, an operator is able to adjust the speed of the conveyor system 14 in the controller 68. The braking spool 70 is rotatably attached to the conveyor bed 60 at the opposite end of the drive sprocket 64. The braking spool 70 follows the drive sprocket 64 to guide the conveyor belt 16 through the conveyor bed 60. Additionally, the braking spool 70 imparts an adjustable drag force on the conveyor belt 16 to keep the conveyor belt 16 adjusted to the conveyor bed surface 62 and prevents the conveyor belt 16 from flexing laterally as it moves through. of the surface removal system 12. The amount of damaged top surface that needs to be removed varies from one conveyor belt to another, depending on how deep the cuts or debris are inside the conveyor belt 16. The present invention provides the precision adjustment of the amount of the top surface that will be removed by the surface removal system 12. In a preferred embodiment, the smoothing drum 32 remains stationary within the surface removal system 12 and the amount of upper surface to be removed is adjusted by the surface removal adjustment of the conveyor bed 74. The removal adjustment of surface 74 provides for the precision adjustment of the conveyor bed 60 in a vertical direction. Additionally, the surface removal adjustment 74 provides a leveling adjustment of the conveyor bed 60. Alternatively, it is recognized that the conveyor bed 60 could remain stationary and the amount of the removed top surface would be adjusted by adjusting the removal system 12 of the smoothing system 30. Additionally, the length of the conveyor bed 60 can be adjusted by the length adjustment of the conveyor bed 72. The length adjustment of the conveyor bed 72 adjusts the conveyor bed 60 to accommodate different size conveyor belts or to absorb the excess conveyor belt after the conveyor belt 16 is loaded on the conveyor belt 60. Fig. 3 shows a partial close-up view of the belt renewal smoothing system 30 in operation (the pressure devices 36 are not shown). nor the guards 38. As shown, the smoothing system 30 flattens the undesired damaged upper surface 24 of the conveyor belt 16, resulting in the smooth top surface 20 as shown in Figs. 4A and 4B. The resulting upper surface is smooth and waterproof, free of blade cuts or debris. Additionally, the web renewal system 10 of the present invention provides a more realistic cutting surface than the originally molded conveyor belt 16, which was generally flat. The present invention allows the plastic modular conveyor belt to be renewed a number of times. Since the surface removal adjustment 74 allows fine adjustment of the amount of surface to be removed, when the surface cuts are not very deep, only a small portion of the surface is removed, if necessary. Since the upper surface 20 of the conveyor belt modules are relatively thick, the conveyor belt 16 can be renewed a number of times in a condition acceptable for use in process conveyor systems. Referring to Fig. 1, an additional polishing system, shown at 80, can also be used to provide a smooth polished finish to the renewed conveyor belt 16. The polishing system 80 includes an oscillating wheel polisher 82, a motor 84, a controller 86 and a support system 88. The oscillating wheel polisher 82 is supported by the support system 88. The oscillating wheel polisher 82 can be selectively adjusted to be in contact with the conveyor belt 16 after it has been passed to through the surface removal system 12. The oscillating wheel polisher 82 is mechanically coupled to the motor 84 and is controlled by the controller 86. The motor 84 rotates the oscillating wheel polisher 82 to polish and brighten the upper surface 20 of the conveyor belt 16. It is recognized that the polishing system 80 does not have to remain in continuous contact with the conveyor belt 16, but is controlled to make contact or with the conveyor belt when desired. It may be necessary for the conveyor belt to be sanitized or disinfected before or after the renovation. In one embodiment, a band scrubber is used to clean the modular conveyor belt. The belt scrubber may include a series of nozzles or spray jets for pressure cleaning of the conveyor belt. Additionally, a chemical cleaner, such as a chloride-based solution, can be used to clean and disinfect the conveyor belt. It is also recognized that the present invention, shown in Fig. 1 set to renew a continuous loop of conveyor belt 16, could be used as a system for renewal of belt for continuous feed. In this operation, a rubber drum roller system 90 can be located on the drive sprocket 64 to retain the conveyor belt 16 against the drive sprocket 64. Additionally, it is recognized that the band refresh system 10 is operable as a portable unit, and could be located at the end of an existing conveyor system to be renovated. In this operation, the conveyor belt would be fed simply from the existing conveyor system on the web renewal system for surface removal and return it to the conveyor system. It is also recognized that the damaged surface that is to be removed could be removed in one pass through the surface removal system 12 or achieved through several passes through the surface removal system 12. Additionally, the smoothing system 30 may include a blade or a number of blades or, may include additional smoothing drums for multiple cutting of the top surface 20. In one embodiment, the speed of the cutters is variable and also the speed at which the conveyor system moves the conveyor belt through the surface removal system 12. Additionally, as shown in Fig. 5, the band renewal system 10 can be incorporated into a process having a centralized control system as generally shown at 100. In one embodiment, the centralized control system 100 includes a controller 102. The controller 102 includes a mechanism capable of developing logical operations, such as a sequence of logical inputs, switches, a control unit based on a microcomputer or another microprocessor. The controller 102 provides manual or automatic operation of the band renewal system 10. The controller 102 accepts user inputs 104, such as the desired cut rate, conveyor speed, depth of cut, web tension, band pulse voltage and the rating of the polishing system. Additionally, the controller 102 accepts alarms from the system 106, other sensors 108 and other inputs 109. In response, the controller 102 automatically controls the band refreshment system 10 providing the time controlled outputs 110, 112, 114, 116 and 120. It is also recognized that other systems can be used for the surface removal system 12 as long as they remain within the scope of the present invention. For example, it is contemplated that the surface removal system 12 may include a drum sander to remove the damaged upper surface portions 24. Although the use of a drum sander is contemplated, the smoothing system is preferred due to the problems inherent associated with sanding materials molded with plastic. It is recognized that with the use of a drum sander, the plastic conveyor belt is more susceptible to warping, a real surface can not be obtained and fine adjustment of the portion to be removed may not be achieved. Additionally, the web renewal system of the present invention is capable of removing the damaged portions on the side of the modular conveyor belt by the use of a side surface removal device such as a trowel or circulating knife mechanism similar to a bench saw.

It is recognized that the present invention can be used to renovate almost any type of industrial conveyor belt formed of plastic, rubber or similar materials. Additionally, the web renewal process can be used as a preliminary step to re-smooth the damaged conveyor belt by applying an additional substrate on the renewed conveyor belt. The web renewal system provides an economical and efficient apparatus and method for removing the damaged upper surface of the modular plastic conveyor belt commonly used on conveyor systems in the food processing industry. With the use of the present invention, the expensive plastic modular conveyor belt no longer needs to be discarded when damaged, but it can be renewed repeatedly for use as long as they comply with federal regulations. It will be understood that this description is, in many aspects, illustrative only. Changes can be made in the details, particularly in the aspects of form, size, material and arrangement of the parts, without exceeding the scope of the invention. Accordingly, the scope of the invention is as defined in the language of the appended claims.

Claims (21)

1. CLAIMS 1 . An apparatus for renewing a conveyor belt having a damaged portion, the apparatus comprising: a. a frame; and b. means attached to the frame to selectively remove a desired amount of the conveyor belt.
2. 2. The apparatus of claim 1, further including: a. conveyor means for selectively moving the conveyor belt relative to the frame.
3. The apparatus of claim 1, wherein the removal means includes a generally rotationally cylindrically shaped, selectively rotating member having at least one blade extending from a longitudinal surface thereof.
4. 4. The apparatus of claim 3, further including: a. means for the application of uniform pressure to the surface of the conveyor belt.
5. The apparatus of claim 1, wherein the means for removing a desired amount of conveyor belt includes means for applying uniform pressure to the surface of the conveyor belt.
6. 6. The apparatus of claim 5, wherein the pressure is applied to the surface of the conveyor belt with a pair of pressure conservation devices.
7. 7. The apparatus of claim 1, further including: means for unloading the removed conveyor belt.
8. 8. The apparatus of claim 1, further including: a. means for adjusting the vertical position of the conveyor belt surface relative to the means for removing a desired amount of conveyor belt.
9. 9. The apparatus of claim 1, further including: a. control means for controlling the amount of conveyor belt removed by adjusting the position of the conveyor belt surface relative to the means for removing a desired quantity from the conveyor belt.
10. 10. The apparatus of claim 1, further including: a. control means for controlling the speed of removal of the desired amount of the conveyor belt surface.
11. 11. A system for the renewal of modular conveyor belt on conveyor systems in the food processing industry, the modular conveyor belt having a damaged surface, the system comprising: a. a frame; b. conveyor means for selectively moving the modular conveyor belt on the conveyor bed relative to the frame; and c. means attached to the frame to selectively remove a desired amount from the surface of the modular conveyor belt as the conveyor belt moves relative to the frame on the conveyor means.
12. The system of claim 11, including: a. control means for selectively controlling the amount of surface removed by adjusting the position of the conveyor bed relative to the means for selectively removing a desired amount from the surface of the modular conveyor belt.
13. The system of claim 11, wherein the removal means include: a. means for smoothing the surface of modular conveyor belt having at least one rotating blade.
14. The system of claim 11, further including: a. means coupled to the conveyor means for selectively imparting a driving force on the modular conveyor belt.
15. 15. The system of claim 11, further including: a. means for adjusting the conveyor frame to accommodate different widths and lengths of the conveyor belt.
16. 16. The system of claim 11, further including: a. means for applying generally uniform pressure to the surface of the modular conveyor belt as it passes under the removal means.
17. 17. The system of claim 11, further including. to. means coupled to the conveyor means for selectively varying the speed at which the conveyor belt moves on the conveyor belt relative to the frame.
18. 18. The system of claim 11, further including: a. control means coupled to the surface removal means to selectively vary the speed of removal of the desired amount of surface.
19. 19. A modular conveyor belt renewal method having a damaged surface, comprising the steps of: a. provide a frame; b. moving the conveyor belt relative to the frame using a conveyor system; and c. remove the damaged portion of the conveyor belt as it moves relative to the frame, with a mechanism attached to the frame. The method of claim 19, wherein the removal mechanism includes a smoothing system. The method of claim 19, further comprising the step of: a. Tension the conveyor belt to the conveyor system as it moves relative to the frame.