US20010020566A1 - Modular power roller conveyor - Google Patents
Modular power roller conveyor Download PDFInfo
- Publication number
- US20010020566A1 US20010020566A1 US09/860,897 US86089701A US2001020566A1 US 20010020566 A1 US20010020566 A1 US 20010020566A1 US 86089701 A US86089701 A US 86089701A US 2001020566 A1 US2001020566 A1 US 2001020566A1
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- United States
- Prior art keywords
- divert
- section
- conveyor
- programmable controller
- active zone
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G47/00—Article or material-handling devices associated with conveyors; Methods employing such devices
- B65G47/22—Devices influencing the relative position or the attitude of articles during transit by conveyors
- B65G47/26—Devices influencing the relative position or the attitude of articles during transit by conveyors arranging the articles, e.g. varying spacing between individual articles
- B65G47/261—Accumulating articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65G—TRANSPORT OR STORAGE DEVICES, e.g. CONVEYORS FOR LOADING OR TIPPING, SHOP CONVEYOR SYSTEMS OR PNEUMATIC TUBE CONVEYORS
- B65G2203/00—Indexing code relating to control or detection of the articles or the load carriers during conveying
- B65G2203/04—Detection means
- B65G2203/042—Sensors
Abstract
A modular power roller conveyor is described having a conveyor section for transporting a product unit. The conveyor section comprises a number of active zones, each active zone containing means for sensing the entry of a product unit into the active zone. A programmable controller generates activation signals to a drive roller in response to the means for sensing. A plurality of carrier rollers are slaved to the drive roller within the active zone such that activation of the drive roller actuates all of the carrier rollers to drive the product unit through the active zone and into the next active zone. The programmable controller also generates a deactuation signal to deactivate the active zone as a product unit exits the zone.
Description
- This application is a division of prior application Ser. No. 08/762,314, filed on Dec. 9, 1996, pending, which is a continuation of prior application Ser. No. 08/331,063, filed Oct. 28, 1994 now U.S. Pat. No. 5,582,286.
- The present invention relates to a conveyor systems and more particularly to a modular conveyor system and a method for conveyor operation.
- The movement of large numbers of product units, such as a tray or pallet, around a manufacturing or processing facility has long proved to be an expensive and time consuming task. Presently, most systems for carrying out the movement of product units around a manufacturing facility utilize static systems that are set up to maintain and transport product units using a particular configuration that is not easily changed. The problem with these type of systems is that manufacturing or processing requirements may change and reconfiguration of the static system is not easily achieved. Thus, weeks or even months may be required to reconfigure a conveyor system to meet the changing needs of the facility.
- Prior art conveyor systems have many problems relating to the maintenance and complexity of the systems. One problem with existing conveyor systems is that the systems normally have complex mechanical gearing consisting of a large number of components. This type of mechanically geared conveyor system requires a great deal of maintenance in order to keep the system in peak operating condition. Air pressure operated systems require a complex pneumatic system in order to operate the conveyor. Pneumatic systems require labor intensive maintenance procedures in order to achieve peak operating conditions of the system. Existing systems also create a great deal of noise when operating. Mechanically geared systems normally comprise a large number of chain and roller drive assemblies creating mechanical noise during operation. Pneumatic systems necessarily require the use of noisy compressors and air injection procedures which add to the noise pollution of the work environment. Finally, each of the above described systems require a great deal of power to operate since the entire system must function at the same time, no matter how many or few product units are present upon the conveyor system at any particular time.
- Therefore, a conveyor system is needed which will allow a manufacturing or processing facility to quickly and easily reconfigure the system to changing facility needs, provide easy maintenance requirements, decrease the amount of noise pollution to the work environment, and provide lower energy consumption than is possible with presently existing systems.
- The present invention overcomes the foregoing and other problems with a modular power roller conveyor system and onboard PLC/power card. The system consists of modular units having a frame for holding a plurality of carrier and drive rollers. These modular units are easily connected to form an adaptable conveyor system. The conveyor section of each module is divided into a number of active zones. Each active zone contains a photosensor and reflector pair for detecting the entry of a product unit into the active zone, a drive roller for driving rollers within the active zone, and a plurality of carrier rollers actuated in response to movement of the drive roller. Each zone is connected to a PLC/power card. Upon detection of a product unit by a photosensor, a control unit generates an activation signal to the drive roller of the active zone the product unit is entering. The drive roller drives the carrier rollers within the active zone allowing the product unit to be transported through the active zone and into the next active zone. At the same time, the controller generates a deactivation signal to the drive roller of the active zone the product unit is exiting to conserve system power.
- FIG. 1 is a perspective view of one section of the modular power roller conveyor of the present invention;
- FIG. 2 is a cut-away representation of one side rail and several rollers of the section of FIG. 1 and the internal connecting brackets;
- FIG. 3 is a side view of one of the carrier rollers;
- FIG. 4 is a lateral cross-section view of the conveyor section of FIG. 1;
- FIG. 5 is a lateral view of the interface between adjacent sections showing the attachment of the roller shafts to the side rail;
- FIG. 6 is a top view of the straight conveyor section of FIG. 1 comprised of four active zone;
- FIG. 7 is a perspective view of a curved conveyor section of the modular power roller conveyor of the present invention;
- FIG. 8 is a tapered roller of the curved conveyor section of FIG. 7;
- FIG. 9 is a top view of the curved conveyor section of FIG. 7;
- FIG. 10 is a top-view of a left-hand divert section of the power roller module;
- FIG. 11 is a lateral view of a left-hand divert section of FIG. 10 of the power roller module;
- FIG. 12 is a top view of the divert section of FIG. 10 illustrating the divert arm in an unactuated first position inside a hollow side rail;
- FIG. 13 is a lateral view of the divert section of FIG. 12;
- FIG. 14 is a top view of a divert section of FIG. 10 illustrating the divert arm in an actuated second position extending from the hollow side rail across the conveyor and diverting a product unit from a first path to a second path;
- FIG. 15 is a lateral view of a divert section of FIG. 14;
- FIG. 16 is a circuit wiring diagram of the controller; and
- FIG. 17 is a schematic of a logic circuit within the controller.
- Referring now to the Drawings, and more particularly to FIG. 1, there is illustrated a perspective view of one embodiment of a
module 8 for the modular power roller conveyor of the present invention. Themodule 8 is astraight conveyor section 10 for transporting received product units. Thestraight conveyor section 10 is supported bylegs 11 and consists of aleft side rail 12, aright side rail 13, a plurality ofcarrier rollers 14 anddrive rollers 16 mounted between theleft side rail 12 and theright side rail 13. The drive rollers and the carrier rollers may be of the type manufactured by Interroll Corporation and identified as model Driverroll. Thecarrier rollers 14 anddrive rollers 16 are interconnected by a plurality of o-ring bands 17 such that actuation of a drive roller will cause actuation of any carrier rollers connected thereto. - The
side rails Openings 18 withinside rails photosensors 34 and reflectors 36 (FIG. 4) for sensing the presence of product units on thestraight conveyor section 10. Mounted to theside rails straight conveyor section 10 are internal connectingbrackets 22 withholes 45 for bolts and nuts to enable thestraight conveyor section 10 to be interconnected with anothermodule 8 and form a conveyor system. An electrical connector mounted in anopening 23 enables amodule 8 to be electrically connected to other modules or to a power supply. - Referring now to FIG. 2, there is shown a cut-away representation of the
side rail 13 andseveral rollers 14 and theinternal connecting bracket 22.Holes 45 in the connectingbracket 22 allow structural connection with anadjoining module 8, while anopening 23 in theinternal connecting bracket 22 allows wire connection between electronic components ofadjacent modules 8. Acover 41 protects the wireway, and is connected toside rail 13 with single-turn screws 35 and rifledholes 43. The shafts on which therollers end 28, and the spring loaded end passes through holes in theside rail 13. - Referring now to FIG. 3 and FIG. 4, there is shown a side view of one of a
carrier roller 14. Thecarrier roller surface 20 is preferably fabricated from a galvanized steel tube. Theshafts 28 of thecarrier roller 14 are spring loaded at each end allowing for easy removal and mounting of the carrier roller within the side rails 12 and 13. Eachcarrier roller 14 also includes a pair ofgrooved channels 30 for placement of the o-ring bands 17 (FIG. 1) between adjacent carrier rollers. Eachdrive roller 16 has an outward appearance similar to that of thecarrier rollers 14. Thedrive roller 16 has aroller surface 26, spring loadedshaft 28 on one side and a lock nut and a full nut on the opposite side, andgroove channels 30. However, thedrive rollers 16 further include internal gearing and an electric motor. Thedrive rollers 16 are preferably twenty-four volt electric conveyor rollers manufactured by the Interroll Corporation. - Referring to FIG. 4, there is shown a lateral cross-section view of the
conveyor section 10 more fully illustrating the placement and operation of thephotosensors 34 andreflectors 36 mounted along theconveyor section 10. Thephotosensor 34 is mounted to alower sensor bracket 38.Lower sensor bracket 38 connects to anupper sensor bracket 40 which connects to the upper surface ofleft side rail 12. The assembly is positioned in such a manner that abeam 42 fromphotosensor 34 is passes through opening 18 withinleft side rail 12. Thebeam 42 passes laterally across theconveyor section 10 and passes through opening 18 in theright side rail 13 to strikereflector 36 and is reflected back tosensor 34 where the reflected beam is detected. Thereflector 36 is mounted to the interior of theright side rail 13 by areflector bracket 44. - Referring to FIG. 5, there is shown a lateral view of the interface between adjacent modules with the
bolts 28 attaching the shafts ofrollers 14 to theside rail 13. A connectingbracket 22 is shown connectingadjacent modules 8 by means ofbolts 37 and nuts 39. Electrical connection is made by means of connectors (not shown) mounted toopenings 23. Thecover 41 is attached atseveral points 35. - Referring now to FIG. 6, there is illustrated a top view of a straight conveyor section including four active zone areas50 a-50 d. Each active zone includes a
drive roller 16 and plurality ofcarrier rollers 14 slaved to the drive roller by o-ring bands 17. Also included within each active zone 50 is a photosensor 34 and areflector 36 located prior to the entry end 52 of the active zone. A programmable controller 54 (FIG. 16) is mounted in theleft side rail 12 and is in communication with eachdrive roller 16, the plurality ofphotosensors 34 and programmable controllers (FIG. 16) in adjacent conveyor sections. - As a product unit leaves one
active zone 50 a, the product unit breaks the light beam 42 (FIG. 4) betweenphotosensor 34 andreflector 36. This causes a detection signal to be transmitted to the controller 54 (FIG. 16) by thephotosensor 34. For example, upon receipt of a detection signal from theactive zone 50 b, the controller 54 (FIG. 16) generates an activation signal to thedrive roller 16 of theactive zone 50 b as the product unit is entering the zone. Activation of thedrive roller 16 initiates movement of the drive roller and all slavedcarrier rollers 14. At the same time, a deactivation signal is transmitted to thedrive roller 16 of theactive zone 50 a as the product unit is exiting this zone. This process continues as the product unit passes from one active zone 50 to another. It is important to note that thedrive roller 16 of an active zone 50 is only activated while a product unit moves through the active zone. When a product unit leaves an active zone 50 and no other product units enter the active zone, thedrive roller 16 and slavedcarrier rollers 14 are not actuated. This results in a conveyor system that uses less power and produces less noise than presently existing systems. - Referring now to FIG. 7, there is shown curved section of the modular power roller conveyor of the present invention. The module of FIG. 7 comprises a
curved conveyor section 60 that change the direction of travel of a product unit by 90°. It is important to note that while this particular module illustrates a 90° turn, a turn from anywhere between 0° and 180° may be constructed. Thecurved conveyor section 60 is supported bylegs 62. As before, thecurved conveyor section 60 comprises aleft side rail 64, aright side rail 66,drive rollers 72 and carrier rollers (14, 74) mounted between theleft side rail 64 and theright side rail 66. Thecarrier rollers 74 are connected to thedrive roller 72 by a plurality of o-ring bands 80 such that actuation of a drive roller will actuate any carrier rollers connected thereto. -
Openings 68 within side rails 64 and 66 facilitate operation of photosensors 34 (FIG. 4) and reflectors 36 (FIG. 4). The photosensor and reflector assemblies are mounted in a manner similar to that discussed with respect to FIG. 3. At each end of thecurved conveyor section 60 connectingbrackets 68 are mounted to the left and right side rails 62 and 64 to interconnect thecurved conveyor section 60 to other conveyor sections. Each end of thecurved conveyor section 60 also includes a electrical connector mounted in anopening 69 for electrical connection between adjacent modules or a power supply. - Referring now to FIG. 8, there is illustrated the
tapered carrier roller 72 of thecurved conveyor section 60. Thecarrier rollers 14 on the straight portions of thecurved conveyor section 60 are the same as those discussed with respect to FIG. 3. On thetapered carrier roller 72, the carrier roller surface is preferably fabricated from galvanized steel tubing overlain with high impact molded copolymer segments. The surface forms a continuous taper from alarge diameter end 75 to asmall diameter end 77 to allow efficient movement of a product unit around the curved section. Spring loadedshafts 76 allow for mounting and removal of thetapered carrier roller 72 within the left and right side frames 64 and 66. Thetapered carrier rollers 72 are mounted such that thesmall diameter end 77 is placed upon the interior radius of thecurved conveyor section 60.Grooved channels 79 allow for placement of o-ring bands 80 (FIG. 7) between adjacent rollers.Drive rollers 72 have a similar appearance to the carrier rollers and are preferably twenty-four volt electric conveyor rollers as manufactured by the Interroll Corporation. - Referring to FIG. 9, there is illustrated a top view of the
curved conveyor section 60 of the curved section module. Theconveyor section 60 comprises a number of active zones 61 a-61 d. As a product unit passes between a photosensor 34 andreflector 36 and into anactive zone 61 b, the photosensor 34 transmits a detection signal to a controller 86 (FIG. 16). In response to the detection signal, the programmable controller 86 (FIG. 16) generates an activation signal to thedrive roller 72 of theactive zone 61 b. Thedrive roller 72 drives each of the slavedcarrier rollers 74 within theactive zone 61 b until the product unit passes to theactive zone 61 c. The detection signal also causes the controller 86 (FIG. 16) to generate a deactivation signal to thedrive roller 72 of theactive zone 61 a as the product unit is exiting this zone. - Referring to FIG. 10 and FIG. 11, there is illustrated a top-view and a side view of a left-hand divert
section 81 of a power roller conveyor. A flexible divertarm 92 is mounted to aside rail 85. A programmable controller 94 (FIG. 16) actuates anair cylinder 83 mounted to theside rail 85 and the extension of the plunger arm within thecylinder 83 extends the flexible divertarm 92 from theside rail 85 across the divertsection 81. Atrack 90 in the plane defined by the surface of the rollers, comprises a narrow groove that serves as a guide for the flexible divertarm 92. The track extends obliquely from theside rail 85, to the limit of extension of the flexible divertarm 92. When thecylinder 83 is actuated, the divertarm 92 slides along theside rail 85 and along thetrack 90, into the path ofproduct units 88 moving along the conveyor. The bottom edge of the divertarm 92 lies within the groove of thetrack 90 and as product units pass along theconveyor 81 the divertarm 92 is encountered and slides along the divert arm. Positioned at an angle with reference to the divertsection 81 is astraight section 98, and product units that encounter the divertarm 92 slide along the divert arm into thestraight section 98 of power roller conveyor. - In a left-hand divert as shown in FIG. 10 the divert arm extends from the
side rail 85, but right-hand divert sections are also available, in which the divertarm 92 extends from the opposite side rail. Also available are dual divert sections in which a divertarm 92 extends from each side rail, and atrack 90 extends from each side rail, so that product unit may be diverted to the left, to the right, or move straight ahead according to instructions from the programmable controller 94 (FIG. 16). - An alternative embodiment of the invention includes a right angle transfer arm that moves up from below the surface defined by the rollers. The right angle transfer arm is raised by instruction from the programmable controller94 (FIG. 16).
- Referring now to FIG. 12 (a top view), and FIG. 13 (a lateral view), of the divert
section 81 in which the divertarm 92 is unactuated and remains positioned along theside rail 85. Aproduct unit 88 passing along the conveyor continues in a straight line, as though the section were a straight modular section. - Referring now to FIG. 14 (a top view), and FIG. 15 (a lateral view), of the divert
section 81 the divertarm 92 is actuated and extends from theside rail 85 into the path of theproduct unit 88 moving along the conveyor. The product unit is diverted into theside path 98. - Referring now to FIG. 16, there is shown a schematic of a preferred implementation of the controller. One such controller appears on each conveyor module. A FLASH-RAM139 (manufacture designation AT29C256) stores ladder logic code as the computer program for the module. A
logic network 137, for example a PSD311 44-pin chip, includes internal logic to interface with amicroprocessor 134. Thelogic network 137 contains a SRAM interconnected to themicroprocessor 134; an EPROM; and other logic and switching circuits. Themicroprocessor 134 controls circuitry associated with the module. Alogic network 138, for example a DS1232, restarts themicroprocessor 134 in the event of microprocessor interruption. Twologic networks 141, for example HCPL-2400 chips, serve as optical isolators for a serial port, protecting themicroprocessor 134 from voltage surges. A networking interface connects atransorb 136 to themicroprocessor 134. Thetransorb 136 clips any voltage above 12 volts, sending it to ground. A high-speed one-megserial port 130 allows themicroprocessor 134 to communicate with thelogic networks 141 of an interconnected module. A port 140 allows modification and installation of logic code into the FLASH-RAM 139 by a system installer when the site is initially configured. The inputs of four circuits of the type generally shown in FIG. 17 are collectively made available throughterminals 132 to themicroprocessor 134. One controller of the type generally shown in FIG. 16 is mounted on each module, as described above, andmeasures 8″×6″×2″. Eight digital inputs atterminals 132 connect to the input pins of themicroprocessor 134 through light emitting diodes (LED's) 133 connected to theinput terminals 132, these terminals also allow controller diagnostics. Sensor signals atterminals 135 from each of several photosensors also serve as inputs to themicroprocessor 134. In the preferred embodiment, the controller operates from a 24 volt AC source, and the interconnected controllers of various modules operate in DEVICE NET and SDS. The controllers communicate on DEVICE NET or on SDS application layers. - Referring now to FIG. 17, there is illustrated a schematic of a logic circuit allowing the controller to alter direction of motion of items on the module, and to enable dynamic braking. Four circuits functionally equivalent to the circuit shown in FIG. 17 reside on each module. One
input 101 controls dynamic braking; when the value of theinput 101 is zero, dynamic braking is engaged, and the motor driving all rollers associated with the module are stopped. Theinput 101 is applied to the input to each of two NORgates gates input 101 has a value of one. The output of the NORgates capacitor debouncer gate isolator JFET input 101 has a value of one, the output of the NORgates JFETs outputs outputs input 101 is zero, the outputs are enabled. - The inverter associated with
input 102 ensures that one and only one of the two initial NORgates output input 102 selects which portion of the circuit to energize. This zero value will be passed through thedebouncer gate JFET output gate gate transistors rail voltage 117 of 30 volts. The high voltage closes theoutput JFET output volt rail voltage 117, powering a motor. Input 102 controls the direction of the rollers; the top half of FIG. 17, if energized, drive the motor in one direction, and the bottom half drives the motor in the other direction, as controlled by an inverter; only one portion of the circuit will operate at any given time. The circuit as shown in FIG. 17 shows only two inputs, but because four such circuits appear on any given module, eight inputs are supplied to the microprocessor (shown in FIG. 16). - Although preferred and alternative embodiments of the present invention have been illustrated in the accompanying Drawings and described in the foregoing Detailed Description, it will be understood that the invention is not limited to the embodiments disclosed, but is capable of numerous rearrangements, modifications and substitutions of parts and elements without departing from the spirit of the invention.
Claims (7)
1. A divert section for a modular conveyor system that includes a series of separate conveyor sections connected end-to-end for transporting a product unit from one conveyor section to another, wherein the divert section comprises:
a frame;
a series of active conveyor zones each including a conveyor mechanism mounted on the frame, each conveyor mechanism including a drive roller and a plurality of carrier rollers, the drive rollers and carrier rollers being mounted between side rails of the frame, wherein the active zones define a main path for movement of a product unit and a divert path that branches from the main path;
a sensor for each zone of each conveyor section, which sensors are positioned to sense entry of a product unit into the respective active zone and generate a detection signal in response thereto;
a divert mechanism, which allows products to travel along the main path when deactuated and directs product units along the divert path when actuated; and
a programmable controller, including a memory for storing program code, a microprocessor for execution of the program code, sensor signal inputs coupled to the microprocessor for receiving sensor signals from each sensor of the divert section, control circuits coupled to the microprocessor which permit the microprocessor to individually control the conveyor mechanism of each active zone of the divert section, wherein the programmable controller further actuates the divert mechanism to divert selected product units from the main path to the divert path.
2. The divert section of , further comprising means for interconnecting the carrier rollers for rotation in unison with the drive roller.
claim 1
3. The divert section of , wherein the divert mechanism includes a pneumatic cylinder, the programmable controller actuating the pneumatic cylinder to engage the divert mechanism.
claim 1
4. The divert section of , wherein the divert mechanism further includes a divert arm, the divert arm being moved into the main path upon actuation.
claim 3
5. The divert section of , further comprising means for interconnecting open ends of the main and divert paths with adjacent conveyor sections.
claim 1
6. The divert section of , wherein the programmable controller further comprises a communications interface whereby the programmable controller of the divert section can be connected to and communicate with a programmable controller of an adjacent conveyor section.
claim 1
7. The divert section of , wherein the sensors comprise photosensors.
claim 1
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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US09/860,897 US20010020566A1 (en) | 1994-10-28 | 2001-05-18 | Modular power roller conveyor |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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US08/331,063 US5582286A (en) | 1994-10-28 | 1994-10-28 | Modular power roller conveyor |
US08/762,314 US6253909B1 (en) | 1994-10-28 | 1996-12-09 | Modular power roller conveyor |
US09/860,897 US20010020566A1 (en) | 1994-10-28 | 2001-05-18 | Modular power roller conveyor |
Related Parent Applications (1)
Application Number | Title | Priority Date | Filing Date |
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US08/762,314 Division US6253909B1 (en) | 1994-10-28 | 1996-12-09 | Modular power roller conveyor |
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US20010020566A1 true US20010020566A1 (en) | 2001-09-13 |
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Application Number | Title | Priority Date | Filing Date |
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US08/331,063 Expired - Lifetime US5582286A (en) | 1994-10-28 | 1994-10-28 | Modular power roller conveyor |
US08/762,314 Expired - Lifetime US6253909B1 (en) | 1994-10-28 | 1996-12-09 | Modular power roller conveyor |
US09/860,897 Abandoned US20010020566A1 (en) | 1994-10-28 | 2001-05-18 | Modular power roller conveyor |
Family Applications Before (2)
Application Number | Title | Priority Date | Filing Date |
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US08/331,063 Expired - Lifetime US5582286A (en) | 1994-10-28 | 1994-10-28 | Modular power roller conveyor |
US08/762,314 Expired - Lifetime US6253909B1 (en) | 1994-10-28 | 1996-12-09 | Modular power roller conveyor |
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Also Published As
Publication number | Publication date |
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US5582286A (en) | 1996-12-10 |
US6253909B1 (en) | 2001-07-03 |
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