WO2000075055A1

WO2000075055A1 - Conveyor transfer assembly

Info

Publication number: WO2000075055A1
Application number: PCT/EP2000/004995
Authority: WO
Inventors: Stephen J. M. Craig
Original assignee: Atecs Mannesmann Ag
Priority date: 1999-06-04
Filing date: 2000-05-31
Publication date: 2000-12-14
Also published as: AU5218700A

Abstract

A transfer assembly for a conveyor system includes a frame, a plurality of rollers mounted to the frame, a plurality of grooved transfer sheaves supported by the frame, and an actuator which selectively moves a group of the transfer conveyors between a retracted position and an extended position such that the transfer belt which is carried by the transfer sheaves is moved between a position below the conveying surface to a position above the conveying surface for lifting an article being conveyed on the rollers and transferring the article in a transfer direction. At least one of the transfer belt and the transfer sheaves are adapted to resist rolling of the transfer belt in the transfer sheaves when the transfer belt is subject to a lateral force from the article being transferred.

Description

CONVEYOR TRANSFER ASSEMBLY

This application claims priority from provisional application entitled

CONVEYOR TRANSFER ASSEMBLY, Ser. No. 60/137,758, filed Jun. 4, 1999, the disclosure of which is incorporated by reference herein in its entirety. TECHNICAL FIELD AND BACKGROUND OF THE INVENTION

The present invention relates to a transfer assembly and, more particularly, to a transfer assembly for use in a live roller conveyor system.

Transfer assemblies are positioned between two conveyor sections and adjacent one or two transfer conveyors for selectively transferring articles carried and moved on the conveyor sections to one of the transfer conveyors. Conventional transfer assemblies may include a plurality of rollers and a plurality of grooved sheaves, which are positioned between the respective rollers. The grooved sheaves are oriented in an orthogonal direction to the conveying direction of the rollers and are typically driven from the main line drive shaft of the adjacent conveyor sections. Extending around the grooved sheaves are transfer belts, which are positioned by the groove sheaves between the rollers just below the conveying surface of the rollers. When a transfer is to take place, a group of the grooved sheaves is raised such that the transfer belts are raised between the rollers to lift the articles on the rollers off the rollers and to transfer them at right angles with respect to the rollers so that the articles can be deposited on the rollers of the adjacent generally orthogonal transfer conveyor. In most applications, the transfer belts are raised under the article while it is still moving. Since the article is moving at right angles to the transfer belts, the article induces lateral forces in the transfer belts. Generally, the transfer belts stop the forward motion of the article while transferring it laterally to the transfer conveyor. However, there is a tendency when the transfer belts engage the article for the article to roll the belts out of their respective sheaves, which can cause damage to the transfer assembly and to the articles being conveyed. Moreover, when a transfer belt is rolled out of a sheave, it may also cause disruption of the operation of the conveyor system.

Consequently, there is a need for a transfer assembly, which will reduce, if not eliminate, the transfer belts from rolling out of the transfer assembly sheaves. SUMMARY OF THE INVENTION

The present invention provides a transfer assembly for positioning between conveyor sections and adjacent a transfer conveyor that exhibits greater retention of the transfer belt, which is used to transfer articles from one of the conveyor sections to the transfer conveyor, while maintaining sufficient engagement with the articles being transferred.

According to one form of the invention, a transfer assembly for conveyor system includes a frame, a plurality of grooved transfer sheaves supported by the frame, and an actuator. The frame includes a conveying surface on which one or more articles are to be carried. The actuator selectively moves a group of the transfer sheaves between a retracted position, in which a transfer belt that is carried by the transfer sheaves is positioned below the conveying surface, to an extended position. When in the extended position, the transfer belt extends above the conveying surface for lifting articles being conveyed on the conveying surface and transferring the article to an adjacent transfer conveyor. At least one of the transfer belt and the transfer sheaves has a non-circular interface to resist rolling of the transfer belt in the transfer sheaves thereby to increase reliability and to increase the retention of the transfer belt in the transfer sheaves.

In one aspect, the transfer belt may include a cross-section with at least one generally planar side, with the transfer sheaves bearing on the generally planar side when the transfer belt is subject to a lateral force from an article being transferred. In this manner, the transfer sheaves restrain the transfer belt from rolling in the sheaves. In further forms, the cross- section of the transfer belt includes at least one rounded driving surface for drivingly engaging the article to be transferred. In other aspects, the cross-section of the transfer belt includes a pair of opposed rounded surfaces, with one of the rounded surfaces defining a driving surface and the other rounded surfaces defining a driven surface. Preferably, the cross-section of the transfer belt includes a second planar side with the planar side interconnecting the rounded surfaces. In this manner, the transfer sheaves bear against one of the planar sides to prevent the transfer belt from rolling in the transfer sheaves when the transfer belt is subject to a lateral force from the article being transferred.

In other aspects, the frame includes a movable sheave support. The group of the transfer sheaves which are moved by the actuator are rotatably supported by the movable sheave support, with the actuator moving the sheave support in order to move the transfer sheaves.

In yet other aspects, the transfer sheaves include projecting flanges which define a groove to restrain the transfer belt from rolling. In addition, the projecting flanges define generally spaced planar sides to restrain the transfer belt from rolling in the transfer sheaves.

According to yet another aspect, the transfer belt preferably includes a plurality of spaced notches along the longitudinal axis of the belt, to thereby increase the flexibility of the transfer belt. The notches may comprise, for example, rounded notches. Preferably, the transfer belt includes a driving portion and a driven portion with the notches being located in at least the driving portion and, more preferably, being located in both the driving portion and the driven portion. In further aspects, the notches in the driving portion are offset along the longitudinal axis from the notches in the driven portion. The improved transfer assembly provides for increased retention of the transfer belt while exhibiting sufficient engagement with the articles to be transferred in order to transfer the articles laterally to a transfer conveyor. These and other advantages will be appreciated from a review of the description of the preferred embodiments in conjunction with the drawings which follow. BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a live roller conveyor system including a transfer assembly of the present invention;

FIG. 2 is a plan view of the transfer assembly of FIG. 1 ;

FIG. 3 is a front elevation view of a transfer assembly of FIG. 1 as viewed along line III- III with the side frame of the transfer assembly removed for clarity;

FIG. 4 is a cross-section view of the transfer device taken along line IV-IV in FIG. 2;

FIG. 5 is a front elevation view of a second embodiment of a transfer assembly of the present invention; FIG. 6 is a cross-section view taken along FIG. VI- VI of FIG. 5;

FIG. 7 is a front elevation view of a third embodiment of the transfer assembly of the present invention;

FIG. 8 is a cross-section view taken along line VIII- VIII of FIG. 7; FIG. 9 is an enlarged side view of the sheave of the transfer assembly of the present invention;

FIG. 10 is a cross-section view taken along line X-X of FIG. 9; FIG. 11 is a fragmentary view of the belt of the transfer assembly of the present invention;

FIG. 12 is a cross-section view taken along line XII-XII of FIG. 11; FIG. 13 is a partial cross-section view similar to FIG. 12 of a second embodiment of a driving surface of the drive belt of the present invention;

FIG. 14 is a partial cross-section view similar to FIG. 13 illustrating a third embodiment of a driving surface of the drive belt; FIG. 15 is a partial cross-section view similar to FIG. 14 illustrating a fourth embodiment of a driving surface of the drive belt;

FIG. 16 is a partial cross-section view similar to FIG. 12 of a second embodiment of a driven surface of the drive belt; FIG. 17 is a partial cross-section view similar to FIG. 16 of a third embodiment of a driven surface;

FIG. 18 is a partial cross-section view similar to FIG. 17 of a fourth embodiment of a driven surface of the drive belt; and

FIGS. 19A-19S are cross-section views similar to FIG. 12 illustrating nineteen configurations of a drive belt of the present invention.

DESCRIPTION OF PREFERRED EMBODIMENTS Referring to FIG. 1, the numeral 10 generally designates a transfer assembly of the present invention. Transfer assembly 10 is used for selectively transferring or diverting articles from a conveyor section, which conveys the articles in a first conveying direction, to a transfer conveyor, which conveys the articles in a second conveying direction typically orthogonal to the first conveying direction.

As best seen in FIG. 1, transfer assembly 10 is positioned between two conveyor sections 12 and 14 and adjacent one or more transfer conveyors 16, 16'. Conveyor sections 12 and 14 each include a plurality of rollers 18, 20 which are respectively supported between frame members 22, 24, 26, and 28 and driven by a belt drive system 30. Each belt drive system 30 includes a plurality of drive belts 32 and a drive shaft 34 (only one shown) which extends through conveyor sections 12 and 14. Rollers 18 and 20 define a conveying surface and a conveying direction as indicated by an arrow in FIG. 1. It should be understood that the invention may be used with other forms of rollers, such as direct belt or padded chain driven rollers or motorized rollers. It may also be used with non-roller conveyors, such as belt conveyors or the like.

Each transfer conveyor 16, 16' similarly includes a plurality of rollers 36, 38 which are respectively mounted between side frame members 38, 40, and 42, 44. Rollers 36 and 38 are similarly driven by a belt drive system 46. Rollers 36 define a second conveying surface and a transfer conveying direction indicated by the arrow in FIG. 1, which is generally orthogonal to the conveying direction defined by conveyor sections 12 and 14 and, further, by the conveying surface of rollers 48 and 50 of transfer assembly 10, as will be more fully described below. In a similar manner, rollers 38 define a third conveying surface and a second transfer direction, indicated by the arrow in FIG. 1 , which is similarly orthogonal to the conveying direction of conveyor sections 12 and 14 and which is opposite to the conveying direction of rollers 36.

As noted above, transfer assembly 10 includes rollers 48 and 50 which are aligned with rollers 18, 20 of conveyor sections 12 and 14. Rollers 48 and 50 are rotatably supported between frame members 52 and 54, which preferably abut and are coupled to frame members 22, 24, and 26, 28 of conveyor sections 12 and 14. In this manner, rollers 48 and 50 define a conveying surface which is generally coplanar with the conveying surface of rollers 18 and 20.

Rollers 48 in the illustrated embodiment comprise input rollers for transfer assembly 10, while rollers 50 comprise output rollers. It should be understood, however, that these terms are being used merely as a convention to indicate direction with respect to the illustrated embodiment and in no way are intended to limit the scope of the invention. In addition to input and output rollers 48, 50, transfer conveyor 10 includes intermediate idler rollers 60 which are aligned with rollers 48 and 50 such that rollers 18, 48, 60, 50, and 20 define a substantially continuous conveying surface and define the conveying direction indicated by the arrow labeled C in FIG. 1.

Positioned between intermediate idler rollers 60 are transfer sheave assemblies 62. Referring to FIGS. 3 and 4, each transfer sheave assembly 62 includes a first group of transfer sheaves 64 and a second group of transfer sheaves 66. Transfer sheaves 64 are preferably idler sheaves and are rotatably mounted on movable transfer sheave supports 68, which are more fully described below. Transfer sheaves 66 include a drive sheave 66a which is drivingly coupled to a drive shaft 70 and an idler sheave 66b, which is mounted on an idler shaft 71 that extends longitudinally through side frame member 52 and 54. Shaft 70 couples to drive shafts 34 of conveyor sections 12 and 14 on both ends by conventional couplings 78 and 80. Shaft 71 is free at both ends and is rotatably supported between side frame members 52 and 54 by bearings, for example bearing blocks 72. As best seen in FIG. 3, bearing blocks 72 are mounted to cross-frame members 74, which extend transversely between side frame members 52 and 54, and form a frame for transfer assembly 10. It should be understood that drive sheave 66a could alternatively be driven directly by a motor or indirectly from a prime mover other than a line shaft.

In addition to driving transfer drive sheaves 66a, shaft 70 drives input and output rollers 48 and 50. As best seen in FIG. 3, each input and output roller 48, 50 includes a drive belt 82 which extends around the respective roller 48, 50 and around shaft 70, for example on a spool 84. It should be understood that conventional methods are preferably used to mount drive sheaves 66a and spools 84 on shaft 70.

As best seen in FIG. 4, extending around each sheave 64, 66 of each transfer assembly 62 is a transfer drive belt 86. Transfer drive belts 86 transfer articles being conveyed on the conveying surface of intermediate rollers 60 laterally with respect to the conveying direction and, most preferably, in a transfer direction generally orthogonal to the conveying direction so that articles are moved from transfer assembly 10 and deposited on one of the adjacent transfer conveyors 16 or 16'. In the illustrated embodiment, transfer conveyor 10 is a right angle transfer assembly and transfers the articles onto transfer conveyor 16. It should be understood and, as will be more fully described below, the transfer assemblies of the present invention may be configured to transfer the articles to the right or to the left or both.

Referring again to FIG. 4, transfer belts 86 are normally positioned below the conveying surface. However, when a transfer is desired, sheaves 64 are moved upwardly from their normal retracted position to an extended position. In their extended position, transfer belts 86 are extended above the conveying surface while the article to be transferred is moving across intermediate rollers 60 so that the article is lifted off rollers 60 and transferred laterally to transfer conveyor 16. As described previously, sheaves 64 are mounted on movable sheave supports 68. In the illustrated embodiment, sheave supports 68 comprise plate members 88 with angled mounting flanges 88a which are supported by a pair of spaced apart beams 90 and 92. Beams 90 and 92 are mounted at their respective distal ends 90a, 90b, 92a, and 92b on bushing bolts 94 for vertical movement there along. Beams 90 and 92 are activated to move up and down bushing bolts 94 by actuators 96, for example pneumatic actuators, hydraulic actuators, or the like. Bushing bolts 94 are mounted to intermediate frame members 98 and 100, which are respectively mounted to cross-member 74 and, thus, also form a part of the frame of transfer assembly 10. Actuators 96 are supported on intermediate frame members 98 and 100 beneath beams 90 and 92 and extend and contract to move beams 90 and 92. Further details of the mounting arrangements of the frame are omitted as they are conventional and may include other frame members and may include, for example, removable fastening arrangements such as bolts, or fixed construction such as welding or rivets, as would be understood by those skilled in the art.

In this manner, when actuators 96 are actuated to extend, beams 90 and 92 move sheave supports 68, which in turn move sheaves 64 to their respective extended positions such that transfer belts 86 lift the articles to be transferred off rollers 60. When in the extended position, belts 86 effectively stop the forward motion of the article. In order to maintain the transfer belt in the transfer sheaves, transfer belts 86 are adapted to resist rolling. In preferred form, each belt includes a non-circular cross-section. As best seen in FIGS. 11 and 12, in the preferred embodiments, each transfer belt 86 includes planar sides 106 and 108, which are preferably parallel. In addition, transfer belt 86 includes opposed and spaced apart rounded portions 102 and 104. Rounded portion 102 provides a driving surface for frictionally engaging the article to be transferred, while rounded portion 104 provides a driven surface to be frictionally engaged by sheaves 64 and 66. Together, rounded portions 102 and 104 and planar sides 106 and 108 form an elongated rounded cross-section. In order to increase the flexibility of transfer belts 86, each transfer belt 86 preferably includes a plurality of notches 110 which are spaced along each belt's longitudinal axis 112. Notches 110 preferably comprise rounded or semi-circular shaped notches and are located along the respective rounded portions 102 and 104 of the belt. However, it should be understood that U-shaped notches, V- shaped notches, or the like may be used as well. In addition, as will be described in reference to FIGS. 19A-19S, the transfer belt may include longitudinally extending grooves formed in its sides. In order to maximize the thickness of the belt, the notches formed in rounded portion 102 are preferably offset along longitudinal axis 112 from the notches formed on rounded portion 104.

Referring to FIGS. 9 and 10, sheaves 64 and 66 each include projecting flanges which define an elongated annular groove 114 therebetween. Groove 114 includes a round portion 116 and a pair of spaced, generally planar sides 118 and 120. Rounded portion 116 preferably includes a similar radiused surface as rounded portion 104 to assure good engagement between the driven surface of belts 86 and sheaves 64, 66. Sides 118 and 120 are also similarly oriented with respect to rounded portion 116 as sides 106 and 108 are to rounded portion 104. Further, sides 118 and 120 have approximately the same height as sides 106 and 108. In this manner, when belts 86 are positioned in sheaves 64, 66, rounded portion 104 of belt 86 seats in rounded portion 116, and rounded portion 102 of belt 86 faces outwardly and projects from groove 114 ^'for engaging an article. Furthermore, when subject to lateral forces from the articles being conveyed, side 118 or 120 will bear against side 106 or 108 of belt 86 to limit belt 86 form rolling in the respective sheave 64, 66. As would be understood by the skilled artisan, belt 86 exhibits the greatest tendency to roll in sheaves 64. Therefore, at least grooved sheaves 64 are adapted to limit rolling of belt 86. In this manner, transfer belt 86 and at least transfer sheaves 64 have a non-circular interface. Consequently, transfer assembly 10 exhibits essentially no rolling of belts 86 out of sheaves 64 or 66. As previously described in reference to the first embodiment, the transfer assembly of the present invention may comprise a left-hand transfer assembly 110. Referring to FIG. 5, transfer assembly 110 includes a plurality of input rollers 148 and a plurality of output rollers 150 and a plurality of idler rollers 160 which are positioned between input and output rollers 148, 150. Similar to the previous embodiment, positioned between idler rollers 160 are a plurality of transfer sheave assemblies 162. Each transfer sheave assembly 162 includes a first group of transfer sheaves 164 and a second group of transfer sheaves 166a, 166b, 166c, and l66d. Transfer sheaves 164 are preferably idler sheaves and are rotatably mounted on a movable transfer sheave support 168, similar to the previous embodiment. Transfer sheaves 166a and 166b are mounted on a drive shaft 170 and an idler shaft 171, also similar to the first embodiment. Transfer sheaves 166c and 166d comprise redirection pulleys so that the transfer belt 186 which extends around sheaves 164, 166a, 166b, 166c, and 166d will be driven in an opposed direction from transfer belt 86. Transfer belt 186 is of similar construction to transfer belt 86. Therefore, reference is made to the first embodiment for further details. Transfer assembly 110 operates in a similar manner to transfer assembly 10 with the exception that transfer belt 186 is driven to move articles to transfer conveyor 16'.

Referring to FIGS. 8 and 9, a third embodiment of the transfer assembly of the present invention is illustrated. Transfer assembly 210 comprises a two-way transfer assembly which includes two groups of transfer sheave assemblies 262 and 262'. Transfer sheave assemblies 262 selectively transfer articles to the right onto, for example, transfer conveyor section 16, whereas transfer sheave assemblies 262' selectively transfer articles to the left onto, for example, transfer conveyor 16'. Transfer sheave assemblies 262 are of similar construction to transfer sheave assembly 62, while transfer sheave assembly 262' is of similar construction to transfer sheave assembly 162. In this manner, articles that are delivered to transfer assembly 210 from adjacent conveyor sections, similar to those shown in FIG. 1, may be transferred laterally either to the left or to the right by respective transfer sheave assembly 262 or 262' to adjacent transfer conveyors 16 or 16'.

For further details of a conventional transfer device which may be modified to incorporate the features of transfer assemblies of the present invention, reference is made to Rapistan Demag "1256" LINE SHAFT POWER TRANSFER CONVEYOR SECTIONS, which are commercially available from Rapistan Demag of Grand Rapids, Michigan.

It can be appreciated from the foregoing that the drive belt of the present invention may incorporate other driving or driven surfaces. For example, referring to FIG. 13, transfer belt 286 includes a wedge shaped driving surface 287 for frictionally engaging the article to be transferred. In the illustrated embodiment, wedge shaped surface 287 includes angles sides 287a and 287b which are substantially of equal magnitude; however, it can be appreciated, that sides 287a and 287b can be increased or decreased to vary the angle and, furthermore, to form an apex 287c offset from the central axis 286a of belt 286. Referring to FIG. 14, belt 386 includes a third embodiment of a driving surface

387. Driving surface 387 includes a plurality of planar portions 387a, 387b, and 387c with central portion 387b being substantially perpendicular to the central axis 386a of belt 386. It can be appreciated that, although surfaces 387a, 387b, and 387c are illustrated as symmetrical, the lengths of each side 387a, 387b, and 387c can be varied to increase or decrease the angles formed therebetween and, further, to offset side 387b from central axis 386a.

Referring to FIG. 15, belt 486 includes a convex curved driving surface 487. It should be understood that the radius of curvature for convex surface 487 may be varied which can be used to vary the stiffness of the belt 486.

Referring to FIG. 16, belt 586 includes a second embodiment of a driven surface 588 which comprises an arcuate convex driven surface similar to driving surface 487. Again, it can be appreciated that the radius of curvature of surface 588 may be varied to increase or decrease flexibility of belt 586.

Referring to FIG. 17, belt 686 includes a wedge shaped driven surface 688 similar to driving surface 287 and includes sides 688a and 688b which are angled to form an apex 688c.

As best seen in FIG. 18, a third embodiment of a driven surface 788 of belt 786 is illustrated. Driven surface 788 is an inverted wedge shaped surface having generally planar sides 788a and 788b which form a triangular groove. Sides 788a and 788b are illustrated as having approximately equal length, but it should be understood that sides 788a and 788b may have unequal lengths and, further, may be varied to increase or decrease the angle of the groove. Referring to FIG. 19A, transfer belt 886 includes a driving surface 887 and a driven surface 888. Driving surface 887 is formed by a projecting rectangular rib 889 which includes an outer planar surface 889a and generally planar sidewalls 889b and 889c. In the illustrated embodiment, sidewalls 889b, 889c are generally parallel; however, it can be appreciated that angle 889d of each respective sidewall 889b, or 889c may be increased or decreased such that rib 889 may have a trapezoidal shaped cross-section. Furthermore, depending on the application, surface 889a may form an acute angle with respect to central axis 886a of belt 886. Driven surface 888 is similarly formed by projecting rib 890. Referring to FIG. 19B, transfer belt 986 includes a pair of driving surfaces 987a and 987b and a pair of driven surfaces 988a and 988b. Driving surfaces 987a and 987b are spaced apart by a rectangular groove 989a. Driven surfaces 988a and 988b are similarly spaced apart by a rectangular groove 989b. It can be appreciated by varying depth of grooves 989a and 889b that the flexibility of belt 986 can be varied.

Referring to FIG. 19C, transfer belt 1086 similarly includes a pair of spaced apart driving surfaces 1087a and 1087b which are spaced apart by an arcuate groove 1089a. Belt 1086 further includes a pair of driven surfaces 1088a and 1088b which are similarly spaced by an arcuate groove 1089b. Referring to FIG. 19D, belt 1186 is of similar construction to belt 886 and includes planar driving and driven surfaces 1187 and 1188. Driving and driven surfaces 1187 and 1188 are similarly formed by projecting ribs 1189 and 11 0, respectively. Rib 1189 includes an outer planar bearing surface 1187a, which defines driving surface 1187, and opposed sides 1189b and 1189c. Sides 1189b and 1189c form an acute angle α with respect to central axis 1186a of belt 1186 to form a trapezoidal shaped rib 1189. It should be understood that the angles formed by sides 1189b and 1189c may be varied. Furthermore, angle may be greater than or less than angle β. Rib 1190 is of similar construction to rib 1189 but may be varied to both increase or decrease the stiffness of belt 1186.

Referring to FIG. 19E, transfer belt 1286 includes projecting ribs 1289 and 1290 above and below central axis 1286a to provide driving and driven surfaces 1287 and 1288, respectively. In this manner, driving and driven surfaces 1287 and 1288 comprise line bearing surfaces. By varying the apex angle and β of ribs 1289 and 1290, the stiffness of belt 1286 and of driving surfaces 1287 and 1288 may be varied.

Referring to FIG. 19F, transfer belt 1386 is of similar construction to transfer belts 986 and 1086, but includes triangular shaped grooves 1389a and 1389b. Referring to FIG. 19G, transfer belt 1486 is of similar construction to transfer belts 1186 and 1286, but includes arcuate projecting ribs 1489 and 1490 to define driving surface 1487 and driven surface 1488, respectively.

Referring to FIGS. 19H, 19K, 19L, and 19M, transfer belts 1586, 1886, 1986, and 2086 each include planar driving and driven surfaces 1587, 1588; 1887, 1888; 1987, 1988; and 2087, 2088, respectively. As best seen in FIG. 19H, belt 1586 includes opposed sides 1589 and 1590, which are generally parallel and include longitudinal grooves formed therein 1589a and 1590a, which provide flexibility to belt 1586. In preferred form, grooves 1589a and 1590a comprise trapezoidal shaped grooves which are symmetrical and generally aligned along central axis 1586a and extend over the full length of belt 1586.

Belt 1886 similarly includes opposed planar substantially parallel opposed sides 1889 and 1890, with triangular shaped grooves 1889 and 1890a, similarly aligned along central axis 1886a.

As best seen in FIG. 19L, belt 1986 includes generally parallel spaced apart opposed sides 1989 and 1990, with each side including an arcuate shaped groove 1989a and 1990a, respectively. Similar to grooves 1589a, 1590a, grooves 1989a and 1990a are aligned along central axis 1986a of belt 1986 and, preferably, extend over the full length of belt 1986. Belt 2086 includes rectangular channel shaped grooves 2089a and 2090a similarly aligned along central axis 2086a of belt 2086. Again, grooves 2089a and 2090a preferably extend along the full length of belt 2086.

It should be understood that grooves 1589a, 1590a, 1689a, 1690a, 1989a, 1986a, 2089a, and 2090a increase the flexibility of belts 1586, 1886, 1986, and 2086, respectively and, further, by varying the angles and depth and width of the respective grooves, the flexibility of the respective belts can be increased as desired.

Referring to FIGS. 19J, 19N, 190, 19P, 19Q, and 19R, belts 1786, 2186, 2286, 2386, 2486, and 2586 are of similar construction to belts 1386, 886, 1286, 986, 1086, and 1486, but include planar driven surfaces 1788, 2188, 2288, 2388, 2488, and 2588 similar to driven surfaces 1888, 1988, and 2088, which provides increased stiffness to the symmetrical belts shown in FIGS. 19A through 19G.

Referring to FIG. 19S, belt 2686 is of similar construction to belt 986 and includes spaced apart driving surfaces 2687a and 2687b which are divided by a trapezoidal shaped groove in contrast to the rectangular groove 1989a. Similarly, driven surfaces 2688a and 2688b are separated by a trapezoidal shaped groove 2690a.

In each of the above embodiments of the transfer belt, the belt includes opposed planar sides or planar portions which are engaged by the respective sheaves in the transfer assembly but include varying driving and driven surfaces. The flexibility of the belt can be increased or decreased by adding grooves, either on the driving surface, driven surface, or the opposed sides of the respective belt or, where applicable, by increasing or decreasing the grooved portions in the driving and/or driven surfaces. In addition, the combinations illustrated are just exemplary combinations of how to adapt the transfer belt to resist rolling. It can be appreciated that different combinations of driving and driven surfaces and sides may be used for the transfer belt. While several forms of the invention have been shown and described, other forms will now become apparent to those skilled in the art. For example, other driver mechanisms and support arrangements may be used to support the movable transfer sheaves. In addition, the number of input, output, and/or idler rollers may be increased or decreased. Furthermore, as shown, the number of transfer sheave assemblies may be increased by positioning one or two sheave assemblies between each idler roller, or may be decreased, for example, by positioning one or two transfer sheaves between every other idler roller. Therefore, the embodiment of the invention shown in the drawings is not intended to limit the scope of the invention which is instead defined by the claims which follow.

Claims

We claim:

1. A transfer assembly for a conveyor system, said transfer assembly for positioning adjacent at least one transfer conveyor, said transfer assembly comprising: a frame, said frame including a conveying surface and defining a conveying direction; a plurality of grooved transfer sheaves supported by said frame, said transfer sheaves supporting a transfer belt, at least one of said transfer sheaves being driven and driving said transfer belt to rotate about said transfer sheaves in a transfer direction non-parallel to said conveying direction, and one of said transfer belt and said transfer sheaves having a non-circular interface to resist rolling of said transfer belt in said transfer sheaves when said transfer belt is subject to a lateral force from the article being conveyed; and an actuator selectively moving a group of said transfer sheaves between a retracted position wherein said transfer belt is below said conveying surface to an extended position wherein said transfer belt extends above said conveying surface for lifting an article being conveyed on said conveying surface from one of the conveyor sections in said conveying direction and transferring the article in said transfer direction to the transfer conveyor.

2. The transfer assembly according to Claim 1, wherein said transfer belt is adapted to resist rolling in said transfer sheaves.

3. The transfer assembly according to Claim 2, wherein said transfer belt includes a cross-section with at least one generally planar portion, said transfer sheaves bearing on said generally planar portion when said transfer belt is subject to a lateral force from an article being transferred to restrain said transfer belt from rolling in said transfer sheaves.

4. The transfer assembly according to Claim 3, wherein said cross-section further includes at least one rounded driving surface for drivingly engaging the article being transferred.

5. The transfer assembly according to Claim 3, wherein said cross-section of said transfer belt further includes a pair of opposed rounded surfaces, one of said rounded surfaces defining a driving surface, an other of said rounded surfaces defining a driven surface, and said driving surface for drivingly engaging the article being transferred.

6. The transfer assembly according to Claim 5, wherein said cross-section of said transfer belt includes a second planar side, said planar sides interconnecting said rounded surfaces, and said transfer sheaves bearing against one of said planar sides to prevent said transfer belt from rolling in said transfer sheaves when said transfer belt is subject to a lateral force when the article is being transferred.

7. The transfer assembly according to Claim 1, wherein said frame includes a movable sheave support, said group of said transfer sheaves rotatably being supported by said movable sheave support, and said actuator moving said sheave support whereby said group of transfer sheaves is moved between said retracted and extended positions.

8. The transfer assembly according to Claim 1, wherein each of said transfer sheaves includes projecting flanges defining a groove therebetween, said projecting flanges further defining generally spaced planar sides to restrain said transfer belt from rolling in said transfer sheaves.

9. The transfer assembly according to Claim 1, wherein said transfer belt includes a longitudinal axis and a plurality of spaced notches along said longitudinal axis to thereby increase the flexibility of said transfer belt.

10. The transfer assembly according to Claim 9, wherein said notches are rounded notches.

11. The transfer assembly according to Claim 10, wherein said transfer belt includes a driving portion and a driven portion, said notches being located in at least said driving portion.

12. The transfer assembly according to Claim 11, wherein said notches are located in said driving portion and said driven portion.

13. The transfer assembly according to Claim 12, wherein said notches in said driving portion are offset along said longitudinal axis from said notches in said driven portion.

14. The transfer assembly according to Claim 13, wherein at least said driving portion is rounded.

15. The transfer assembly according to Claim 14, wherein said driven portion is rounded.

16. The transfer assembly according to Claim 1, further comprising a plurality of rollers mounted to said frame, said transfer sheaves being positioned between at least two respective rollers of said plurality of rollers.

17. A transfer assembly for a conveyor system, said transfer assembly comprising: a frame including a conveying surface and a conveying direction; a first group of grooved sheaves rotatably and movably supported by said frame; a second group of grooved sheaves being rotatably supported by said frame, said first and second groups of sheaves defining a first group of transfer sheaves supporting a transfer belt extending thereabout; at least one of said grooved sheaves being driven and driving said transfer belt to rotate about said first and second groups of sheaves in a transfer direction non-parallel to said conveying direction, and said transfer belt having a non-circular cross-section to resist rolling in said grooved sheaves; and an actuator selectively moving said first group of grooved sheaves between a retracted position wherein said transfer belt is below said conveying surface to an extended position wherein said transfer belt extends above said conveying surface for lifting an article being conveyed on said conveying surface and transferring the article in said transfer direction.

18. The transfer assembly according to Claim 17, wherein said non-circular cross- section includes opposed rounded surfaces, one of said opposed rounded surfaces comprising a driving surface for driving and urging the article in said transfer direction.

19. The transfer assembly according to Claim 18, wherein said non-circular cross- section further includes generally planar side surfaces interconnecting said rounded surfaces, said grooved sheaves contacting one of said generally planar side surfaces to restrain said transfer belt from rolling out of said grooved sheaves.

20. The transfer assembly according to Claim 19, wherein said generally planar side surfaces are generally parallel.

21. The transfer assembly according to Claim 18, wherein said transfer belt includes a longitudinal axis, said transfer belt including a plurality of notches spaced along said longitudinal axis to increase the flexibility of said transfer belt.

22. The transfer assembly according to Claim 17, wherein said frame includes a movable support, said first group of grooved sheaves being rotatably mounted on said movable support, said movable support moved by said actuator whereby said first group of sheaves moves between said retracted position and said extended position.

23. The transfer assembly according to Claim 17, further comprising a plurality of said group of transfer sheaves, each of said groups of said transfer sheaves being positioned between a pair of respective rollers and including a respective transfer belt extending thereabout.

24. The transfer assembly according to Claim 23, wherein said at least one group of said transfer sheaves are driven in said transfer direction, said transfer direction defining a first transfer direction, and another group of said transfer sheaves being driven in a second transfer direction opposite from said first transfer direction.

25. The transfer assembly according to Claim 23, further comprising a plurality of rollers mounted to said frame, said grooved sheaves being positioned between at least two of said rollers.

26. A transfer assembly for a conveyor system, said transfer assembly comprising: a frame for positioning between conveyor sections; a plurality of rollers rotatably supported by said frame, said rollers defining a conveying surface and a conveying direction; a drive shaft rotatably supported by said frame, said drive shaft being adapted to couple to a driver; a sheave support movably mounted to said frame; a first and second group of sheaves defining transfer sheaves, said transfer sheaves being positioned between two of said rollers and supporting a transfer belt, one of said second group of sheaves comprising a drive sheave and being mounted to said drive shaft for rotating therewith, said drive sheave driving said transfer belt to rotate about said first and second groups of sheaves in a transfer direction toward an adjacent transfer conveyor, said transfer direction being non-parallel to said conveying direction, and said transfer belt having a non-circular cross-section; and an actuator selectively moving said sheave support between a retracted position wherein said transfer belt is below said conveying surface to an extended position wherein said transfer belt extends above said conveying surface for lifting an article being conveyed on said conveying surface and transferring the article in said transfer a direction to the adjacent transfer conveyor.

27. The transfer assembly according to Claim 26, wherein each of said transfer sheaves includes an elongated groove, said elongated groove restraining rolling of said transfer belt in said transfer sheaves.

28. The transfer assembly according to Claim 26, wherein said transfer belt includes an elongate rounded cross-section.

29. The transfer assembly according to Claim 28, wherein said elongate rounded cross-section includes spaced apart rounded portions, a first of said rounded portions defining a driving surface, and another of said rounded portions defining a driven surface, and said driven surface frictionally engaging said grooved transfer sheaves.

30. The transfer assembly according to Claim 29, wherein said transfer belt further includes generally planar sides, said planar sides interconnecting said rounded portions.

31. The transfer assembly according to Claim 30, wherein each of said transfer sheaves includes an elongated groove, said elongated groove including planar sides for engaging said planar sides of said transfer belt to restrain said transfer belt from rolling in said transfer sheaves.

32. The transfer assembly according to Claim 31, wherein said planar sides are generally parallel.

33. The transfer assembly according to Claim 26, wherein said transfer belt includes opposed sides for engagement by said transfer sheaves to resist rolling of said transfer belt in said transfer sheaves.

34. The transfer assembly according to Claim 33, wherein at least one of said opposed sides includes a groove to thereby increase the flexibility of said transfer belt.

35. The transfer assembly according to Claim 33, wherein said transfer belt includes a driving surface and a driven surface, and at least one of said driving surface and said driven surface being defined by a projecting rib.

36. The transfer assembly according to Claim 35, wherein said projecting rib includes one of a rounded cross-section, a triangular cross-section, a rectangular cross-section, and a trapezoidal cross-section.

37. The transfer assembly according to Claim 33, wherein said transfer belt includes a driving surface and a driven surface, at least one of said driving surface and said driven surface including a groove therein to define one of a pair of spaced apart driving surface portions and a pair of driven surface portions.