Lubricating method and apparatus for conveyor belts and systems
This invention relates to a method and apparatus for lubricating conveyor belts and systems and in particular to a method and apparatus for facilitating the movement of items such as bottles, cans and other containers relative to the surface of a conveyor belt or system.
In the drinks industry, it is common to use specialist bottling machines in order to maximise the efficiency with which bottles are filled. Manufacturers need to fill, cap and label bottles automatically and quickly, in order to optimise production, and in sterile, hygienic conditions in order to meet Health and Safety Regulations. During production, the bottles are moved along a conveyor system or belt, along a line of specialist machinery adapted for washing, rinsing, filling, and capping.
Similar systems are used in the production of canned drinks and when packaging a variety of other liquids and solids into containers.
In order to facilitate movement of the bottles along the production line and to ease bottle handling, it is standard to use a type of wet track lubrication, in other words to apply a mixture of water and detergent to the conveyor belt. However, this approach can lead to problems, as large amounts of the water and detergent combination are needed to provide sufficient lubrication. Where large amounts of water and detergent are used, spillage often occurs which can lead to dangerous and slippery conditions within the work place. In addition, it will be appreciated that the use of large amounts of water with electrical machinery is potentially hazardous in the event of water ingress. The presence of the water and detergent combination is also known to increase the risk of corrosion and bacterial growth on the machinery. These problems can greatly affect the efficiency of the bottling plant, as regular maintenance and cleaning is required, resulting in a large amount of production downtime.
Furthermore the combination of water and detergent on the conveyor belt leaves significant friction between the bottle and surface of the belt causes the conveyor to drag the bottles along. As a result the bottles fall over easily, especially on fast moving conveyors. This can cause jams and reduce the efficiency of the machine line and mechanical stress on the conveyor. In addition the risk of bottle breakage is high, particularly if glass bottles are being processed, and plastic bottles may become scratched. A particular disadvantage with this type of system is that it is necessary for an operator to be on hand to pick up any fallen bottles.
Current methods of lubricating production lines result in a large amount of waste and increased costs.. Even this form of lubrication remains preferable to none as products would be unable to move around at all otherwise . Nevertheless it is paramount that production conditions are optimised so that the product can be packaged quickly, without loss of quality or quantity. Attempts have been made to overcome these problems by altering the manner in which the bottles or containers are fed onto the production line, and also by adding special additives such as low foam surfactants and water softeners to the water and detergent mix and using new conveyors made with special material such as Kevlar. However these alternative forms of lubrication can be expensive and the problems associated with wet lubrication still persist includingfouling, spilling and waste.
It would be advantageous to provide a method for lubricating conveyor belts which eliminates the problems which are inherent with the use of water and detergent for the lubrication of conveyor belts in order to reduce costs and production down-time.
According to a first aspect of the present invention, there is provided a method of facilitating the movement of items relative to the surface of a conveyor belt by dispensing an oil on to the surface of said conveyor belt.
Most preferably the oil is waterless.
Preferably the oil is synthetic.
Preferably the oil is a non-mineral oil.
Preferably the oil is a non-silicate oil.
Preferably the oil is a non-vegetable oil.
Most preferably the oil is food safe.
Preferably the oil has a viscosity index above 150 and has an affinity for the surface of the conveyor belt.
Preferably the oil has no solid particle additives.
The oil may comprise a blend of different oils.
Advantageously the oil reduces friction and ensures smooth movement of each item on the conveyor belt relative to other items on the conveyor belt and also relative to the surface of the conveyor belt itself.
Preferably the oil is dispensed from a reservoir.
The oil is typically dispensed from the reservoir to a plurality of sites on the conveyor belt. Typically the oil is dispensed from the reservoir on to the conveyor belt via a pipe system which is connected to the reservoir.
Preferably a plurality of brushes is located at each of the sites on the conveyor belt at which the oil is to be dispensed in order to distribute the oil over the surface of the conveyor belt.
The method may comprise the step of dispensing a cleaning fluid with the oil via the pipe system. Alternatively the method may comprise the step of dispensing a cleaning fluid independently from the oil via the pipe system.
The oil may be dispensed to the plurality of sites on the conveyor belt simultaneously. Alternatively the oil may be dispensed to selected sites which require lubrication.
Preferably the amount of oil which is dispensed at each of the plurality of sites on the conveyor belt can be altered. The amount of dispensed oil can be altered such that distribution differs between the sites on the conveyor belt to which the oil is dispensed. Preferably this is achieved using a series of valves and plugs associated with the pipe system.
According to a second aspect of the present invention there is a provided a method of lubricating a conveyor belt using a food-safe, synthetic, oil which is non- mineral and non-silicate and has no solid particle additives.
Preferably the oil is a waterless.
Preferably the oil is stored in a reservoir and is dispensed oh to the conveyor belt using a pipe system that is connected to the reservoir.
Preferably the oil is dispensed from the reservoir at various sites on the conveyor belt.
The oil may be distributed along the conveyor belt by one or more brushes .
The oil may be dispensed with a cleaning fluid.
The method may also comprise the step of dispensing a cleaning fluid independently from the oil.
The oil can either be dispensed to all of the sites on the conveyor belt, or alternatively to selected sites which require lubrication, via the pipe system. Preferably the quantity of oil dispensed at each site on the conveyor belt can be altered. The quantity of oil that is dispensed can be altered such that distribution differs between the sites on the conveyor. Control of the flow of oil through the pipe system is preferably achieved using a series of valves and plugs.
According to a third aspect of the present invention, there is provided apparatus for lubricating the surface of a conveyor belt:
• a reservoir for storing a lubricant. • a pipe system, connected to the reservoir, for dispensing the lubricant at sites along the conveyor belt • one or more brushes adapted to distribute the lubricant on the conveyor belt.
Preferably the pipe system includes one or more plugs which can be used to suppress the flow of oil through one or more sections of the pipe system such that lubricant can either be dispensed to all of the sites on the
conveyor belt, or alternatively to selected sites which require lubrication.
The reservoir may be connected to a timer. Advantageously this allows the frequency with which the lubricant is dispensed from the reservoir to be controlled.
The one or more brushes may comprise a first and second section, wherein the first section comprises the bristles of the brush and is detachable from the second section which can be used to mount the brush on the apparatus.
Preferably two or more brushes are supplied at each of the sites on the conveyor belt at which lubricant is dispensed.
Preferably the brushes are connected to the pipe system and lubricant is dispensed on to the conveyor belt through one or more outlets on the brushes . The brush then acts to distribute the lubricant that has been dispensed on to the surface of the conveyor belt.
Typically each of the brushes receives an equally divided share of the lubricant dispensed from the reservoir. This is preferably achieved using a series of distribution valves.
Preferably the lubricant is a food-safe, synthetic, oil, which is non-mineral, and non-silicate and has no solid particle additives.
According to a fourth aspect of the present invention, there is provided apparatus for delivering a measured
amount of oil on to the surface of a conveyor system for transporting bottles, containers and packages, comprising:
• a reservoir for storing the oil. • a pipe system, connected to the reservoir, for dispensing the oil at sites along the conveyor belt • one or more brushes adapted to distribute the oil on the conveyor belt.
Preferably the pipe system includes one or more plugs which can be used to suppress the flow of oil through one or more sections of the pipe system such that oil can either be dispensed to all of the sites on the conveyor belt, or alternatively to selected sites which require lubrication.
The reservoir may be connected to a timer. Advantageously this allows the frequency with which the oil is dispensed from the reservoir to be controlled.
The one or more brushes may comprise a first and second section, wherein the first section comprises the bristles of the brush and is detachable from the second section, which can be used to mount the brush on the apparatus.
Preferably two or more brushes are supplied at each of the sites on the conveyor belt at which oil is dispensed.
Preferably the brushes are connected to the pipe system and oil is dispensed on to the conveyor belt through one or more outlets on the brushes. The brush then acts to
distribute the oil that has been dispensed on to the surface of the conveyor belt.
Typically each of the brushes receives an equally divided share of the lubricant dispensed from the reservoir. This is preferably achieved using a series of distribution valves .
In order to provide a better understanding of the present invention, an embodiment will now be described by way of example only and with reference to the accompanying Figures in which:
Figures 1 and 2 illustrate in schematic form the apparatus for lubricating a conveyor belt in a preferred embodiment according to the present invention;
Figure 3 illustrates in schematic form a brush suitable for use with the apparatus in accordance with the present invention;
Figures 4 and 5 illustrate the brush of the apparatus of the present invention in use on a conveyor belt, and;
Figure 6 illustrates the secondary unit of the present invention.
The invention is a method and system that can be used to lubricate conveyor belts and in particular to a method and apparatus for facilitating the movement of items such as bottles, cans and other containers relative to the surface of a conveyor belt or system.
Although the embodiments of the invention described with reference to the drawings comprise a method and apparatus for use on bottling machines in bottling plants, the method and apparatus may also be advantageously employed in other systems where a moving conveyor is used to transport bottles, containers and packages, and where lubrication of the conveyor belt surface to ease handling of the items being transported on the belt is required. The method may be used on any type of conveyor belt and is suitable for use with bottles and containers made of a variety of materials including plastic, glass and aluminium.
In particular the invention allows a measured amount of lubricant to be dispensed and distributed on to relatively fast moving conveyor belts or conveyor systems on which, for example, bottles, containers and other packages are moved.
The oil that is dispensed on to the surface of the conveyor belt is synthetic, food safe and also non- mineral, non vegetable and non silicate. This is advantageous as silicones and minerals are not food safe, react badly with plastic packaging and may contaminate the containers that are being transported. The oil also has no solid particle additives which might be deposited in the gaps between slats on the conveyor and has a viscosity that gives it affinity to the conveyor belt and makes it adhere to the items on the conveyor belt. Any synthetic food safe oil such which has these properties is suitable for this purpose, such as those supplied by R. S Clare Stanhope Street, Liverpool, L8 5RQ United Kingdom. These are a blend of Hi food grade approved
food safe oil and dispersants with additives to reduce oxidising and enhance the anti wear and load carrying properties of the oil. The oil is a completely clear liquid with a flash point above 160°C, a viscosity index above 150, ISO Grade of 100, AGMA Grade of 3 and pour point of -58°C.
The oil reduces the friction co-efficient on the conveyor belt by 70 to 80% in comparison to current methods, which use water and detergent combinations. As a consequence the bottles or containers do not "drag" on the surface of the conveyor belt and are therefore less prone to fall over. In contrast the bottles are able to move freely relative to each other and the surface of the conveyor which greatly increases the speed of the line.
In addition the problems of fouling, micro-organism growth and spillage are greatly reduced, if not removed by the use of the oil described herein.
With reference to Figures 1 and 2, the system comprises a reservoir 1 suitable for storing an oil as described above. The oil is transported from the reservoir to a conveyor belt 2 via a system of circulatory pipes 3. The circulatory pipes are arranged around the conveyor belt such that the lubricant is dispensed from the circulatory pipes at various sites along the length of the conveyor belt.
A set or block of brushes 4, typically in the region of 5 or 6 brushes, is located at each of the sites on the conveyor belt at which the oil is to be dispensed. Each brush is positioned above the conveyor belt such that the
bristles of the brush make contact with the surface of the conveyor belt.
The reservoir 1 is associated with a transformer 5. Oil from the reservoir 1 is passed through a first unit 6 having primary distribution valve 6 which divides the quantity of oil which is dispensed from the reservoir into equal amounts which can be fed into tributary branches of the circulation pipes which carry the oil to the sites on the conveyor belt at which lubrication occurs. The tributary branches of the circulation pipes in turn carry the oil through a second unit 7 having secondary distribution valve which again divide the oil passing through them into equal amounts, which are then distributed to each of the brushes at that particular site. An equal proportion of the oil is therefore supplied to each of the brushes in the apparatus at each site on the conveyor belt. The secondary unit 7 is shown in more detail in Figure 6.
In the preferred embodiment each of the brushes is connected to the circulation pipe system such that oil is dispensed through the bristles on the brush on to the conveyor. The brush therefore acts to distribute or smear the oil over the surface of the conveyor belt.
Although in the depicted embodiment one brush is shown, a plurality of brushes at various sites around the conveyor belt is employed in order to ensure efficient distribution of the oil over the entire length and surface of the conveyor belt, as appropriate.
In an alternative embodiment the circulatory pipes 4 can dispense an appropriate amount of lubricant to an area near the one or more brushes .
Each brush in the set or block can be controlled independently of the other. A series of blocking plugs can be used to control the amount of oil that is supplied to each brush. For example the outlet valve on one or more of the brushes in the set can be blocked using the blocking plug which will result in the remaining brushes in the set being supplied with a greater quantity of oil. For example a blocking plug may be used to redirect the oil through the tributary branch circulation pipes such that one or more of the brushes in the set receives more than one share of the oil which is divided by the primary or secondary distribution valve.
The oil is ejected from the reservoir into the circulation pipes via a pump 13. The pump is associated with a timer, which may be employed to ensure that an appropriate quantity of the lubricant is ejected at regular pre-determined intervals, when required. For example the oil may be dispensed for a 10-minute period followed by a "dwell" period where no oil is dispensed. In addition the pipe system may be arranged in such a manner that oil is dispensed in quantities or ratios which match the need at particular sites on the conveyor belt. Oil may be dispensed at all of the sites on the conveyor belt at once, or alternatively may be programmed to be dispensed only at selected sites where and when oil is required. In addition the quantity of oil dispensed at each site can be altered. In this manner more oil can be dispensed to areas which require greatest lubrication,
whilst less oil is dispensed to areas which require less lubrication. The ability to control where and when the oil is dispensed on the conveyor belt will minimise waste and costs.
In Figure 2, the reservoir is contained within a control unit 8 and the brush 4 is shown in position on the conveyor belt 2.
An example of a brush 4 used to distribute the oil on the conveyor belt is shown in Figure 3. The brush 4 is of a two part construction having a first part 10 that can be mounted in position on the apparatus, in connection to a tributary branch of the circulatory pipe system such that the bristles 11 are in contact with the conveyor belt, as shown in Figures 4 and 5. The brush also has a second part 12, which is detachable from the first part 10 and comprises the bristles 11. It will be appreciated that as it will be necessary from time to time to clean the bristles to ensure the bristles do not become clogged, coated or saturated with oil, so that the brush remains effective at distributing the lubricant on the conveyor belt. The two-part design of the brush allows the bristles of the brush to be removed quickly, without the need to stop the apparatus, so that they can be cleaned.
To further assist cleaning, cleaning fluid may be dispersed using the circulation pipes. The cleaning fluid may be dispersed separately from the oil, i.e. during production down time or alternatively may be dispensed with and simultaneously to the oil in order to maximise the amount of time spent on production.
The method and apparatus herein described, exhibits significant advantages over apparatus and methods currently in use . The use of an oil as opposed to a water/detergent mix ensures that the conveyor belt is lubricated without the risk of corrosion or bacteria growth. In addition, there is less risk of ingress into the electrical components of the apparatus. Furthermore, as the apparatus is adapted to distribute appropriate quantities of oil where and when required, costs are reduced as there are many fewer stoppages, minimal waste and less spillage. Line efficiency is increased, slip risks are minimised and overall hygiene and the mechanical performance of the conveyor is improved.
Further modifications and improvements may be added without departing from the scope of the invention herein described.