BUFFER STORAGE SYSTEM FOR OVERHEAD CONVEYOR SYSTEMS

Abstract

A buffer storage device (100) for an overhead conveyor system (10) having individually conveyable transport units (40), with a closed conveying path that includes a buffer section (117) along which transport units are conveyable downstream, a feed section (104) for feeding transport units to a feed point (102) of the buffer section, a discharge section (105) for discharging transport units from a discharge point (103) of the buffer section, and one or more additional bypass sections (113) which in each case connect a starting point along the buffer section to a destination point along the buffer section.

Claims

1. A buffer storage device (100) for an overhead conveyor system (10) having individually conveyable transport units (40), comprising: a closed conveying path comprising a buffer section (117) along which transport units are conveyable downstream; a feed section (104) for feeding transport units to a feed point (102) of the buffer section; a discharge section (105) for discharging transport units from a discharge point (103) of the buffer section; and one or more additional bypass sections (113) which in each case connect a starting point along the buffer section to a destination point along the buffer section.

2. The buffer storage device according to claim 1, wherein a bypass section forms a return section (110), which together with the buffer section (117) forms the closed conveying path.

3. The buffer storage device according to claim 2, wherein one or more bypass sections (113) are designed as ascending sections (111, 111a, 111b) that connect the starting point of the bypass section to a destination point of the bypass section situated upstream from the stated starting point.

4. The buffer storage device according to claim 2, wherein one or more bypass sections (113) are designed as drop sections (120, 120a) that connect the starting point of the bypass section to a destination point of the bypass section situated downstream from the stated starting point.

5. The buffer storage device according to claim 1, wherein the buffer storage device (100) has two or more feed sections (104, 104, 104, 104a-104d) for feeding transport units.

6. The buffer storage device according to claim 5, wherein the two or more feed sections (104, 104, 104, 104a-104d) discharge into the buffer section (117) at two or more feed points (102, 102a-102d).

7. The buffer storage device according to claim 1, wherein the buffer storage device (100) has two or more discharge sections (105, 105, 105, 105a) for discharging transport units.

8. The buffer storage device according to claim 7, wherein the two or more discharge sections (105, 105, 105, 105a) branch off from the buffer section (117) at two or more discharge points (103, 103a).

9. The buffer storage device according to claim 1, wherein the entire buffer section (117) or a portion of the buffer section has a downward slope.

10. The buffer storage device according to claim 1, wherein the transport units (40) are conveyable by the force of gravity along the entire buffer section (117) or a portion of the buffer section.

11. The buffer storage device according to claim 1, wherein the transport units (40) are conveyable by a drive, for example a power and free conveyor or a circulating conveyor, on the entire buffer section (117) or a portion of the buffer section.

12. The buffer storage device according to claim 1, wherein the entire buffer section (117) or a portion of the buffer section has the form of a downwardly leading conveying path.

13. The buffer storage device according to claim 1, wherein one or more accumulation points (106, 106a-106g) at which transport units (40) may be accumulated and released in a selective manner are provided along the buffer section (117).

14. The buffer storage device according to claim 1, wherein a storage ring device (130) is provided along the conveying path of the buffer storage device (100), wherein said storage ring device can take transport units (40) from the buffer storage device at a transfer point and store them, then withdraw them and transfer them to the transfer point of the buffer storage device.

15. The buffer storage device according to claim 1, wherein a sorting device is provided along the conveying path of the buffer storage device (100), wherein the sorting device takes transport units (40) from the buffer storage device, sorts the transport units (40), and transfers the transport units (40) back to the buffer storage device in an altered sequence.

16. The buffer storage device according to claim 1, wherein the buffer storage device (100) includes a locating system, for example a radio-based locating system, with which a location of transport units (40) and/or transport goods (200) within the buffer storage device may be determined.

17. The buffer storage device according to claim 1, wherein the buffer storage device (100) includes a monitoring system with one or more sensor units situated along the conveying path, via which data of data carrier elements of passing transport units (40) and/or passing transport goods (200) may be received.

18. A buffer storage system (100a) having two or more buffer storage devices (100) according to claim 1, connected in parallel.

19. The buffer storage system (100a) according to claim 18, wherein connecting sections are provided between two or more buffer storage devices (100) connected in parallel, and wherein transport units (40) can change from one buffer storage device to another buffer storage device, via said connecting sections.

20. An overhead conveyor system (10) having a buffer storage device (100) according to claim 1.

21. The overhead conveyor system according to claim 20, having a sorting device situated downstream from the buffer storage device (100).

22. An overhead conveyor system (10) having a buffer storage system (100a) according to claim 18.

23. The overhead conveyor system according to claim 22, having a sorting device situated downstream from the buffer storage system (100a), respectively.

Description

BRIEF DESCRIPTION OF SEVERAL VIEWS OF THE DRAWINGS

[0086] In order to facilitate a fuller understanding of the present invention, reference is made below to the appended drawings. The drawings show embodiments of the inventive subject matter strictly by way of example. Identical or functionally equivalent parts in the figures and the associated description are provided with the same or similar reference numerals.

[0087] FIG. 1 schematically shows a first possible embodiment of a buffer storage device according to the invention;

[0088] FIG. 2 schematically shows a second possible embodiment of a buffer storage device according to the invention;

[0089] FIG. 3 schematically shows a third possible embodiment of a buffer storage device according to the invention;

[0090] FIG. 4 schematically shows a fourth possible embodiment of a buffer storage device according to the invention;

[0091] FIG. 5 schematically shows one possible embodiment of a suspended storage system according to the invention having three parallel buffer storage devices according to the invention;

[0092] FIG. 6a schematically shows an example of an advantageous transport unit in the form of a suspended conveyor bag, in an open state, which may be used in a buffer storage device according to the invention;

[0093] FIG. 6b schematically shows the suspended conveyor bag of FIG. 6a, in a loaded state;

[0094] FIG. 7 schematically shows another example of an advantageous transport unit in the form of a transport carrier, which may be used in a buffer storage device according to the invention;

[0095] FIG. 8 schematically shows another example of an advantageous transport unit for the suspended transport of a plurality of transport goods, which may be used in a buffer storage device according to the invention;

[0096] FIG. 9a schematically shows the transport unit from FIG. 8 in the loaded state, in an oblique perspective view from below, with portions of the transport goods not shown;

[0097] FIG. 9b schematically shows the transport unit from FIG. 8 in the loaded state in a side view perpendicular to the conveying direction;

[0098] FIG. 9c schematically shows in a front view in the conveying direction; and

[0099] FIG. 10 schematically shows the transport unit from FIG. 8, being partially loaded and with opened closure element.

DETAILED DESCRIPTION OF THE INVENTION

[0100] One possible embodiment variant of a buffer storage device 100 according to the invention for an overhead conveyor system 10 having individually conveyable transport units is illustrated strictly schematically in FIG. 1. A buffer section 117 extends downwardly from a starting point 121 of the buffer section to an end point 122 of the buffer section. Transport units can move downstream, driven by gravity, on the downwardly sloping buffer section along the conveying direction 12.

[0101] A bypass section 113 in the form of a return section 110 leads from the end point 122 of the buffer section 117 back to the starting point 102 of the buffer section 117, and together with the buffer section 117 forms a closed conveying path.

[0102] In the exemplary embodiment shown, multiple feed sections 104, 104, 104 come together at a feed point 102, which in this case is identical to the starting point 121 of the buffer section; transport units may be supplied to the feed sections from various sources. For example, in a storage facility, transport goods may be removed, and supplied to the buffer storage device 100 by means of the transport units via a feed section. Likewise, in various production facilities, semifinished products, components, etc., may be loaded onto transport units and supplied to the buffer store 100 via a feed section.

[0103] Multiple discharge sections 105, 105, 105 branch off at a discharge point 103, which in this case is identical to the end point 122 of the buffer section 117; transport units may be further conveyed on these discharge sections to various destinations, for example to production facilities, output points, and further subsystems of the overhead conveyor system such as sorting devices, etc.

[0104] Downstream from the starting point 121 of the buffer section 117, a bypass section 113, which in the example shown is designed as a drop section 120, branches off from the buffer section and opens into the buffer section. The discharge of transport units to the bypass section 113 at the starting point of the bypass section takes place via a suitable switch device 115. Analogously, the feeding of a transport unit back to the buffer section at the destination point of the bypass section takes place via a suitable switch device.

[0105] The technical configuration of the switch devices is a function of the specific design of the overhead conveyor system 10. Such switch devices for specific overhead conveyor systems are known to those skilled in the art.

[0106] Situated upstream from the destination point of the bypass section, at which the bypass section 113 opens into the buffer section 117, is an accumulation point 106b, behind which an upstream accumulation section 101 is situated on the buffer section. Provided at the accumulation point is a blocking device that reversibly prevents further movement of the transport units by gravity, for example by temporarily blocking a trolley of the transport unit in a form-fit manner. This may be achieved, for example, with an appropriately controlled separating device.

[0107] Due to the temporary blocking of the conveying path, further transport units run up against the blocked transport unit and are held back on the accumulation section 101. When the blocking device releases the transport unit, it once again moves downstream by gravity along the conveying direction 12.

[0108] The blocking device, which ensures a sufficient running clearance on the buffer section between the previously accumulated transport units, is advantageously designed as a separating device.

[0109] The purpose, among others, of the various accumulation points 106, 106a, 106b, 106c, 106d in the shown exemplary embodiment of a buffer section 117 is to control the feed of transport units from a bypass section into the buffer section. Only when a transport unit is inserted at the correct location in the flow of goods does the blocking device release the flow of goods at the accumulation point. In addition, the accumulation points may be used to increase the storage capacity of the buffer storage device according to the invention, since the effective conveying speed is reduced, and thus the effective density of the transport units over the entire buffer section is increased.

[0110] Provided on the buffer section 117 is a further bypass section 113 in the form of an ascending section 111, which branches off from the buffer section 117 at a starting point beneath the accumulation point 106c, and upstream opens into the buffer section 117 at a destination point beneath an accumulation point 106a. With this ascending section 113 it is thus possible to insert upstream transport units back into the flow of goods in a selective manner.

[0111] In the exemplary embodiment shown, also provided at two locations along the buffer section 117 are storage rings 130, 130 which may receive transport units from the flow of goods and deliver them back to the flow of goods. The storage rings 130, 130 correspond to bypass sections in which the starting point and the destination point coincide. Various storage rings 130, 130 for overhead conveyor systems are known which may be used in a buffer storage device according to the invention.

[0112] Provided above the destination points of the storage rings 130, 130 is an accumulation point 106b, 106c, respectively, at which the flow of goods may be stopped as needed in order to insert a transport unit from the storage ring in question into the flow of goods.

[0113] The storage rings 130, 130 may also be used as an auxiliary loop, based on the first in, first out principle, for variably expanding the buffer section, for example by introducing the complete flow of goods into the storage ring, and at the same time continuously emptying the contents of the storage ring from the ring store and returning them downstream to the buffer section in an unaltered sequence. Depending on the conveying frequency, the transport units may be introduced into the storage ring or removed therefrom, individually or in groups. When the expansion of the buffer section is no longer needed, the arriving transport units are held back at the accumulation point until the storage ring is completely empty, and are subsequently released.

[0114] Analogously, bypass sections designed as drop sections 120 may be used to temporarily shorten the buffer section by diverting the entire flow of goods via the bypass section in question.

[0115] A temporary change in the effective length, and thus the capacity, of the buffer section as proposed above may be advantageous in particular when major changes in the production sequence require considerable rearrangements in the composition of the continuous flow of goods, for example due to a breakdown on a production line.

[0116] It may also be useful to adjust the capacity of the buffer section, for example when the capacity of a production facility changes significantly. Mentioned as an example is the changeover of a production facility from daytime production mode to a nighttime production mode, when fewer personnel are used and therefore the production rate is greatly reduced. The supplying of components via the buffer storage device is correspondingly reduced. The buffer storage device may be adapted to the lower capacity requirement by deactivating an expansion of the buffer section that is achieved with a storage ring.

[0117] Efficient sorting requires sufficient capacities, since a sorting operation may often be inefficient close to the capacity limit of a sorting system. At the same time, for a buffer storage device according to the invention the storage capacity during normal operation should not be too high, since this increases the volume requirements of the facility without added value for the sorting function according to the invention. However, by changing the effective buffer section as needed, a buffer storage device according to the invention may more efficiently adapt the flow of goods to the changed circumstances, and for example temporarily process larger sorting volumes in an efficient manner.

[0118] The buffer storage device described above has the advantage in particular that the transport units on the buffer section and the bypass sections designed as drop sections are conveyable by gravity without active drive systems. The energy requirements during operation are correspondingly minimized.

[0119] For the line sections designed as ascending sections, the conveying means, which are generally implemented as continuous conveyor chains, do not have to run continuously, but rather may be activated as needed. Even during continuous operation, the energy consumption is comparatively low, since the ascending sections accept a small proportion compared to the overall line of the buffer storage device. This applies in particular when in a closed conveying path the slope of the ascending sections is selected to be much greater than the gradient of the downwardly sloping buffer sections.

[0120] The storage rings may likewise be implemented in such a way that instead of a horizontal continuous conveyor, a drop section is connected to an ascending section.

[0121] FIG. 2 shows another schematic example of a buffer storage device 100 according to the invention in an overhead conveyor system 10. A buffer section 117, the same as in the preceding example, runs on a downward slope from a starting point 121 of the buffer section to an end point 122 of the buffer section, and a bypass section 113 in the form of a return section 110 leads from the end point 122 back to the starting point 102. Multiple feed sections 104, 104, 104 open into the buffer section 117 of the buffer storage device 100 at a feed point 102 that is identical to the starting point 121 of the buffer section. Multiple discharge sections 105, 105, 105 branch off from the buffer section 117 at a discharge point 103 that is identical to the end point 122 of the buffer section 117.

[0122] In addition, a further feed section 104a opens into the buffer section 117 farther downstream at a feed point 102a beneath an accumulation point 106b. A sorting effect may be achieved merely by such a placement of the feed point.

[0123] A further discharge section 105a likewise branches off from the buffer section at a discharge point 103a within the buffer section 117. In this case as well, a sorting effect may thus be achieved.

[0124] A bypass section 113 in the form of a drop section 120 branches off from the buffer section 117 at the accumulation point 106a. The bypass section later splits into multiple branches, and opens into the buffer section at three different destination points, namely, the accumulation points 106b, 106d, and 106f. Thus, it is possible not only for such a bypass section 113 to insert a transport unit back into the flow of goods at a certain location on the buffer section, but also to do this at the best suitable location in a flexible manner, depending on the requirements. For example, the destination point for each transport unit discharged onto the bypass section 113 may be selected in such a way that the flow of goods is least restricted.

[0125] The bypass section 113 designed as a return section 110 likewise branches off. A first branch of the ascending section 111 opens into the buffer section at the accumulation point 106 at the starting point 102 of the buffer section. Two other branches 111b, 111b of the ascending section 111 open into the buffer section 117 downstream at the accumulation points 106h and 106c. In addition, a bypass section 113 in the form of a subsection 11 la branches off from the buffer section 117 at the accumulation point 106, and opens into the first ascending section 111. Such a system of ascending sections allows very flexible movement of transport units to other locations upstream in the flow of goods.

[0126] In one generalized embodiment variant of a buffer storage device according to the invention, multiple drop sections or ascending sections branch off from the buffer section at various starting points and open into the buffer section at various destination points. Individual line sections of the drop sections or ascending sections advantageously coincide.

[0127] FIG. 3 illustrates yet another exemplary embodiment of a buffer storage device 110 according to the invention. The buffer section 117 has the shape of a flat spiral that leads continuously downwardly from a starting point 102 along a conveying direction to an end point 103 situated at a lower level. From there, a return section as an ascending section leads back to the starting point 102 of the buffer section 117.

[0128] In the exemplary embodiment shown, the return section 110 has three inclined conveying devices 112, 112, 112, having different pitch angles, situated in succession. Such a subdivision of the ascending section has the advantage that the load and the energy consumption for the inclined conveying devices are less.

[0129] A first feed section 104 opens into the buffer section 117 at the starting point 102. Four additional feed sections 104a, 104b, 104c, 104d open into the buffer section 117 of the buffer storage device 110 farther downstream at the feed points 102a, 102b, 102c, 102d, respectively. A first discharge section 105 branches off from the buffer section 117 at the discharge point 103. Another discharge section 105a branches off from the buffer section farther upstream at a discharge point 103a.

[0130] Suitable switch devices 115, only schematically illustrated, are provided at the points at which the feed sections 103, 104a-104d or the return section 110 open(s) into the buffer section 117, or at which the discharge sections 105, 105a branch off from the buffer section 117. Separating devices 114, likewise only schematically illustrated, accumulate the flow of goods on the line on which they are situated, and thus ensure correct operation of the switch devices 115, in that in particular they release transport units only individually for further transport and prevent collisions of transport units.

[0131] Such a combination of multiple feed sections and discharge sections allows a sorting function of the buffer storage device 110 according to the invention, in that the supplied transport units may be inserted into the continuous flow of goods at the desired location.

[0132] FIG. 4 shows a variant of such a buffer storage device 110 according to the invention. Junctions 118 of conveying paths are marked with dashed-line rectangles in this figure. Branches 119 of conveying paths are marked with dashed-line circles. The buffer storage device 110 has only one discharge section 105.

[0133] Two bypass sections implemented as drop sections 120, 120a branch off from the buffer section 117 at two loop end points of the buffer section 117, and in each case two windings of the buffer section 117 open into the buffer section 117 at a lower level.

[0134] Another bypass section branches off at a loop of the buffer section 117, and on a first ascending section 111a overcomes a certain height difference by means of an inclined conveying device before it merges into a downwardly sloping line section 111b, and lastly, opens into the buffer section 117 three loops above the starting point.

[0135] FIG. 5 shows an example of a buffer storage system 100a according to the invention. Three buffer storage devices similar to those from FIGS. 3 and 4 are adjacently situated. Transport units 40, transport bags in the example shown, reach the buffer sections 117 of the three buffer storage devices of the buffer storage system, connected in parallel, via a shared feed section 104. At the end point of the buffer sections, the transport units 40 leave the buffer storage system 100a on a shared discharge section 105. A plurality of further feed sections 104a open into the buffer sections at various locations on the three buffer storage devices.

[0136] Such a buffer storage system has a very high storage capacity per unit volume, and occupies a very small base area. The base area may even be used for other purposes, since the buffer storage system requires no facility parts on the floor and may be operated overhead.

[0137] FIG. 6 shows an example of a transport unit 40 that may be used in a buffer storage device according to the invention or in a buffer storage system according to the invention. A trolley 41 of the transport unit 40 runs on a running rail 13 of an overhead conveyor system. Facing away from the running rail 13, a coupling device 50 is mounted on the trolley 41, and a transport bag 54 in turn is pivotably suspended on the coupling device. The transport bag 54 is constructed in such a way that in the empty state it automatically folds up along provided hinge elements due to its intrinsic weight, so that the transport units in the empty state (see FIG. 6b) may be accumulated or held in a space-saving manner. In the loaded state (see FIG. 6a), the transport good 200 in the form of a piece good unit, for example a package, is situated within the now folded-out transport bag 54.

[0138] FIG. 7 illustrates another example of a transport unit 40 that is suitable for comparably large transport goods 200 such as automotive body parts 202. The transport unit 40 has two trolley elements 41b, 41c that are connected to one another via a strut 41a, and thus together form a trolley. This trolley runs on a running rail (not illustrated) along a conveying path 11 in the running direction 12. A transport carrier 57 is stored in a suspended manner on the trolley via a coupling device 50 that is pivotably connected to the strut 41a. The transport carrier 57 has multiple carrier elements 58 on which an automotive body part 202 is stored.

[0139] FIGS. 8, 9, and 10 show a particularly advantageous transport unit 40. The transport unit 40 has a trolley 41 similar to the one in FIG. 6, with rollers 44 that are provided to give rolling support to the trolley in the running rail (not illustrated) and to hold the trolley laterally in the track. A coupling bolt 42 allows reversible coupling of the trolley 41 to a conveying means (not illustrated), for example an inclined conveyor, a continuous conveyor, or a screw conveyor.

[0140] A carrier device 60 that is suitable for storing in a suspended manner or transporting a plurality of bottles (in the present case, twelve bottles) or similar containers is situated below the trolley.

[0141] The trolley 41 has a spacer 43 on both sides in the running direction 12, which ensures a sufficient distance from the preceding and following transport unit during compacted storage or during loading of the transport unit 40 when transport units are accumulated on the conveying path, thus preventing undesirable contact of the carrier devices 60 or the transport good. The spacers may also be used as shock absorber elements, in that they are made of an elastomer, for example, and/or have a spring element.

[0142] A carrier device 60 is situated below the trolley 41, transverse to the running direction 12, and in the exemplary embodiment shown is fixedly connected to the trolley. This orientation of the carrier device in relation to the trolley allows a compacted arrangement of the transport units on the conveying path.

[0143] Alternatively, a connection by means of a coupling device is also possible which, for example, allows rotation of the carrier device with respect to the trolley. For example, such a coupling device may be designed as an articulated element that allows a swivel motion about a horizontal rotational axis transverse to the conveying direction. The carrier device stored in a suspended manner on the articulated joint thus remains horizontally oriented on nonhorizontal sections of a conveying path. Such a transport unit is also suited for the buffer storage devices described above.

[0144] Alternatively or additionally, the coupling device may allow rotation of the carrier device about a vertical rotational axis, which allows the orientation of the carrier device to be changed in relation to the running direction.

[0145] The carrier device 60 has two parallel carrier channels 61. Each carrier channel 61 has two projections 62.

[0146] In the example shown in FIGS. 8, 9, and 10, the transport goods 200 to be transported are bottle-like containers 203 that have a circumferential collar 210 in the area of the opening. This protrusion 210 rests on the two projections 62 when a transport unit 40 is loaded.

[0147] In the exemplary embodiment shown, the carrier device 60 is designed as a hollow profile which may be cost-effectively produced from aluminum, for example. For the projections 62, separate profile strips are provided which are joined to the hollow profile, for example screwed, adhesively bonded, or connected in a form-fit manner.

[0148] The projection strips 62 may be made, for example, of HDPE, PP, or PTFE, or some other material having low sliding friction. Since only the projection strips are subjected to mechanical wear during operation, easy replacement is advantageous.

[0149] Alternatively, the carrier device may have a one-part design or may be divided into even further parts. For example, the individual carrier channels may be manufactured as one part, for example from fiber-reinforced plastic material, and connected to a shared carrier plate in order to form the carrier device.

[0150] In the exemplary embodiment shown, one end of the carrier channel 61 is permanently closed with a stop element 63 that prevents the bottles 203, 200 from falling out.

[0151] The loading of the carrier device takes place via the opposite opening in the carrier channel. The bottles 203, 200 may be introduced into the carrier channels by sliding, for example, with the protrusion 210 sliding on the projections. To prevent the transport goods 200 from falling out after the transport unit is loaded, the filling opening of the transport channels 61 is reversibly closed with a closure element 64. In the example shown, the closure element is designed as an elastic spring tongue element 64 whose tongue closes the carrier channel 61 in a form-fit manner. For loading, the spring tongue is lifted so that the filling opening is exposed. After loading is complete, the tongue is released and returns to its closed position. An analogous procedure is carried out for unloading.

[0152] Alternatively, both sides of the carrier channel may be reversibly closed with a closure element. This allows, for example, loading and unloading of the transport unit from both sides.

[0153] The present invention is not to be limited in scope by the specific embodiments described herein. Indeed, various modifications of the present invention, in addition to those described herein, will be apparent to those skilled in the art from the foregoing description and accompanying drawings. Thus, such modifications are intended to fall within the scope of the appended claims. Additionally, various references are cited throughout the specification, the disclosures of which are each incorporated herein by reference in their entirety.