DROP AND SLIDE OUT IDLER ASSEMBLY

Abstract

The invention is directed to a drop and slide out idler assembly that can all be removed from a first side of a conveyor system. The assembly includes a first end roller unit with a roller having an axis of rotation at an angel with respect to the horizontal, and a middle roller unit with a roller having an axis of rotation that is horizontal. The assembly further includes a second end roller having a roller that can be raised at one end to have an axis of rotation at an angle with respect to the horizontal, and lowered to have an axis of rotation that is horizontal. In the lowered position, the second end roller unit can be slid out from under a conveyor belt of the system through the first side.

Claims

1. A removable drop and slide out idler assembly for use with a conveyor comprising: a base; a first end roller unit mounted to the base having a roller with an axis of rotation at an angle with respect to horizontal; a middle roller unit mounted to the base that is couple-able on a first side to the first roller unit, the middle roller unit having a roller with a horizontal axis of rotation; and, a second end roller unit mounted to the base that is couple-able to a second side of the middle roller unit, the second end roller having a roller movable from a first raised position having an axis of rotation at an angle with respect to horizontal, to a retracted position wherein the axis of rotation of the roller of the second end roller unit is horizontal.

2. The removable drop and slide out idler assembly of claim 1 wherein the first end roller unit, middle roller unit and second end roller unit are slidably mounted to the base.

3. The removable drop and slide out idler assembly of claim 2 wherein the second end roller unit comprises a slide handle pivotably mounted to a first end of a support brace, and wherein a second end of the support brace is connected to an end of the roller of the second roller unit.

4. The removable drop and slide out idler assembly of claim 3 wherein the slide handle is connected to the support brace by a fixed pin having an outwardly extending portion that extends outward from the slide handle.

5. The removable drop and slide out idler assembly of claim 4 further comprising an end lock plate having a notch for engaging the outwardly extending portion of the fixed pin of the slide handle when the second end roller unit is in the raised position.

6. The removable drop and slide out idler assembly of claim 1 wherein the second roller unit is at a 20° angle with respect to horizontal when in the raised position.

7. The removable drop and slide out idler assembly of claim 1 wherein the second roller unit is at a 35° angle with respect to horizontal when in the raised position.

8. The removable drop and slide out idler assembly of claim 1 wherein the second roller unit is at a 45° angle with respect to horizontal when in the raised position.

9. The removable drop and slide out idler assembly of claim 2 wherein the second roller unit includes a screw drive system for raising and lowering the roller on the second roller unit.

10. The removable drop and slide out idler assembly of claim 2 wherein the second roller unit includes a motorized system for raising and lowering the roller on the second roller unit.

11. The removable drop and slide out idler assembly of claim 2 wherein the second roller unit includes a hydraulic system for raising and lowering the roller on the second roller unit.

12. A drop and slide roller unit for an idler assembly comprising: a frame supporting a roller having an axis of rotation; a slidable mounting structure connected to the frame; and, an apparatus for raising a first end of the frame to a first position where the axis of rotation is at an angle with respect to the horizontal and for lowering the frame to a second position where the axis of rotation is horizontal.

13. The drop and slide roller unit of claim 12 wherein the apparatus for raising and lowering the frame comprises: a slide handle; and, a support brace pivotably connected to the slide handle, the support brace connected to the first end of the frame.

14. The drop and slide roller unit of claim 13 wherein the slide handle is connected to the support brace by a fixed pin having a portion that extends outward from the slide handle.

15. The drop and slide roller unit of claim 12 wherein the slide handle includes a notch for receiving a locking pin on a base.

16. The drop and slide roller unit of claim 12 wherein the apparatus for raising and lowering the frame comprises: a screw drive.

17. The drop and slide roller unit of claim 16 wherein the screw-drive can be operated manually.

18. The drop and slide roller unit of claim 16 wherein the screw-drive can be operated with a power drill.

19. A method for servicing an idler assembly for a conveyor having three roller units from only a first side of the conveyor comprising: slidably removing a first end roller unit having a roller with an angled axis of rotation from a first side of the conveyor; slidably removing a middle end roller having a roller with a horizontal axis of rotation from the first side of the conveyor; dropping an end of a second end roller unit having a roller with an angled axis of rotation to a position wherein the axis of rotation is horizontal; and, slidably removing the second end roller unit from the first side of the conveyor.

20. The method of claim 19 wherein the step of dropping an end of a second end roller unit having a roller with an angled axis of rotation to a position wherein the axis of rotation is horizontal comprises: operating a screw-drive to lower the second end of the roller unit.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0026] To understand the present invention, it will now be described by way of example, with reference to the accompanying drawings in which:

[0027] FIG. 1 is a perspective view of an idler assembly with all three roller units in position for use with a conveyor in accordance with an aspect of the present invention;

[0028] FIG. 2 is a perspective view of the far end roller unit from the assembly of FIG. 1, in a dropped position;

[0029] FIG. 3 is a perspective view of the far end roller unit of FIG. 2 being removed from a first side of the assembly;

[0030] FIG. 4 is a perspective view of the far end roller unit of FIG. 2 partially raised;

[0031] FIG. 5A is a perspective view of the far end roller unit of FIG. 2 in a raised position;

[0032] FIG. 5B is a perspective end view of the far end roller unit of FIG. 5A in the raised position;

[0033] FIG. 6 is a perspective view of the middle roller unit of the assembly being slid into position next to the far end roller unit;

[0034] FIG. 7 is a perspective view of the middle roller unit and the far end roller unit in position;

[0035] FIG. 8 is a perspective view of the near end roller unit being slid into position next to the middle roller unit;

[0036] FIG. 9 is a perspective view of the idler assembly with the near roller unit in position next to the middle roller unit;

[0037] FIG. 10 is an end view of the idler assembly with the conveyor shown in cross-section;

[0038] FIG. 11 is a perspective view of an idler assembly with a first end roller unit and middle roller unit removed, and a far end roller unit in a raised position;

[0039] FIG. 12 is a perspective view of the assembly of FIG. 11 with the far end roller unit partially lowered;

[0040] FIG. 13 is a perspective view of the assembly of FIGS. 11 and 12 with the far end roller unit completely lowered and in position for removal; and,

[0041] FIG. 14 is a perspective view of the assembly of FIGS. 11-13 with the far end roller unit being slid off the base.

DETAILED DESCRIPTION

[0042] While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated.

[0043] FIGS. 1-10 show removal and installation of a drop and slide idler assembly 10 in accordance with one aspect of the invention. The idler assembly 10 includes a first end roller unit 12, a middle roller unit 14 and a second end roller unit (i.e., a drop and slide roller unit) 16. The idler assembly 10 is configured to enable removal of all three roller units 12, 14, 16 from the same side of a conveyor belt system without requiring removal of the conveyor belt 18.

[0044] Each roller unit 12, 14, 16 includes a frame for supporting a cylindrical roller 20, 22, 24 having a central axis of rotation. Collectively, during operation, the rollers 20, 22, 24 in the units 12, 14, 16 are configured to form a trough like shape that mirrors the shape of the conveyor belt 18 (shown in cross-section in FIG. 10). The rollers 20, 24 in the two end roller units 12, 16 are each raised at one end such that each roller's axis of rotation is at an angle with respect to a horizontal line (represented by the base or floor). Both ends of the roller 22 in the middle unit 14 remain low and the axis of rotation is horizontal.

[0045] Each of the roller units 12, 14, 16 are configured to be slide-ably mounted to a fixed base 26 below the conveyor belt 18. The fixed base 26 can be formed from a plurality of components welded together (i.e., sometimes referred to as a fixed base weldment herein). The assembly 10 is designed to be removed from the fixed base 26, completely dismantled, inspected, and serviced by (optimally) one person from only one side of the conveyor system.

[0046] The first end roller 12 is designed to just slide off the fixed base 26 from a first side of the conveyor system as is. That is, there is no impediment to removing the first end roller 12 in the angled position it is in. Similarly, the middle roller unit 14, which is set below the lowest point of the conveyor belt 18, can also be slid out in the same direction as the first end roller unit 12. Again, there is no impediment to the unit 14 given its low horizontal position.

[0047] A problem arises with attempting to remove the second end roller unit 16 (i.e., the far end—from the first side) in the same direction as the first roller unit 12 and the middle roller unit 14. Namely, the trough shape of the conveyor belt 18 blocks the second roller unit 16 while it's in an angled position as shown in FIG. 1 or 10. The present invention overcomes this obstacle by providing a roller unit that can drop (i.e., retract from the raised portion) into a low horizontal position (similar to the position of the middle roller unit 14) which allows the roller unit to slide under the conveyor belt 18 in the same manner as the middle roller unit 14 and out the first side of the conveyor system. The roller unit 16 is put back in place in a similar manner.

[0048] As shown in the embodiment of FIG. 1, the second end roller unit 16 includes a slide lock handle 28 pivotably connected to a support brace 30 by a fixed retaining pin 32 (the slide lock handle, support brace each have two portions spanning the width of the roller—each portion includes a fixed retaining pin). The support brace 30 maintains the far end 34 of the second roller unit 16 in a raised position, and is used to both raise and lower the far end 34 in combination with the slide lock handle 28.

[0049] In the raised position, the fixed retaining pin 32 is locked in a notch 36 of an end plate 38 at one end of the fixed base 26. Pulling the slide lock handle 28 disengages the fixed pin 32 from the end plate 38 and allows the end 34 of the second roller unit 16 to drop (i.e., retract) to a lower profile with the axis of rotation of the roller 24 in a horizontal position. Further pulling the handle 28 moves a notch 40 in the handle 28 to a position where it engages a lock pin 42 on the frame of the roller unit 16. This allows the unit 16 to be pulled out of the first side of the conveyor in a similar manner as the middle roller unit 14.

[0050] As is evident in FIG. 2, the fixed base 26 has a first planar angled portion 44 joined at a top most point to a second planar angled portion 46. Each end of the fixed base 26 includes a bracket 48 which can be used to secure the fixed base 26 to cross-beams 50 (see e.g., FIG. 3) using bolts 52. A plurality of track clips 54 are positioned along the fixed base 26 to support the roller units.

[0051] To reinstall the assembly 10, the second roller unit 16, while in the dropped or retracted position, is placed back on the fixed base 26 on the first side of the conveyor system, and slid back toward the end plate 38 (see FIG. 3). When the unit 16 stops against the back plate 38, the slide lock handle 28 is lifted to disengage it from the slide lock pin 42 and is further pushed back toward the end plate 38. This action causes the end 34 of the second roller unit 16 to raise into a full working position, and simultaneously engages the fixed pin 32 into the slot 36 of the end plate 38 as illustrated in FIGS. 4 and 5A.

[0052] Once the second roller unit 16 is installed and raised into position, the middle roller unit 14 can be placed on the fixed base 26 and slid into position next to the second roller unit 16 (see FIG. 6). As shown in FIG. 5B, the second roller unit 16 includes a locating finger or flange 56 that extends outward in the direction of the middle roller unit 14. The middle roller unit 14 includes a slot 58 on the side facing the second roller unit 16 (in fact, it has one slot on each side) that is aligned with the finger 56. The slot 58 engages the finger 56 as the middle roller unit 14 stops against the second roller unit 16 as shown in FIG. 7.

[0053] After the middle roller unit 14 is in place, the first end roller unit 12 is placed on the fixed base 26 as illustrated in FIG. 8. The first end roller unit 12 includes a locating finger 60 that aligns with a slot 58 on the side of the middle roller unit 14 facing the first end roller unit 12. The first end roller unit 12 is pushed until it stops against the middle roller unit 14 as illustrated in FIG. 9. A side bolt 60 and lock washer, and an end bolt 64 and lock washer are used to secure the units 12, 14, 16 in place. As is readily evident, the side bolt 60 and end bolt 64 need to be removed at the beginning of the process for removing the idler assembly 10.

[0054] Another form of a drop and slide roller unit 70 is shown in FIGS. 11-14. The roller unit 70 includes a screw-drive 72 that can be turned by an end nut 74 on one side of the unit 70. The screw-drive 72 can be turned manually (e.g., by a ratchet 76) or by a powered drive (e.g., a power drill).

[0055] Turning the screw-drive 72 one direction causes a nut 78 connected to a support brace 80 (shown holding the far end 82 of the roller unit 70 in a raised position in FIG. 11) to move toward the opposite side of the drive 72 and lower the far end 82 of the roller unit 70 into a horizontal position (see FIGS. 12 and 13). Once lowered, the unit 70 can be slid outward toward the first side of the conveyor system as shown in FIG. 14. To raise the far end 82 of the unit 70 back into operating position (e.g., during installation or after servicing or repair), the screw-drive is turned the opposite direction until the nut 78 rests against the end plate 84. The screw-drive system allows for a more controlled raising and lowering of the drop and slide roller unit 70. This can prevent injury to a service person or damage to the unit (e.g., if otherwise allowed to drop too quickly).

[0056] In addition to the slide handle and screw drive systems discussed above, other structures or mechanisms can be used to raise and lower the drop and slide roller unit. For example, a variety of electric or gas powered motors can be utilized. Alternatively, a hydraulic system could be employed or a manual or powered jack apparatus.

[0057] The idler assembly can be adapted for use with a variety of trough idler configurations (including those having two or more drop and slide units, and/or middle units and/or near side units) as well as a variety of trough angles and belt widths.

[0058] Many modifications and variations of the present invention are possible in light of the above teachings. It is, therefore, to be understood within the scope of the appended claims the invention may be protected otherwise than as specifically described.