Automatically compliant/releaseable pinch roller mounting system

Abstract

An article conveyor system for handling and conveying articles, pieces, or units of mail comprises first and second conveyor belts which are adapted to have a bite section formed therebetween by means of a pinch roller forcing a portion of the first conveyor belt toward a portion of the second conveyor belt. In order to accommodate different articles, pieces, or units of mail which have different thickness dimensions, the pinch roller is mounted upon a pivot arm, and the pivot arm is operatively connected to a pneumatic actuator. Consequently, as the different articles, pieces, or units of mail are transported through the bite section of the conveyor system, the pinch roller, through means of its pivotal mounting upon the pivot arm, is able to move in a substantially reciprocating fashion or floating manner against the constant bias of the pneumatic actuator so as to accommodate the different articles, pieces, or units of mail. The conveyor system can thus accommodate different articles, pieces, or units of mail having different thickness dimensions without experiencing any jamming, thus effectively eliminating operational downtime of the system.

What is claimed as new and desired to be protected by Letters Patent of the United States of America, is:  
     
         1 . An article conveyor system for conveying articles having different thickness dimensions, comprising: 
 a first conveyor belt;    first conveyor belt drive means for driving said first conveyor belt;    a second conveyor belt;    second conveyor belt drive means for driving said second conveyor belt such that said second driven conveyor belt operatively cooperates with said first driven conveyor belt so as to convey articles as a result of the articles being disposed between said first and second conveyor belts;    a pinch roller adapted to be disposed in contact with a portion of said second conveyor belt so as to effectively force said portion of said second conveyor belt toward a portion of said first conveyor belt in order to define a bite section, between said portions of said first and second conveyor belts, within which articles to be conveyed are effectively grasped so as to be conveyed by said first and second conveyor belts; and    means mounting said pinch roller for constantly adjusting the disposition of said pinch roller and said portion of said second conveyor belt with respect to said portion of said first conveyor belt so as to constantly adjust said bite section defined between said portions of said first and second conveyor belts in response to different articles, having different thickness dimensions, being conveyed through said bite section defined between said first and second conveyor belts such that said conveyor system can accommodate different articles having different thickness dimensions without experiencing jamming.    
     
     
         2 . The system as set forth in  claim 1 , wherein said means mounting said pinch roller comprises: 
 a pivot arm upon which said pinch roller is rotatably mounted; and    actuating means for biasing said pivot arm toward said portion of said first conveyor belt, and for permitting said pinch roller to be moved away from said portion of said first conveyor belt, in response to different thickness dimensions of the different articles being conveyed through said bite section defined between said first and second conveyor belts.    
     
     
         3 . The system as set forth in  claim 2 , wherein: 
 said actuating means comprises a pneumatic actuator.    
     
     
         4 . The system as set forth in  claim 3 , wherein: 
 said pneumatic actuator comprises a pneumatic piston-cylinder assembly comprising a piston member having a piston head and a piston rod disposed within a cylinder,    wherein a free end portion of said piston rod is operatively connected to said pivot arm.    
     
     
         5 . The system as set forth in  claim 4 , further comprising: 
 a source of air adapted to be fluidically connected to said piston-cylinder assembly by means of a pneumatic circuit;    a pressure regulator disposed within said pneumatic circuit so as to regulate incoming air from said source of air to a predetermined pressure value; and    a two-position control valve disposed within said pneumatic circuit for alternatively controlling regulated air pressure to piston head and piston rod chambers defined within said cylinder so as to cause extension and retraction of said piston member, and thereby cause extension and retraction of said pivot arm and said pinch roller mounted upon said pivot arm as a result of said pivot arm being operatively connected to said piston rod.    
     
     
         6 . The system as set forth in  claim 5 , further comprising: 
 an exhaust line disposed within said pneumatic circuit and fluidically connected to said two-position control valve; and    a bleed orifice disposed within said exhaust line for bleeding excess air pressure from said exhaust line when said exhaust line is fluidically connected to said piston head chamber of said piston-cylinder assembly and when said piston member is forcibly retracted into said cylinder as a result of said pinch roller being forced away from said first conveyor belt in response to accommodating an article having a relatively large thickness dimension.    
     
     
         7 . The system as set forth in  claim 5 , further comprising: 
 a vacuum sensor for detecting the presence of an article to be conveyed by said first and second conveyor belts and for generating an article-present signal; and    a plurality of photocells operatively disposed within the vicinity of said bite section defined between said first and second conveyor belts for determining the passage of an article, previously detected by said vacuum sensor, through said bite section defined between said first and second conveyor belts and for generating article-passage signals so as to ensure an article has not become jammed within said bite section defined between said first and second conveyor belts.    
     
     
         8 . The system as set forth in  claim 7 , further comprising: 
 a central processing unit operatively connected to said vacuum sensor, said plurality of photocells, said first and second conveyor belt drive means, said pressure regulator, and said two-position control valve;    said central processing unit being adapted to receive said signals from said vacuum sensor and said plurality of photocells and to generate first operational signals to said first and second conveyor belt drive means, said pressure regulator, and said two-position control valve, in response to said signals from said vacuum sensor and said plurality of photocells, so as to cause extension of said piston member of said piston-cylinder assembly and thereby movement of said pinch roller toward said portion of said first conveyor belt so as to establish said bite section defined between said first and second conveyor belts; and    said central processing unit being adapted to generate second operational signals to said first and second conveyor belt drive means so as to terminate operation of said first and second conveyor belt drive means and to said two-position control valve, in response to the absence of receiving any signals from said vacuum sensor and said plurality of photocells, so as to cause retraction of said piston member of said piston-cylinder assembly and thereby movement of said pinch roller away from said portion of said first conveyor belt so as to eliminate said bite section defined between said first and second conveyor belts and thereby place said system in an idle state.    
     
     
         9 . The system as set forth in  claim 7 , further comprising: 
 a central processing unit operatively connected to said vacuum sensor, said plurality of photocells, said first and second conveyor belt drive means, said pressure regulator, and said two-position control valve;    said central processing unit being adapted to receive said signals from said vacuum sensor and said plurality of photocells and to generate first operational signals to said first and second conveyor belt drive means, said pressure regulator, and said two-position control valve, in response to said signals from said vacuum sensor and said plurality of photocells, so as to cause extension of said piston member of said piston-cylinder assembly and thereby movement of said pinch roller toward said portion of said first conveyor belt so as to establish said bite section defined between said first and second conveyor belts; and    said central processing unit being adapted to generate second operational signals to said first and second conveyor belt drive means so as to terminate operation of said first and second conveyor belt drive means and to said two-position control valve, in response to the presence of said signal from said vacuum sensor but in the absence of receiving all of said signals from said plurality of photocells thereby indicating a jammed mode within said system, so as to cause retraction of said piston member of said piston-cylinder assembly and thereby movement of said pinch roller away from said portion of said first conveyor belt so as to eliminate said bite section defined between said first and second conveyor belts and thereby facilitate extraction of a jammed article from said system.    
     
     
         10 . An article conveyor system for conveying articles of mail having different thickness dimensions, comprising: 
 a first conveyor belt;    first conveyor belt drive means for driving said first conveyor belt;    a second conveyor belt;    second conveyor belt drive means for driving said second conveyor belt such that said second driven conveyor belt operatively cooperates with said first driven conveyor belt so as to convey mail articles as a result of the mail articles being disposed between said first and second conveyor belts;    a pinch roller adapted to be disposed in contact with a portion of said second conveyor belt so as to effectively force said portion of said second conveyor belt toward a portion of said first conveyor belt in order to define a bite section, between said portions of said first and second conveyor belts, within which mail articles to be conveyed are effectively grasped so as to be conveyed by said first and second conveyor belts; and    means mounting said pinch roller for constantly adjusting the disposition of said pinch roller and said portion of said second conveyor belt with respect to said portion of said first conveyor belt so as to constantly adjust said bite section defined between said portions of said first and second conveyor belts in response to different mail articles, having different thickness dimensions, being conveyed through said bite section defined between said first and second conveyor belts such that said conveyor system can accommodate different mail articles having different thickness dimensions without experiencing jamming.    
     
     
         11 . The system as set forth in  claim 10 , wherein said means mounting said pinch roller comprises: 
 a pivot arm upon which said pinch roller is rotatably mounted; and    actuating means for biasing said pivot arm toward said portion of said first conveyor belt, and for permitting said pinch roller to be moved away from said portion of said first conveyor belt, in response to different thickness dimensions of the different mail articles being conveyed through said bite section defined between said first and second conveyor belts.    
     
     
         12 . The system as set forth in  claim 11 , wherein: 
 said actuating means comprises a pneumatic actuator.    
     
     
         13 . The system as set forth in  claim 12 , wherein: 
 said pneumatic actuat or comprises a pneumatic piston-cylinder assembly comprising a piston member having a piston head and a piston rod disposed within a cylinder, wherein a free end portion of said piston rod is operatively connected to said pivot arm.    
     
     
         14 . The system as set forth in  claim 13 , further comprising: 
 a source of air adapted to be fluidically connected to said piston-cylinder assembly by means of a pneumatic circuit;    a pressure regulator disposed within said pneumatic circuit so as to regulate incoming air from said source of air to a predetermined pressure value; and    a two-position control valve disposed within said pneumatic circuit for alternatively controlling regulated air pressure to piston head and piston rod chambers defined within said cylinder so as to cause extension and retraction of said piston member, and thereby cause extension and retraction of said pivot arm and said pinch roller mounted upon said pivot arm as a result of said pivot arm being operatively connected to said piston rod.    
     
     
         15 . The system as set forth in  claim 14 , further comprising: 
 an exhaust line disposed within said pneumatic circuit and fluidically connected to said two-position control valve; and    a bleed orifice disposed within said exhaust line for bleeding excess air pressure from said exhaust line when said exhaust line is fluidically connected to said piston head chamber of said piston-cylinder assembly and when said piston member is forcibly retracted into said cylinder as a result of said pinch roller being forced away from said first conveyor belt in response to accommodating a mail article having a relatively large thickness dimension.    
     
     
         16 . The system as set forth in  claim 15 , further comprising: 
 a vacuum sensor for detecting the presence of a mail article to be conveyed by said first and second conveyor belts and for generating a mail-present signal; and    a plurality of photocells operatively disposed within the vicinity of said bite section defined between said first and second conveyor belts for determining the passage of a mail article, previously detected by said vacuum sensor, through said bite section defined between said first and second conveyor belts and for generating mail-passage signals so as to ensure a mail article has not become jammed within said bite section defined between said first and second conveyor belts.    
     
     
         17 . The system as set forth in  claim 16 , further comprising: 
 a central processing unit operatively connected to said vacuum sensor, said plurality of photocells, said first and second conveyor belt drive means, said pressure regulator, and said two-position control valve;    said central processing unit being adapted to receive said signals from said vacuum sensor and said plurality of photocells and to generate first operational signals to said first and second conveyor belt drive means, said pressure regulator, and said two-position control valve, in response to said signals from said vacuum sensor and said plurality of photocells, so as to cause extension of said piston member of said piston-cylinder assembly and thereby movement of said pinch roller toward said portion of said first conveyor belt so as to establish said bite section defined between said first and second conveyor belts; and    said central processing unit being adapted to generate second operational signals to said first and second conveyor belt drive means so as to terminate operation of said first and second conveyor belt drive means and to said two-position control valve, in response to the absence of receiving any signals from said vacuum sensor and said plurality of photocells, so as to cause retraction of said piston member of said piston-cylinder assembly and thereby movement of said pinch roller away from said portion of said first conveyor belt so as to eliminate said bite section defined between said first and second conveyor belts and thereby place said system in an idle state.    
     
     
         18 . The system as set forth in  claim 16 , further comprising: 
 a central processing unit operatively connected to said vacuum sensor, said plurality of photocells, said first and second conveyor belt drive means, said pressure regulator, and said two-position control valve;    said central processing unit being adapted to receive said signals from said vacuum sensor and said plurality of photocells and to generate first operational signals to said first and second conveyor belt drive means, said pressure regulator, and said two-position control valve, in response to said signals from said vacuum sensor and said plurality of photocells, so as to cause extension of said piston member of said piston-cylinder assembly and thereby movement of said pinch roller toward said portion of said first conveyor belt so as to establish said bite section defined between said first and second conveyor belts; and    said central processing unit being adapted to generate second operational signals to said first and second conveyor belt drive means so as to terminate operation of said first and second conveyor belt drive means and to said two-position control valve, in response to the presence of said signal from said vacuum sensor but in the absence of receiving all of said signals from said plurality of photocells thereby indicating a jammed mode within said system, so as to cause retraction of said piston member of said piston-cylinder assembly and thereby movement of said pinch roller away from said portion of said first conveyor belt so as to eliminate said bite section defined between said first and second conveyor belts and thereby facilitate extraction of a jammed article from said system.    
     
     
         19 . A mounting system for a pinch roller for use in connection with an article conveyor system, for conveying articles having different thickness dimensions, wherein the conveyor system includes a first conveyor belt, a first conveyor belt drive for driving the first conveyor belt, a second conveyor belt, and a second conveyor belt drive for driving the second conveyor belt such that the second driven conveyor belt operatively cooperates with the first driven conveyor belt so as to convey articles as a result of the articles being disposed between the first and second conveyor belts, comprising: 
 a pinch roller adapted to be disposed in contact with a portion of the second conveyor belt so as to effectively force the portion of the second conveyor belt toward a portion of the first conveyor belt in order to define a bite section, between the portions of the first and second conveyor belts, within which articles to be conveyed are effectively grasped so as to be conveyed by the first and second conveyor belts; and    means mounting said pinch roller for constantly and automatically adjusting the disposition of said pinch roller and the portion of the second conveyor belt with respect to the portion of the first conveyor belt so as to constantly and automatically adjust the bite section defined between the portions of the first and second conveyor belts in response to different articles, having different thickness dimensions, being conveyed through the bite section defined between the first and second conveyor belts such that the conveyor system can accommodate different articles having different thickness dimensions without experiencing jamming.    
     
     
         20 . The system as set forth in  claim 19 , wherein said means mounting said pinch roller comprises: 
 a pivot arm upon which said pinch roller is rotatably mounted; and    actuating means for biasing said pivot arm toward the portion of said first conveyor belt, and for permitting said pinch roller to be moved away from the portion of the first conveyor belt, in response to different thickness dimensions of the different articles being conveyed through the bite section defined between the first and second conveyor belts.    
     
     
         21 . The system as set forth in  claim 20 , wherein: 
 said actuating means comprises a pneumatic actuator.    
     
     
         22 . The system as set forth in  claim 21 , wherein: 
 said pneumatic actuator comprises a pneumatic piston-cylinder assembly comprising a piston member having a piston head and a piston rod disposed within a cylinder, wherein a free end portion of said piston rod is operatively connected to said pivot arm.    
     
     
         23 . The system as set forth in  claim 22 , further comprising: 
 a source of air adapted to be fluidically connected to said piston-cylinder assembly by means of a pneumatic circuit;    a pressure regulator disposed within said pneumatic circuit so as to regulate incoming air from said source of air to a predetermined pressure value; and    a two-position control valve disposed within said pneumatic circuit for alternatively controlling regulated air pressure to piston head and piston rod chambers defined within said cylinder so as to cause extension and retraction of said piston member, and thereby cause extension and retraction of said pivot arm and said pinch roller mounted upon said pivot arm as a result of said pivot arm being operatively connected to said piston rod.    
     
     
         24 . The system as set forth in  claim 23 , further comprising: 
 an exhaust line disposed within said pneumatic circuit and fluidically connected to said two-position control valve; and    a bleed orifice disposed within said exhaust line for bleeding excess air pressure from said exhaust line when said exhaust line is fluidically connected to said piston head chamber of said piston-cylinder assembly and when said piston member is forcibly retracted into said cylinder as a result of said pinch roller being forced away from the first conveyor belt in response to accommodating an article having a relatively large thickness dimension.    
     
     
         25 . The system as set forth in  claim 23 , further comprising: 
 a vacuum sensor for detecting the presence of an article to be conveyed by the first and second conveyor belts and for generating an article-present signal; and    a plurality of photocells operatively disposed within the vicinity of the bite section defined between the first and second conveyor belts for determining the passage of an article, previously detected by said vacuum sensor, through the bite section defined between the first and second conveyor belts and for generating article-passage signals so as to ensure an article has not become jammed within the bite section defined between the first and second conveyor belts.    
     
     
         26 . The system as set forth in  claim 25 , further comprising: 
 a central processing unit operatively connected to said vacuum sensor, said plurality of photocells, the first and second conveyor belt drives, said pressure regulator, and said two-position control valve;    said central processing unit being adapted to receive said signals from said vacuum sensor and said plurality of photocells and to generate first operational signals to the first and second conveyor belt drives, said pressure regulator, and said two-position control valve, in response to said signals from said vacuum sensor and said plurality of photocells, so as to cause extension of said piston member of said piston-cylinder assembly and thereby movement of said pinch roller toward the portion of the first conveyor belt so as to establish the bite section defined between the first and second conveyor belts; and    said central processing unit being adapted to generate second operational signals to the first and second conveyor belt drives so as to terminate operation of the first and second conveyor belt drives and to said two-position control valve, in response to the absence of receiving any signals from said vacuum sensor and said plurality of photocells, so as to cause retraction of said piston member of said piston-cylinder assembly and thereby movement of said pinch roller away from the portion of the first conveyor belt so as to eliminate the bite section defined between the first and second conveyor belts and thereby place the conveyor system in an idle state.    
     
     
         27 . The system as set forth in  claim 25 , further comprising: 
 a central processing unit operatively connected to said vacuum sensor, said plurality of photocells, the first and second conveyor belt drives, said pressure regulator, and said two-position control valve;    said central processing unit being adapted to receive said signals from said vacuum sensor and said plurality of photocells and to generate first operational signals to the first and second conveyor belt drives, said pressure regulator, and said two-position control valve, in response to said signals from said vacuum sensor and said plurality of photocells, so as to cause extension of said piston member of said piston-cylinder assembly and thereby movement of said pinch roller toward the portion of the first conveyor belt so as to establish the bite section defined between the first and second conveyor belts; and    said central processing unit being adapted to generate second operational signals to the first and second conveyor belt drives so as to terminate operation of the first and second conveyor belt drives and to said two-position control valve, in response to the presence of said signal from said vacuum sensor but in the absence of receiving all of said signals from said plurality of photocells thereby indicating a jammed mode within the conveyor system, so as to cause retraction of said piston member of said piston-cylinder assembly and thereby movement of said pinch roller away from the portion of the first conveyor belt so as to eliminate the bite section defined between the first and second conveyor belts and thereby facilitate extraction of a jammed article from the conveyor system.    
     
     
         28 . A mounting system for a pinch roller for use in connection with a mail article conveyor system, for conveying mail articles having different thickness dimensions, wherein the conveyor system includes a first conveyor belt, a first conveyor belt drive for driving the first conveyor belt, a second conveyor belt, and a second conveyor belt drive for driving the second conveyor belt such that the second driven conveyor belt operatively cooperates with the first driven conveyor belt so as to convey mail articles as a result of the mail articles being disposed between the first and second conveyor belts, comprising: 
 a pinch roller adapted to be disposed in contact with a portion of the second conveyor belt so as to effectively force the portion of the second conveyor belt toward a portion of the first conveyor belt in order to define a bite section, between the portions of the first and second conveyor belts, within which mail articles to be conveyed are effectively grasped so as to be conveyed by the first and second conveyor belts; and    means mounting said pinch roller for constantly and automatically adjusting the disposition of said pinch roller and the portion of the second conveyor belt with respect to the portion of the first conveyor belt so as to constantly and automatically adjust the bite section defined between the portions of the first and second conveyor belts in response to different mail articles, having different thickness dimensions, being conveyed through the bite section defined between the first and second conveyor belts such that the conveyor system can accommodate different mail articles having different thickness dimensions without experiencing jamming.    
     
     
         29 . The system as set forth in  claim 28 , wherein said means mounting said pinch roller comprises: 
 a pivot arm upon which said pinch roller is rotatably mounted; and    actuating means for biasing said pivot arm toward the portion of said first conveyor belt, and for permitting said pinch roller to be moved away from the portion of the first conveyor belt, in response to different thickness dimensions of the different mail articles being conveyed through the bite section defined between the first and second conveyor belts.    
     
     
         30 . The system as set forth in  claim 29 , wherein: 
 said actuating means comprises a pneumatic actuator.    
     
     
         31 . The system as set forth in  claim 30 , wherein: 
 said pneumatic actuator comprises a pneumatic piston-cylinder assembly comprising a piston member having a piston head and a piston rod disposed within a cylinder, wherein a free end portion of said piston rod is operatively connected to said pivot arm.    
     
     
         32 . The system as set forth in  claim 31 , further comprising: 
 a source of air adapted to be fluidically connected to said piston-cylinder assembly by means of a pneumatic circuit;    a pressure regulator disposed within said pneumatic circuit so as to regulate incoming air from said source of air to a predetermined pressure value; and    a two-position control valve disposed within said pneumatic circuit for alternatively controlling regulated air pressure to piston head and piston rod chambers defined within said cylinder so as to cause extension and retraction of said piston member, and thereby cause extension and retraction of said pivot arm and said pinch roller mounted upon said pivot arm as a result of said pivot arm being operatively connected to said piston rod.    
     
     
         33 . The system as set forth in  claim 32 , further comprising: 
 an exhaust line disposed within said pneumatic circuit and fluidically connected to said two-position control valve; and    a bleed orifice disposed within said exhaust line for bleeding excess air pressure from said exhaust line when said exhaust line is fluidically connected to said piston head chamber of said piston-cylinder assembly and when said piston member is forcibly retracted into said cylinder as a result of said pinch roller being forced away from the first conveyor belt in response to accommodating a mail article having a relatively large thickness dimension.    
     
     
         34 . The system as set forth in  claim 32 , further comprising: 
 a vacuum sensor for detecting the presence of a mail article to be conveyed by the first and second conveyor belts and for generating a mail article-present signal; and    a plurality of photocells operatively disposed within the vicinity of the bite section defined between the first and second conveyor belts for determining the passage of a mail article, previously detected by said vacuum sensor, through the bite section defined between the first and second conveyor belts and for generating mail article-passage signals so as to ensure a mail article has not become jammed within the bite section defined between the first and second conveyor belts.    
     
     
         35 . The system as set forth in  claim 34 , further comprising: 
 a central processing unit operatively connected to said vacuum sensor, said plurality of photocells, the first and second conveyor belt drives, said pressure regulator, and said two-position control valve;    said central processing unit being adapted to receive said signals from said vacuum sensor and said plurality of photocells and to generate first operational signals to the first and second conveyor belt drives, said pressure regulator, and said two-position control valve, in response to said signals from said vacuum sensor and said plurality of photocells, so as to cause extension of said piston member of said piston-cylinder assembly and thereby movement of said pinch roller toward the portion of the first conveyor belt so as to establish the bite section defined between the first and second conveyor belts; and    said central processing unit being adapted to generate second operational signals to the first and second conveyor belt drives so as to terminate operation of the first and second conveyor belt drives and to said two-position control valve, in response to the absence of receiving any signals from said vacuum sensor and said plurality of photocells, so as to cause retraction of said piston member of said piston-cylinder assembly and thereby movement of said pinch roller away from the portion of the first conveyor belt so as to eliminate the bite section defined between the first and second conveyor belts and thereby place the conveyor system in an idle state.    
     
     
         36 . The system as set forth in  claim 34 , further comprising: 
 a central processing unit operatively connected to said vacuum sensor, said plurality of photocells, the first and second conveyor belt drives, said pressure regulator, and said two-position control valve;    said central processing unit being adapted to receive said signals from said vacuum sensor and said plurality of photocells and to generate first operational signals to the first and second conveyor belt drives, said pressure regulator, and said two-position control valve, in response to said signals from said vacuum sensor and said plurality of photocells, so as to cause extension of said piston member of said piston-cylinder assembly and thereby movement of said pinch roller toward the portion of the first conveyor belt so as to establish the bite section defined between the first and second conveyor belts; and    said central processing unit being adapted to generate second operational signals to the first and second conveyor belt drives so as to terminate operation of the first and second conveyor belt drives and to said two-position control valve, in response to the presence of said signal from said vacuum sensor but in the absence of receiving all of said signals from said plurality of photocells thereby indicating a jammed mode within the conveyor system, so as to cause retraction of said piston member of said piston-cylinder assembly and thereby movement of said pinch roller away from the portion of the first conveyor belt so as to eliminate the bite section defined between the first and second conveyor belts and thereby facilitate extraction of a jammed mail article from the conveyor system.