Differential speed conveyor accumulation system and method

Abstract

A product conveying and accumulation system and method employs a primary product transporting conveyor with accumulation and re-circulating sections. The conveyor is configured to receive products from an upstream destination and discharge products to a downstream destination. A second conveyor, operable at a considerable slower speed than the first conveyor, is located in the same transverse plane as and is aligned adjacent to the first conveyor. Both conveyors travel in the same direction at the adjacent alignment. As products are discharged from the system, a wall of product is formed on the slower moving conveyor. As a result, products on the inner lane of the faster moving conveyor which would otherwise tend to move inward towards the discharge point, causing product turbulence and disruption, are urged back onto the inner lane by the product wall and then smoothly discharged from the system to the downstream destination. The use of this slower conveyor increases product stability by substantially eliminating product turbulence caused by the product bunching and nesting which normally occurs at the product discharge point. A substantially increased rate of product outfeed results.

1 - 17 . (canceled) 
     
     
         18 . A product conveying and accumulation system, said system comprising:
 first conveying means for the movement of products from an upstream destination to a product discharge location, said first conveying means moving in a designated direction and at a constant speed;   second conveying means for the accumulation of products from the first conveying means and for movement of products back to the first conveying means; and   means, stationary in relation to the first and second conveying means, for receiving products from the first conveying means, said stationary means being aligned substantially adjacent to and between the first and second conveying means and, at this adjacent alignment, parallel to and in direct side by side contact with the first and second conveying means, whereby products are moved from the first conveying means directly onto the stationary means at the adjacent alignment and remain substantially stationary thereon, such that products being moved by the first conveying means are compelled away from the product discharge location as a result of the presence of the products on the stationary means, thereby causing product separation with and, substantially eliminating product turbulence and instability at the product discharge location.   
     
     
         19 . The product conveying and accumulation system as in  claim 18  wherein the first conveying means and the stationary means are in substantially the same transverse plane at the adjacent alignment. 
     
     
         20 . The product conveying and accumulation system as in  claim 18  further comprising guide means substantially located at the product discharge location for directing products from the first conveying means to a downstream destination. 
     
     
         21 . The product conveying and accumulation system as in  claim 18  in which there are multiple product discharge locations. 
     
     
         22 . A product conveying and accumulation system, said system comprising:
 first conveying means for the movement of product from an upstream destination to a product discharge location, said first conveying means moving in a designated direction and at a constant speed;   second conveying means for the accumulation of products from the first conveying means and for movement of products back to the first conveying means; and   intermediate means for receiving products from the first conveying means, said intermediate means being aligned substantially adjacent to and located between the first and second conveying means and, at this adjacent alignment, parallel to and in direct side by side contact with the first and second conveying means, whereby products are moved from the first conveying means directly onto the intermediate means at the adjacent alignment and are positioned on the intermediate means such that products being moved by the first conveying means and approaching said product discharge location are compelled away from the product discharge location as a result of the presence of the products on the intermediate means, thereby causing product separation with and substantially eliminating product turbulence and instability at the product discharge location.   
     
     
         23 . The product conveying and accumulation system as in  claim 22  wherein the first conveying means and the intermediate means are in substantially the same transverse plane at the adjacent alignment. 
     
     
         24 . The product conveying and accumulation system as in  claim 22  further comprising guide means substantially located at the product discharge location for directing products from the first conveying means to a downstream destination. 
     
     
         25 . The product conveying and accumulation system as in  claim 22  wherein the intermediate means comprises a single, continuous loop conveyor. 
     
     
         26 . The product conveying and accumulation system as in  claim 22  in which there are two product discharge locations. 
     
     
         27 . The product conveying and accumulation system as in  claim 22  wherein the intermediate means moves at a slower speed than the first conveying means. 
     
     
         28 . The product conveying and accumulation system as in  claim 22  further comprising drive means for moving the first conveyor means at the constant speed and for moving the intermediate means at a speed slower than the first conveying means. 
     
     
         29 . The product conveying and accumulation system as in  claim 22  wherein the intermediate means is stationary. 
     
     
         30 - 33 . (canceled) 
     
     
         34 . A method of transporting and accumulating products, said method comprising the steps of:
 providing a first conveyor for transporting products to a product discharge location;   moving the first conveyor at a designated speed and designated direction;   aligning a second conveyor in spaced relation to the first conveyor;   moving said second conveyor at substantially the same speed as the first conveyor and, at the spaced alignment, in the same direction as the first conveyor;   aligning an intermediate conveyor section adjacent to and between the first and second conveyors and, at this adjacent alignment, parallel to and in direct side by side contact with the first and second conveyors;   placing products on the first conveyor;   moving the products on the first conveyor towards the product discharge location at the speed of the first conveyor;   delivering products from the first conveyor to directly onto the intermediate conveyor section;   maintaining the products on the intermediate conveyor at a substantially static position on the intermediate conveyor section;   establishing separation between the products and the product discharge location by the movement of products on the first conveyor and the positioning of products on the intermediate conveyor section;   substantially eliminating product turbulence and instability at the product discharge location, and   transporting products from the first conveyor to a downstream destination.   
     
     
         35 . The method as in  claim 34  further providing a discharge guide to direct products from the first conveyor means to the downstream destination. 
     
     
         36 . The method as in  claim 35  further comprising forming a wall of products on the intermediate conveyor section which inhibits products being transported from the first conveyor to the downstream destination from contacting the guide, thereby disrupting the transportation and accumulation of products. 
     
     
         37 . The method as in  claim 34  further comprising compelling products being transported from the first conveyor to the downstream destination away from the product discharge location.