Conveyor carousel with distributed drive system

Abstract

A carousel according to the invention uses a number of smaller, less expensive drive units at different locations along the carousel path in place of a single larger drive unit of comparable capacity. Closed loop control according to the invention allows individual drives to be de-energized when the power requirements do not demand their usage. When not energized, the drives may be disengaged from the chain, such as by way of a linear actuator as described hereafter. Benefits of such a system include reduced mechanical costs, longer drive life, better redundancy/higher availability, correct drive power, lower energy use, closed loop system monitoring and reduced collateral damage.

1. A carousel conveyor system, comprising:
 an endless conveyor support frame including one or more endless support rails disposed along a generally elliptical carousel path; 
 a friction drive chain disposed on the conveyor support frame for movement along the carousel path; 
 a pallet assembly including a series of overlapped pallets configured to fit over an upper surface of the conveyor support frame, including a pallet support assembly including wheels that support the pallets on the rails of the conveyor support frame; and connectors securing the pallet assembly to the drive chain for movement in unison therewith; 
 at least two friction drive units each including an electric motor, electrical disconnects for connecting and disconnect disconnecting each motor from a source of electrical power, and a friction drive wheel positioned for driving contact with the drive chain, which drive units are located at spaced apart positions on the conveyor support frame along the carousel path; 
 a controller programmed with control logic for operation of the drive units and connected to receive signals that indicate electrical load on the motor of that drive unit during carousel operation and also connected to the disconnects in a manner that is effective to turn the associated motor on or off in response to a signal from the controller, wherein the control logic takes an action in response to feedback comprising the signals from each drive unit that indicate electrical current being drawn by the motors. 
 
     
     
       2. The system of  claim 1 , wherein the control logic takes action in response to feedback comprising signals from each drive unit that indicate electrical current being drawn by the motors. 
     
     
       3. The apparatus system of  claim 1 , wherein the action in response to feedback comprises turning one of the drive unit motors on or off. 
     
     
       4. The apparatus system of  claim 1 , wherein the action in response to feedback comprises turning one of the drive unit motors on in response to one or more feedback signals indicating an increase in load on the carousel requiring additional drive force application to the drive chain. 
     
     
       5. The apparatus system of  claim 1 , wherein the action in response to feedback comprises turning one of the drive unit motors off in response to one or more feedback signals indicating a decrease in load on the carousel requiring less drive force application to the drive chain. 
     
     
       6. The apparatus system of  claim 1 , wherein the action in response to feedback comprises turning all of the drive unit motors off in response to one or more feedback signals indicating a jam condition has occurred on the carousel. 
     
     
       7. The apparatus system of  claim 1 , wherein at least one of the drive units is redundant in that not all of the drive units need to run at the same time in order for the carousel conveyor to operate at a predetermined load. 
     
     
       8. A carousel conveyor system, comprising:
 an endless conveyor support frame including one or more endless support rails disposed along a carousel path;   a drive chain disposed on the conveyor support frame for movement along the carousel path;   a pallet assembly including a series of pallets configured to fit over an upper surface of the conveyor support frame, including a pallet support assembly including wheels that support the pallets on the rails of the conveyor support frame; and connectors securing the pallet assembly to the drive chain for movement in unison therewith;   at least two drive units each including an electric motor, electrical disconnects for connecting and disconnecting each motor from a source of electrical power, and configured to drive the drive chain, which drive units are located at spaced apart positions on the conveyor support frame along the carousel path;   a controller programmed with control logic for operation of the drive units and connected to receive signals that indicate electrical load on the motor of that drive unit during carousel operation and also connected to the disconnects in a manner that is effective to turn the associated motor on or off in response to a signal from the controller, wherein the control logic takes an action in response to feedback comprising the signals from each drive unit that indicate electrical current being drawn by the motors.   
     
     
       9. The system of claim 8, wherein the control logic takes action in response to feedback comprising signals from each drive unit that indicate electrical current being drawn by the motors. 
     
     
       10. The system of claim 8, wherein the action in response to feedback comprises turning one of the drive unit motors on or off. 
     
     
       11. The system of claim 8, wherein the action in response to feedback comprises turning one of the drive unit motors on in response to one or more feedback signals indicating an increase in load on the carousel requiring additional drive force application to the drive chain. 
     
     
       12. The system of claim 8, wherein the action in response to feedback comprises turning one of the drive unit motors off in response to one or more feedback signals indicating a decrease in load on the carousel requiring less drive force application to the drive chain. 
     
     
       13. The system of claim 8, wherein the action in response to feedback comprises turning all of the drive unit motors off in response to one or more feedback signals indicating a jam condition has occurred on the carousel. 
     
     
       14. The system of claim 8, wherein at least one of the drive units is redundant in that not all of the drive units need to run at the same time in order for the carousel conveyor to operate at a predetermined load. 
     
     
       15. The system of claim 8, wherein the at least two drive units are each configured to drive the drive chain using a friction drive wheel. 
     
     
       16. The system of claim 8, wherein the at least two drive units are each configured to drive the drive chain using a sprocket. 
     
     
       17. The system of claim 8, wherein the at least two drive units are each configured to drive the drive chain using a linear induction motor. 
     
     
       18. The system of claim 8, wherein the conveyor path includes rounded portions and straight portions.