Abstract: A closure mechanism to inhibit escape of heat from an oven chamber of a conveyor oven having a conveyor hanger. The closure mechanism includes a plurality of plates configured to couple to a first and second pluralities of connection tabs of a conveyor oven. Each of the plurality of plates include a connection portion, an angled portion configured to extend downward from the connection portion within a slot of the conveyor oven and an engagement portion extending downward from the angled portion to form an engagement surface.

Abstract: A conveyor system including a fixed, non-powered rail defining a conveyor path, and a plurality of automated conveyor carriers supported on the rail. Each carrier includes an on-board motor, at least one wheel forming an interface with the rail, and an on-board power source selectively powering the on-board motor to drive the ACC along the rail. Each of the plurality of carriers operates to power the on-board motor from the on-board power source under the direction of instructions programmed to a local controller. Each of the local controllers is programmed with an algorithm for independent wear monitoring of the at least one wheel and further programmed to take at least one responsive action based on an identification of the at least one wheel being worn.

Abstract: A self-monitoring flexible drive system including a drive motor having an output member coupled to a flexible drive means configured to move one or more work pieces by loading the flexible drive means in tension. The drive motor is supported by a mount that fixes a position of the drive motor while allowing free rotation. A torque sensor measures torque applied to the flexible drive means by the drive motor. The torque sensor is provided by a torque arm fixedly secured with respect to a housing of the drive motor, and a load measuring support arm supporting a distal portion of the torque arm against a stationary support. A controller receives a variable non-binary output signal from the torque sensor that indicates a value of the measured torque. The controller is programmed to output a signal configured to modify an input drive signal controlling the output of the drive motor.

Abstract: An oven system includes an oven chamber defined by side walls and a top wall. The oven chamber includes a slot formed in the top wall. A conveyor rail extends longitudinally along the slot at a position outside of the oven chamber. A conveyor hanger is coupled to and movable along the conveyor rail to support a material within the oven chamber. A first support bracket and a second support bracket each extend longitudinally along a length of the top wall of the oven chamber. The second support bracket is spaced from the first support bracket to define the slot that extends longitudinally along the top wall of the oven chamber. A closure mechanism is coupled to the first and second support brackets to inhibit heat from releasing out of the oven chamber.

Abstract: In one aspect, the invention provides a coating process system including a continuous conveyor, a first end defining a loading station for loading work pieces to the conveyor, and a second end defining an unloading station for unloading work pieces from the conveyor. A series of workstations is configured to render coated work pieces and arranged at a first level to extend between the first and second ends. A cure oven is arranged at a second level above the first level, the conveyor making a plurality of runs between the first and second ends at different sub-levels within the second level. A first post-oven run of the conveyor extends from an outlet of the cure oven to the unloading station. A second post-oven run of the conveyor extends from the unloading station to the loading station.

Abstract: A conveyor system including a fixed, non-powered rail defining a conveyor path, and a plurality of automated conveyor carriers supported on the rail. Each carrier includes an on-board motor and electrical power source selectively powering the motor to drive the carrier along the rail. Each of the plurality of ACCs operates to power the on-board motor from the on-board electrical power source under the direction of instructions programmed to a local controller on the respective ACC. Wherein each of the local controllers of the respective ACCs is programmed to carry out independent power level management for its own on-board electrical power source and configured to selectively operate an adaptive low power indicator to communicate a low power status based only in part on the power level of the on-board electrical power source and further based on one or more parameters of a current work cycle.

Abstract: A method of operating a conveyor system includes providing a fixed, non-powered rail defining a conveyor path, the rail supporting first and second consecutive automated conveyor carriers (ACC), each of which includes a motor-powered self-driving trolley. First and second loads are suspended from the first and second ACCs. The first and second ACCs are driven independently along the rail by executing instructions from independent on-board controllers of the first and second ACCs, wherein a first spacing between the first and second ACCs is maintained through a first section of the rail. The first ACC is accelerated away from the second ACC to increase the spacing from the first spacing to a second spacing for navigating a second section of the rail, the second section being a curved section.

Abstract: A conveyorized industrial system includes at least one work station including a heated oven chamber. A fixed, non-powered rail defines a conveyor path including an oven zone in which the rail extends through or over the heated oven chamber. An automated conveyor carrier (ACC) is suspended from the rail by a self-driving trolley having an on-board motor for driving the ACC along the rail, and by at least one additional free-rolling trolley. The ACC further comprises an enclosure containing one or both of an inverter and a battery, the enclosure having a wall defining an interior space of the enclosure. A heat protection system is provided in addition to the wall, the heat protection system operating to limit an internal temperature of the enclosure during transport along the oven zone.

Abstract: A method of constructing a conveyor system includes decommissioning an existing conveyor system by removing electrification or a powered chain from a conveyor rail. Carriers of the existing conveyor system are removed from the rail. An automated conveyor carrier (ACC) is installed onto the rail so that a drive wheel of a self-driving trolley of the ACC is put into contact with the rail. A battery is installed on the ACC. Electrical connection is established from the battery to the self-driving trolley.

Abstract: A method of operating a conveyor system includes providing a fixed, non-powered first rail supporting first and second trolleys of a first carrier, at least one of which is self-driving. The first and second trolley are conveyed in line along the first rail with a load bar therebetween. The first carrier defines a length measured along the first rail and a width measured transverse. The first carrier is conveyed to a branch point where a second rail branches from the first rail. The second trolley is conveyed along the second the rail to turn the first carrier so that it is conveyed with the load bar traversing between the first and second rails. The width is substantially less than the length such that the turning of the first carrier reduces an occupancy of the first carrier along the first rail.

Abstract: A conveyor system includes a fixed, non-powered rail defining a conveyor path. An automated conveyor carrier (ACC) is supported by the rail and drivable along the rail by an on-board motor in a self-driving trolley of the ACC, the motor powering a drive wheel. The rail defines a first section and a second section separate from the first section. The conveyor system is adapted to provide a first amount of traction for the ACC on the rail in the first section and a second amount of traction, greater than the first amount of traction, in the second section.

Abstract: An oven system includes an oven chamber defined by side walls and a top wall. The oven chamber includes a slot formed in the top wall. A conveyor rail extends longitudinally along the slot at a position outside of the oven chamber. A conveyor hanger is coupled to and movable along the conveyor rail to support a material within the oven chamber. A first support bracket and a second support bracket each extend longitudinally along a length of the top wall of the oven chamber. The second support bracket is spaced from the first support bracket to define the slot that extends longitudinally along the top wall of the oven chamber. A closure mechanism is coupled to the first and second support brackets to inhibit heat from releasing out of the oven chamber.

Abstract: In one aspect, the invention provides a coating process system including a continuous conveyor, a first end defining a loading station for loading work pieces to the conveyor, and a second end defining an unloading station for unloading work pieces from the conveyor. A series of workstations is configured to render coated work pieces and arranged at a first level to extend between the first and second ends. A cure oven is arranged at a second level above the first level, the conveyor making a plurality of runs between the first and second ends at different sub-levels within the second level. A first post-oven run of the conveyor extends from an outlet of the cure oven to the unloading station. A second post-oven run of the conveyor extends from the unloading station to the loading station.

Abstract: A conveyor system includes a fixed, non-powered rail defining a conveyor path. An automated conveyor carrier (ACC) is supported by the rail and drivable along the rail by an on-board motor in a self-driving trolley of the ACC, the motor powering a drive wheel. The rail defines a first section and a second section separate from the first section. The conveyor system is adapted to provide a first amount of traction for the ACC on the rail in the first section and a second amount of traction, greater than the first amount of traction, in the second section.

Abstract: A method of operating a conveyor system includes providing a fixed, non-powered first rail supporting first and second trolleys of a first carrier, at least one of which is self-driving. The first and second trolley are conveyed in line along the first rail with a load bar therebetween. The first carrier defines a length measured along the first rail and a width measured transverse. The first carrier is conveyed to a branch point where a second rail branches from the first rail. The second trolley is conveyed along the second the rail to turn the first carrier so that it is conveyed with the load bar traversing between the first and second rails. The width is substantially less than the length such that the turning of the first carrier reduces an occupancy of the first carrier along the first rail.

Abstract: A conveyor system including a fixed, non-powered rail defining a conveyor path, and a plurality of automated conveyor carriers supported on the rail. Each carrier includes an on-board motor and electrical power source selectively powering the motor to drive the carrier along the rail. Each of the plurality of ACCs operates to power the on-board motor from the on-board electrical power source under the direction of instructions programmed to a local controller on the respective ACC. Wherein each of the local controllers of the respective ACCs is programmed to carry out independent power level management for its own on-board electrical power source and configured to selectively operate an adaptive low power indicator to communicate a low power status based only in part on the power level of the on-board battery and further based on one or more parameters of a current work cycle.

Abstract: A method of constructing a conveyor system includes decommissioning an existing conveyor system by removing electrification or a powered chain from a conveyor rail. Carriers of the existing conveyor system are removed from the rail. An automated conveyor carrier (ACC) is installed onto the rail so that a drive wheel of a self-driving trolley of the ACC is put into contact with the rail. A battery is installed on the ACC. Electrical connection is established from the battery to the self-driving trolley.

Abstract: A method of operating a conveyor system includes providing a fixed, non-powered rail defining a conveyor path, the rail supporting first and second consecutive automated conveyor carriers (ACC), each of which includes a motor-powered self-driving trolley. First and second loads are suspended from the first and second ACCs. The first and second ACCs are driven independently along the rail by executing instructions from independent on-board controllers of the first and second ACCs, wherein a first spacing between the first and second ACCs is maintained through a first section of the rail. The first ACC is accelerated away from the second ACC to increase the spacing from the first spacing to a second spacing for navigating a second section of the rail, the second section being a curved section.

Abstract: A conveyorized industrial system includes at least one work station including a heated over chamber. A fixed, non-powered rail defines a conveyor path including an oven zone in which the rail extends through or over the heated oven chamber. An automated conveyor carrier (ACC) is suspended from the rail by a self-driving trolley having an on-board motor for driving the ACC along the rail, and by at least one additional free-rolling trolley. The ACC further comprises an enclosure containing one or both of an inverter and a battery, the enclosure having a wall defining an interior space of the enclosure. A heat protection system is provided in addition to the wall, the heat protection system operating to limit an internal temperature of the enclosure during transport along the oven zone.

Abstract: An adjustable transfer mechanism for a power and free conveyor system includes a free track defining a conveyor path. A first power track defines a first drive path for a first drive member of the first power track to drive a trolley. The first power track is positioned to extend along the conveyor path up to a divergence point where the first power track diverges from the conveyor path. A second power track defines a second drive path for a second drive member of the second power track to drive the trolley. The second power track is positioned to extend along the conveyor path from a convergence point downstream of the divergence point so that the second drive member can pick up the trolley dropped off by the first power track. At least one of the divergence and convergence points is adjustable along the conveyor path.