FOOD GRADE SHEET STACKER
An assembly includes a primary conveyor, a secondary conveyor, a shuttle conveyor, and a controller. The primary conveyor and the secondary conveyor are operable to convey sheets of food items to a discharge zone to form two-high stacks of sheets. The shuttle conveyor is positioned to receive the two-high stacks of sheets via the discharge zone and is operable to stack the two-high stacks of sheets one upon another to form a column of sheets. The controller operably communicates with a load sensor of the shuttle conveyor to calculate an inclusion of one additional sheet of food items to cause a final weight of the column of sheets to fall within a predetermined range.
This application claims the benefit of priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application No. 63/759,628, filed on February 18, 2025, and titled “FOOD GRADE SHEET STACKER,” the entire contents of which are hereby incorporated by reference in their entirety for all purposes.
BACKGROUNDHigh speed industrial-scale processing of food items into organized, stacked, and packaged products that are ready for delivery to end users generate efficiencies within the food supply and help to reduce food costs for consumers. Handling food items on an industrial scale presents several challenges that are not necessarily a consideration in other industrial applications. Best practices suggest that food grade processing equipment should be fabricated using food compatible materials and should be configured with regular cleaning and sanitizing in mind. Moreover, as with virtually all industrial processes, the faster the processing equipment can reliably operate, the lower the corresponding costs.
One application of industrial scale food processing involves the stacking of multiple sheets of pre-sliced food product one upon the other. In one example, upstream processing equipment may slice a food product, such as bacon, salami, or the like, and place multiple slices of the food product onto a food-compatible sheet such as parchment paper, coated paper, or the like, in a process known in the art as underleaving. The sheets containing the slices of food product may then be conveyed to further downstream equipment for sorting, stacking, packaging, and other processing.
Due to advances in slicing and underleaving equipment, in some operations the process of sorting and stacking the sheets of sliced food product has become an operational bottleneck that prevents further increasing overall operating speeds. Accordingly, there is a need for efficient, effective, high-speed food-grade equipment that is able to sort and stack sheets of sliced food items.
SUMMARYIn some aspects, a food grade classifying conveyor assembly may be for stacking sheets of food items received at an assembly intake. The food grade classifying conveyor assembly may include a first conveyor, a second conveyor, a stacking conveyor, a sensor, and a controller. The first conveyor may be operable to convey first sheets of food items from the assembly intake to a discharge zone. The second conveyor may define a waiting zone upstream of the discharge zone. The second conveyor may be operable to convey second sheets of food items from the assembly intake to the waiting zone where the second sheets of food items are held until an add-a-sheet condition is met. The stacking conveyor may be positioned downstream of the discharge zone and may be operable to stack the first sheets of food items received via the discharge zone to form a column of sheets. The sensor may be operable to sense a weight of the column of sheets. The controller may operably communicate with the sensor and the second conveyor and may be operable to determine whether the add-a-sheet condition is met. In response to determining that the add-a-sheet condition is met, the controller may operate the second conveyor to move one of the second sheets of food items from the waiting zone to the discharge zone at substantially the same time as, and to stack with, one of the first sheets of food items conveyed via the first conveyor.
The controller may be operable to determine whether the add-a-sheet condition is met by calculating whether the inclusion of the one of the second sheets of food items in the column of sheets will cause a final weight of the column of sheets to fall within a predetermined range. The food grade classifying conveyor assembly may further include a diverter assembly operable to divert the sheets of food items received from the assembly intake to one of the first conveyor and the second conveyor. The food grade classifying conveyor assembly may further include a third conveyor operable to convey third sheets of food items from the assembly intake to the discharge zone. The first conveyor may operate at a baseline average speed. The third conveyor may operate at a third conveyor average speed that differs from the baseline average speed such that individual ones of the third sheets of food items conveyed via the third conveyor arrive at the discharge zone at substantially the same time as, and are stacked with, individual ones of the first sheets of food items conveyed via the first conveyor, thereby forming two-high stacks of sheets. The controller may be operable to independently control the baseline average speed, the third conveyor average speed, and the second conveyor. A shuttle conveyor may receive the two-high stacks of sheets via the discharge zone and may be operable to stack the two-high stacks of sheets one upon another to form the column of sheets. The food grade classifying conveyor assembly may further include a diverter assembly operable to divert sheets of food items received from the assembly intake to one of the first conveyor, the third conveyor, and the second conveyor. The third conveyor may be positioned above the first conveyor, and the second conveyor may be positioned above the third conveyor.
The food grade classifying conveyor may further include a lane switch conveyor positioned upstream of the assembly intake. The lane switch conveyor may include an infeed location, a transition zone, a first discharge path, and a second discharge path. The lane switch conveyor may be operable to divert sheets of food items received at the infeed location between the first discharge path and the second discharge path. The first conveyor and the second conveyor may each include: a first lane that receives sheets of food items from the first discharge path, and a second lane that receives sheets of food items from the second discharge path. The controller may control and coordinate operation of the lane switch conveyor, the first lane, and the second lane.
In other aspects, a food grade classifying conveyor assembly may be for stacking sheets of food items. The food grade classifying conveyor assembly may include a primary conveyor, a secondary conveyor, a tertiary conveyor, a stacking conveyor, and a controller. The primary conveyor may be operable to convey primary sheets of food items to a discharge zone. The secondary conveyor may be operable to convey secondary sheets of food items to the discharge zone such that individual ones of the secondary sheets of food items arrive at the discharge zone at substantially the same time as, and are stacked with, individual ones of the primary sheets of food items, thereby forming two-high stacks of sheets. The tertiary conveyor may define a waiting zone and may be operable to convey tertiary sheets of food items to the waiting zone where the tertiary sheets of food items are held until an add-a-sheet condition is met. The stacking conveyor may be positioned to receive the two-high stacks of sheets via the discharge zone and may be operable to stack the two-high stacks of sheets one upon another to form a column of sheets. The controller may be operable to determine whether the add-a-sheet condition is met. In response to determining that the add-a-sheet condition is met, the controller may operate the tertiary conveyor to move one tertiary sheet of food items from the waiting zone to the discharge zone at substantially the same time as, and to stack with, one of the primary sheets of food items conveyed via the primary conveyor and one of the second sheets of food items conveyed by the secondary conveyor, thereby forming a three-high stack of sheets.
The food grade classifying conveyor assembly may further include a sensor to sense a weight of the column of sheets. The controller may operably communicate with the sensor and the tertiary conveyor. The controller may determine whether the add-a-sheet condition is met by calculating whether inclusion of one tertiary sheet of food items in the column of sheets will cause a final weight of the column of sheets to fall within a predetermined range. The primary conveyor may convey the primary sheets of food items to the discharge zone at a baseline average speed. The secondary conveyor conveys the secondary sheets of food items to the discharge zone at a secondary average speed that differs from the baseline average speed. The food grade classifying conveyor assembly may further include a second sensor positioned upstream of the primary conveyor to identify a leading edge of each sheet of food items received by the food grade classifying conveyor assembly. The controller may regulate the secondary conveyor average speed in response to a location of the leading edge of each sheet of food items received by the food grade classifying conveyor assembly. The secondary conveyor may be positioned above the primary conveyor, and the tertiary conveyor may be positioned above the secondary conveyor. The food grade classifying conveyor assembly may further include a diverter assembly including a primary diverter and a secondary diverter. The primary diverter may be operable to divert sheets of food items to the tertiary conveyor, and the secondary diverter may be operable to divert sheets of food items to either the primary conveyor or the secondary conveyor. The food grade classifying conveyor assembly may further include a reject conveyor and a reject diverter. The reject conveyor may have a receiving end and a discharge end. The rejected diverter may be positioned upstream of the diverter assembly and may be operable, in response to a reject signal, to divert reject sheets of food items to the reject conveyor.
In other aspects, a food grade sheet stacker may be for stacking sheets of food items. The food grade sheet stacker may include a lane switch conveyor, a first lane of classifying conveyors, and a second lane of classifying conveyors. The lane switch conveyor may include an infeed location, a transition zone, a first discharge path, and a second discharge path. The lane switch conveyor may be operable to divert sheets of food items receive at the infeed location between the first discharge path and the second discharge path. The first lane of classifying conveyors may be positioned to receive sheets of food items via the first discharge path. The second lane of classifying conveyors may be positioned to receive sheets of food items via the second discharge path. Each of the first lane of classifying conveyors and the second lane of classifying conveyors may include a discharge zone, a primary conveyor, a secondary conveyor, a tertiary conveyor, and a diverter assembly. The primary conveyor may be operable to convey sheets of food items to the discharge zone at a baseline average speed. The secondary conveyor may be operable to convey sheets of food items to the discharge zone at a secondary conveyor average speed that differs from the baseline average speed such that individual ones of the sheets of food items conveyed via the secondary conveyor arrive at the discharge zone at substantially the same time as, and are stacked with, individual ones of the sheets of food items conveyed via the primary conveyor, thereby forming two-high stacks of sheets. The tertiary conveyor may be operable to convey sheets of food items to a waiting zone. The diverter assembly may be operable to divert sheets of food items to one of the primary conveyor, the secondary conveyor, and the tertiary conveyor. Each tertiary conveyor may be operable in response to a signal to add one of the sheets of food items from the respective waiting zone of the tertiary conveyor to a two-high stack of sheets formed by the corresponding secondary conveyor, thereby forming a three-high stack of sheets.
The food grade sheet stacker may include a pair of stacking conveyors. Each stacking conveyor may be positioned to receive the two-high stacks of sheets and the three-high stacks of sheets from one of the first lane of classifying conveyors and the second lane of classifying conveyors. Each stacking conveyor may be operable to stack the received two-high stacks of sheets and three-high stacks of sheets one upon the other to form a column of sheets. Each of the first lane of classifying conveyors and the second lane of classifying conveyors may include a sensor that is operable to sense a weight of the column of sheets formed by a respective one of the stacking conveyors. When one of the sensors senses that the weight of the column of sheets formed by the corresponding stacking conveyor meets a predetermined criteria, a signal may be sent to the corresponding tertiary conveyor. The food grade sheet stacker may further include a first sensor, a second sensor, and a third sensor. The first sensor may be positioned upstream of the infeed location and may be operable to identify a leading edge of each sheet of food items received by the food grade sheet stacker. The second sensor may be positioned upstream of the diverter assembly of the first lane of classifying conveyors and may be operable to identify a leading edge of each sheet of food items received from the first discharge path. The third sensor may be positioned upstream of the diverter assembly of the second lane of classifying conveyors and may be operable to identify a leading edge of each sheet of food items received from the second discharge path. The food grade sheet stacker may further include a controller operable to independently control, for each of the first lane of classifying conveyors and the second lane of classifying conveyors, the baseline average speed, the secondary conveyor average speed, and the tertiary conveyor. For each of the first lane classifying and the second lane of classifying conveyors, the secondary conveyor may be positioned above the primary conveyor, and the tertiary conveyor may be positioned above the secondary conveyor. Each diverter assembly may include a primary diverter and a secondary diverter. The primary diverter may be operable to divert sheets of food items to the tertiary conveyor. The secondary diverter may be operable to divert sheets of food items received via the primary diverter to either the primary conveyor or the secondary conveyor.
In other aspects, a shuttle conveyor may be for stacking items one upon another. The shuttle conveyor may include a frame, a roller assembly, a carriage, and a conveyor web. The frame may have a longitudinal extend associated with a conveying direction. The roller assembly may be mounted in a cantilevered fashion from the frame. The roller assembly may include a subframe and a plurality of rollers. The subframe may be laterally spaced from the frame. The plurality of rollers may be rotatably supported by and extend between the frame and the subframe. The plurality of rollers may include a tensioner roller that is movable between an engaged position and a disengaged position. The carriage may be reciprocatingly movable relative to the frame. The carriage may have a first lateral side mounted to the frame and a second lateral side supported by the subframe. The conveyor web may define at least one closed loop of material and extend along a conveying path that engages the carriage and the plurality of rollers. When the tensioner roller is moved to the disengaged position, the conveyor web may be movable from the frame and the subframe by passing the conveyor web around the subframe.
The conveyor web may be removable from the frame and the subframe without removing any of the plurality of rollers. The plurality of rollers further include an infeed roller. The carriage may include a discharge roller on a distal end thereof and an idler roller on a proximal end thereof. During reciprocating movement of the carriage, the discharge roller and the idler roller may move toward and away from the infeed roller. The conveying path may extend from the infeed roller, around the discharge roller, around the idler roller, and around the tensioner roller. When the tensioner roller is in the disengaged position, the idler roller may be removable from the carriage. The first lateral side of the carriage may include a first slotted receptacle that receives a first end of the idler roller. The second lateral side of the carriage may include a second slotted receptacle that receives a second end of the idler roller. When the tensioner roller is moved to the engaged position to apply tension to the conveyor web, the first and second ends of the idler roller may be urged, respectively, into engagement with the fist and second slotted receptacles. The conveying path may include a serpentine path segment that extends around the discharge roller in a first direction, around the idler roller in a second direction, and around the tensioner roller in the first direction.
The first lateral side of the carriage may include a first movable support assembly adjacent a proximal end of the carriage and a second movable support assembly adjacent a distal end of the carriage. The first and second movable support assemblies may engage the frame to movably support the carriage. The second lateral side of the carriage may include a third movable support assembly adjacent the proximal end of the carriage and engaging the subframe to movably support the carriage. A distal end of the second lateral side of the carriage may be supported in a cantilevered manner by the first, second and third movable support assemblies. The frame may include a guide member defining a longitudinal axis that is parallel to the conveying direction. The first movable support assembly and the second movable support assembly may limit movement of the carriage along and about each ordinal axis except for the longitudinal axis. The third movable support assembly may engage the subframe to limit rotation of the carriage about the longitudinal axis. During operation, the conveyor web may define a conveying surface having a length. The length of the conveying surface may change during reciprocating movement of the carriage relative to the frame.
In other aspects, a shuttle conveyor may be for stacking items one upon another. The shuttle conveyor may include a frame, a roller assembly, and a carriage. The frame may include a guide member that defines a longitudinal axis. The roller assembly may be mounted to the frame. The roller assembly may include a plurality of rollers and a subframe laterally spaced from the frame. The carriage may be reciprocatingly movable relative to the frame. The carriage may have a first lateral side mounted to the frame and a second lateral side supported by the subframe. The first lateral side may include a first movable support assembly adjacent a proximal end of the carriage and a second movable support assembly adjacent a distal end of the carriage. The first and second movable support assemblies may engage the frame to movably support the carriage. The second lateral side may include a third movable support assembly adjacent the proximal end of the carriage and engaging the subframe to movably support the carriage. A distal end of the second lateral side of the carriage may be supported in a cantilevered manner by the first, second, and third movable support assemblies.
The roller assembly may be mounted in a cantilevered fashion from the frame. Each of the plurality of rollers may be rotatably supported by and extend between the frame and the subframe. The plurality of rollers may include a tensioner roller that is movable between an engaged position and a disengaged position. The shuttle conveyor may further include a conveyor web defining at least one closed loop of material and extending along a conveying path that engages the carriage and the plurality of rollers. When the tensioner roller is moved to the disengaged position, the conveyor web may be removable from the frame and the subframe by passing the conveyor web around the subframe.
The first movable support assembly and the second movable support assembly may be movable relative to the frame along the longitudinal axis and limit movement of the carriage along and about each ordinal axis except for the longitudinal axis. The third movable support assembly may engage the subframe to limit rotation of the carriage about the longitudinal axis. The guide member may be a guide tube. The first movable support assembly may include a first roller. The second movable support assembly may include a second roller. The first roller and the second roller may engage the guide tube. The subframe may include a guide rail. The third movable support assembly may include a third roller that engages the guide rail.
In other aspects, a food grade classifying conveyor assembly may be for stacking sheets of food items received at an assembly intake. The assembly may include a primary conveyor, a secondary conveyor, a tertiary conveyor, a diverter assembly, a collecting conveyor, and a controller. The primary conveyor may be operable to convey sheets from the intake to a discharge zone at a baseline average speed. The secondary conveyor may be operable to convey sheets from the intake to the discharge zone at a secondary conveyor average speed that differs from the baseline average speed such that sheets conveyed via the secondary conveyor arrive at the discharge zone at substantially the same time as, and are stacked with, sheets conveyed via the primary conveyor, thereby forming two-high stacks of sheets. The tertiary conveyor may define a waiting zone upstream of the discharge zone, and the tertiary conveyor may be operable to convey sheets from the intake to the waiting zone where sheets are held stationary until an add-a-sheet condition is met. The diverter assembly may be operable to divert sheets received from the intake to one of the primary conveyor, the secondary conveyor, and the tertiary conveyor. The collecting conveyor may be positioned to receive the stacks of sheets via the discharge zone and may be operable to stack the stacks of sheets one upon the other to form a column of sheets. The collecting conveyor may include a load sensor operable to sense a weight of the column of sheets. The controller may operably communicate with the load sensor and the tertiary conveyor and may be operable to calculate that one additional sheet is needed for a final weight of the column of sheets to fall within a predetermined range, and that the add-a-sheet condition is therefore met. In response to calculating that the add-a-sheet condition is met, the controller may operate the tertiary conveyor to move one sheet from the waiting zone to the discharge zone at substantially the same time as, and to stack with, the sheets conveyed via the primary conveyor and the secondary conveyor, thereby forming a three-high stack of sheets that is added to the column of sheets by the collecting conveyor.
The conveyor assembly may further include a reject conveyor and a reject diverter. The reject conveyor may have a receiving end and a discharge end. The reject diverter may be positioned upstream of the diverter assembly and may be operable, in response to a reject signal, to divert reject sheets to the reject conveyor. The conveyor assembly may further include a sensor positioned upstream of the diverter and operable to identify a leading edge of each sheet received by the conveyor assembly. The controller may regulate the secondary conveyor average speed in response to a location of the leading edge of each sheet received by the conveyor assembly. The controller may be operable to independently control the baseline average speed, the secondary conveyor average speed, and the tertiary conveyor. The secondary conveyor may be positioned above the primary conveyor, and the tertiary conveyor may be positioned above the secondary conveyor. The diverter assembly may include a primary diverter and a secondary diverter. The primary diverter may be operable to divert sheets to the tertiary conveyor, and the secondary diverter may be operable to divert sheets to either the primary conveyor or the secondary conveyor.
The conveyor assembly may further include a lane switch conveyor positioned upstream of the assembly intake. The lane switch conveyor may include an infeed location, a transition zone, a first discharge path, and a second discharge path. The lane switch conveyor may be operable to divert sheets received at the infeed location between the first discharge path and the second discharge path. The assembly may include a first lane that receives sheets from the first discharge path and a second lane that receives sheets from the second discharge path. Each lane may include a respective primary conveyor, secondary conveyor, tertiary conveyor, diverter assembly, and collecting conveyor. The controller may control and coordinate operation of the lane switch conveyor, the first lane, and the second lane.
In other aspects, a food grade sheet stacker may be for stacking sheets of food items. The stacker may include a lane switch conveyor, a first lane of classifying conveyors, and a second lane of classifying conveyors. The lane switch conveyor may include an infeed location, a transition zone, a first discharge path, and a second discharge path. The lane switch conveyor may be operable to divert sheets received at the infeed location between the first discharge path and the second discharge path. The first lane of classifying conveyors may be positioned to receive sheets via the first discharge path. The second lane of classifying conveyors may be positioned to receive sheets via the second discharge path. Each of the first lane of classifying conveyors and the second lane of classifying conveyors may include a discharge zone, a primary conveyor, a secondary conveyor, a tertiary conveyor, and a diverter assembly. The primary conveyor may be operable to convey sheets to the discharge zone at a baseline average speed. The secondary conveyor may be operable to convey sheets to the discharge zone at a secondary conveyor average speed that differs from the baseline average speed such that sheets conveyed via the secondary conveyor arrive at the discharge zone at substantially the same time as, and are stacked with, sheets conveyed via the primary conveyor, thereby forming two-high stacks of sheets. The tertiary conveyor may be operable to convey sheets to a waiting zone where sheets are held stationary. The diverter assembly may be operable to divert sheets to one of the primary conveyor, the secondary conveyor, and the tertiary conveyor. Each tertiary conveyor may be operable in response to a signal calling for delivery of a three-high stack of sheets to add one of the sheets from the respective tertiary conveyor waiting zone to the two-high stack of sheets formed by the corresponding secondary conveyor, thereby forming a three-high stack of sheets.
The stacker may further include a pair of collecting conveyors. Each collecting conveyor may be positioned to receive stacks of sheets from one of the first lane of classifying conveyors and the second lane of classifying conveyors. Each collecting conveyor may be operable to stack the received stacks of sheets one upon the other to form a column of sheets. Each collecting conveyor may include a load sensor operable to sense a weight of the column of sheets. The signal calling for delivery of the three-high stack of sheets may be sent in response to the load sensor sensing that the weight of the column of sheets meets a predetermined criteria. The stacker may further include a reject conveyor and a reject diverter. The reject diverter may be operable in response to a reject signal to divert reject sheets to the reject conveyor. The stacker may further include a first sensor, a second sensor, and a third sensor. The first sensor may be positioned upstream of the infeed location and operable to identify a leading edge of each sheet received by the stacker. The second sensor may be positioned upstream of the diverter assembly and operable to identify a leading edge of each sheet received from the first discharge path. The third sensor may be positioned upstream of the diverter assembly and operable to identify a leading edge of each sheet received from the second discharge path. The stacker may further include a controller operable to independently control, for each of the first lane of classifying conveyors and the second lane of classifying conveyors, the baseline average speed, the secondary conveyor average speed, and the tertiary conveyor. For each of the first lane of classifying conveyors and the second lane of classifying conveyors, the secondary conveyor may be positioned above the primary conveyor, and the tertiary conveyor may be positioned above the secondary conveyor. Each diverter assembly may include a primary diverter and a secondary diverter. The primary diverter may be operable to divert sheets to the tertiary conveyor, and the secondary diverter may be operable to divert sheets received via the primary diverter to either the primary conveyor or the secondary conveyor.
In other aspects, a lane switch conveyor may include a plurality of laterally extending conveyor rails, a plurality of carriage members, a shuttle assembly, and a plurality of cleaning nozzles. The plurality of laterally extending conveyor rails may be movable along a conveying path. The conveying path may have an upper segment, a lower segment, and end segments joining the upper segment and the lower segment. Each conveyor rail may have a substantially C-shaped cross section defining an open section of the conveyor rail and a closed section of the conveyor rail. Each conveyor rail may be mounted such that when the conveyor rail is positioned along the upper segment, the open section faces toward the lower segment, and when the conveyor rail is positioned along the lower segment, the open section faces toward the upper segment. Each carriage member may be slidably mounted on a respective one of the plurality of conveyor rails for movement therewith along the conveying path, and for movement relative thereto in a lateral direction. Each carriage member may include a mounting section and a guiding section. The mounting section may have a cross section that extends around and at least partially encloses the open section of the C-shaped cross section of the conveyor rail to which the carriage member is mounted. The guiding section may extend over the closed section of the conveyor rail to which the carriage member is mounted without covering the open section of the conveyor rail to which the carriage member is mounted. The shuttle assembly may be operable to engage each of the carriage members and to move the carriage members laterally relative to the conveyor rails as the conveyor rails move along the upper segment of the conveying path. The plurality of cleaning nozzles may be positioned between the upper segment and the lower segment of the conveying path.
At least some of the plurality of cleaning nozzles may be oriented to spray cleaning fluid upwardly into the open sections of the conveyor rails. The plurality of cleaning nozzles may be a first plurality of cleaning nozzles, and the conveyor assembly may further include a second plurality of cleaning nozzles positioned below the lower segment of the conveying path. At least some of the second plurality of cleaning nozzles may be oriented to spray cleaning fluid upwardly onto the closed sections of the conveyor rail. The mounting section may include less than 50% of the lateral length of each carriage member. Each carriage member may include a guide projection that extends downwardly when the carriage member moves along the upper segment. The shuttle assembly may engage the guide projection to move the carriage member laterally along the conveyor rail as the carriage member and the conveyor rail move along the upper segment of the conveying path. The shuttle assembly may include an intake guide and a diverter. The intake guide may have an upstream end and a downstream end. The intake guide may include a first guide wall and a second guide wall that converge toward one another as they extend from the upstream end toward the downstream end. The diverter may have a diverting tip, a pivot end, and first and second diverter walls. The diverting tip may be positioned adjacent to the downstream end of the intake guide. The pivot end may be positioned downstream of the diverting tip. The first and second diverter walls may extend between the diverting tip and the pivot end and may diverge away from one another as they extend from the diverting tip to the pivot end. The diverter may be pivotable about the pivot end to move the diverting tip between a first position adjacent to the first guide wall for diverting carriage members toward a first discharge path and a second position adjacent the second guide wall for diverting carriage members toward a second discharge path.
In other aspects, a shuttle conveyor may be for stacking items one upon the other. The shuttle conveyor may include a frame, a roller assembly, a carriage, and a conveyor web. The frame may have a longitudinal extent associated with a conveying direction. The roller assembly may be mounted in a cantilever fashion from the frame. The roller assembly may include a subframe laterally spaced from the frame, an infeed roller, and a tensioner roller. Each of the infeed roller and the tensioner roller may have a first end rotatably supported by the frame and a second end rotatably coupled to the subframe. The carriage may be reciprocatingly movable relative to the frame. The carriage may have a first lateral side mounted to the frame and a second lateral side supported by the subframe. The carriage may include a discharge roller on a distal end thereof, and an idler roller on a proximal end thereof such that, during reciprocating movement of the carriage, the discharge roller and the idler roller move toward and away from the infeed roller. The conveyor web may define at least one closed loop of material and extend along a conveying path that extends from the infeed roller, around the discharge roller, around the idler roller, and around the tensioner roller. The tensioner roller may be movable relative to the main frame and the subframe between an engaged position that applies tension to the conveyor web such that the idler roller is secured to the carriage by way of the tension applied to the conveyor web, and a disengaged position that releases tension from the conveyor web such that the idler roller is removable from the carriage.
When the idler roller is removed from the carriage, the conveyor web may be removable from the subframe. The conveyor web may be removable from the subframe by passing the conveyor web around the subframe. The conveyor web may be removable from the subframe by passing the conveyor web around the subframe without removing the infeed roller or the tensioner roller. The first lateral side of the carriage may include a first slotted receptacle that receives a first end of the idler roller. The second lateral side of the carriage may include a second slotted receptacle that receives a second end of the idler roller. When the tensioner roller is moved to the engaged position to apply tension to the conveyor web, the first and second ends of the idler roller may be urged, respectively, into engagement with the first and second slotted receptacles. When the tensioner roller is moved to the disengaged position to release tension from the conveyor web, the first and second ends of the idler roller may be removable, respectively, from the first and second slotted receptacles. The first lateral side of the carriage may include a first movable support assembly adjacent the proximal end of the carriage and a second movable support assembly adjacent the distal end of the carriage. The first and second movable support assemblies may engage the frame to movably support the carriage. The second lateral side of the carriage may include a third movable support assembly adjacent the proximal end of the carriage and engage the subframe to movably support the carriage. A distal end of the second lateral side of the carriage may be supported in a cantilevered manner by the first, second, and third movable support assemblies. During operation, the conveyor web may define a conveying surface having a length that extends between the infeed roller and the discharge roller. The length of the conveying surface may change during reciprocating movement of the carriage relative to the frame. The roller assembly may further include a drive roller spaced from the infeed roller and the tensioner roller. The driver roller may have one end supported by the frame and a second end coupled to the subframe. The drive roller may provide driving rotatable force to the conveyor web during operation of the shuttle conveyor. The conveyor path may include a serpentine path segment that extends around the discharge roller in a first direction, around the idler roller in a second direction, and around the tensioner roller in the first direction.
Before any exemplary configurations of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the accompanying drawings. The disclosure is capable of other configurations and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.
In the illustrated configuration, sheets of food product received by the system 10 from upstream processing equipment arrive first at a reject diverter 34 that is operable to divert sheets to either a reject conveyor 38 or to a lane switch conveyor 46, 48. As described further herein, the lane switch conveyor 46 is an example implementation illustrated, at least partially, in
The reject diverter 34 operates in response to reject signals provided by upstream processing equipment to divert sheets of food product that do not meet certain predefined characteristics. For example, upstream equipment may detect or determine that a particular sheet of food product is overweight, underweight, contains an incorrect number of food product items, or fails to meet some other criteria that results in a particular sheet of food product being deemed unsuitable for further processing. When this occurs, the upstream equipment may send a reject signal to the system 10, including, potentially but not necessarily, to the controller 26, to cause the reject diverter 34 to move to the broken-line position illustrated in
For sheets that meet upstream processing criteria, the reject diverter 34 remains in the solid-line position shown in
In
The diverter assembly 50 is positioned upstream of a series of classifying conveyors 54, 58, 62 that cooperate with one another to form stacks of sheets of food items. While the illustrated exemplary configuration includes three classifying conveyors 54, 58, 62, the system 10 may include more or fewer classifying conveyors 54, 58, 62 as may be appropriate for a particular application. More specifically, the exemplary series of classifying conveyors includes a primary conveyor 54 that, in the illustrated configuration, is at a bottom-most location, a secondary conveyor 58 that, in the illustrated configuration, is positioned above the primary conveyor 54, and a tertiary conveyor 62 that, in the illustrated configuration, is positioned above the secondary conveyor. The diverter assembly 50 includes a primary diverter 66 that is upstream of the primary conveyor 54, the secondary conveyor 58, and the tertiary conveyor 62, and that is configured to divert sheets of food items either to the tertiary conveyor 62 (broken line configuration of the primary diverter 66 in
As discussed in additional detail further below, operation of the diverter assembly 50, the primary conveyor 54, the secondary conveyor 58, and the tertiary conveyor 62 are coordinated with one another to stack sheets of food items one upon the other to form stacks of sheets of food items. To this end, a discharge zone 74 is located at the downstream end of each of the primary conveyor 54, the secondary conveyor 58, and the tertiary conveyor 62. At the discharge zone 74, a sheet conveyed by the secondary conveyor 58 may be stacked with (for example placed upon) a sheet conveyed by the primary conveyor 54 to form a two-high stack of sheets. In addition, if a three-high stack of sheets is desired, a sheet conveyed by the tertiary conveyor 62 may be stacked with (for example placed upon) a sheet conveyed by the secondary conveyor 58, and those sheets may then be stacked with (for example placed upon) a sheet conveyed by the primary conveyor 54, thereby forming a three-high stack of sheets. It should be appreciated that systems 10 having more or fewer conveyors 54, 58, 62 and more or fewer diverters 66, 70 may be arranged and configured, depending on the application, to convey a single sheet at a time through the discharge zone 74, to form two-high or three-high stacks of sheets as discussed above, or to form stacks of sheets containing four or more individual sheets.
A stacking conveyor in the form of a shuttle conveyor 78 is positioned downstream of the conveyors 54, 58, 62, and is configured to receive stacks of sheets therefrom. The shuttle conveyor 78 includes a reciprocating carriage (represented with broken lines in
The collecting conveyor 82 defines a support surface 86 that may be raised and lowered in the direction of arrow B in
Although not shown in the schematic representation of
Having provided a general overview of system operation with respect to the schematic of
Referring also to
Referring also to
To facilitate positioning of the sheets 90 to the first discharge path 106 or the second discharge path 108, the lane switch conveyor 46 includes a plurality of laterally extending conveyor rails 110 that are movable along a conveying path 114 (see
The lane switch conveyor 46 also includes a plurality of carriage members 138 that are positioned and configured to support and guide the sheets 90 as the sheets 90 move through the lane switch conveyor. Each carriage member 138 is slidably mounted on a respective one of the plurality of conveyor rails 110 for movement therewith along the conveying path 114, as well as for movement relative thereto in a lateral direction (e.g. left to right in
In the illustrated example of
Referring also to
During operation of the shuttle assembly 154 the diverter 178 is pivotable about the pivot end 186 between a first position that diverts carriage members 138 toward the first discharge path 106 and a second position (shown in
More specifically, as a carriage member 138 moves along the conveying path 114 from the infeed location 102 toward the transition zone 104, the guide projection 150 enters the intake guide 158 and the first and second guide walls 170, 174 align the guide projection 150 with the pivot end 186 of the diverter 178. If the diverter 178 is in the first position, as the guide projection 150 travels through the transition zone 104 it engages the first diverter wall 190 and is guided thereby to the left in
It should be appreciated that the guided movement of the guide projection 150 described above moves the corresponding carriage member 138, and lateral movement of adjacent carriage members 138 in turn moves sheets 90 conveyed by such carriage members 138 toward the first or second discharge path 106, 108. Pivotal movement of the diverter 178 between the first and second positions may be regulated by the controller 26 based at least in part on information received from the first sensor 98 regarding the position of sheets 90 being fed to the lane switch conveyor 46 from upstream equipment. Furthermore, while the lane switch conveyor 46 illustrated and described herein is configured to maneuver sheets toward first and second discharge paths 106, 108, the lane switch conveyor 46 could be configured to maneuver sheets to three or more discharge paths by, for example, reconfiguring, replacing, or supplementing one or more of the intake guide 158, diverter 178, and shuttle guide 198.
Referring also to
Referring also to
With reference to
In
In the illustrated example construction, each tertiary conveyor 62 includes an upstream segment 246 and a downstream segment 250. Each upstream segment 246 is positioned to receive sheets 90 directly from a corresponding primary diverter 66, and each downstream segment 250 is positioned to receive sheets directly from a corresponding upstream segment 246. Each downstream segment 250 defines a waiting zone 254 where sheets 90 may be held until an add-a-sheet condition (discussed below) is met. To facilitate the ability of the downstream segments 250 to hold sheets, each upstream segment 246 may define a deceleration zone 258 in which a speed of the sheets 90 as received from the primary diverter 66 is reduced before delivering the sheet to the downstream segment 250 which then slows the sheet 90 to a complete stop. Thus, by controlling the speeds of the upstream segments 246 and downstream segments 250 independently of each other the forces associated with deceleration of the sheets 90 between the primary diverter 66 and the waiting zone 254 may be reduced. Sheets 90 in the waiting zone 254 may be held substantially stationary, may be slowed to a very low speed, or may be shuttled back and forth until the add-a-sheet condition is met.
In a similar manner, each secondary conveyor 58 of the illustrated exemplary construction includes an upstream segment 262 and a downstream segment 266 that may be operated independently to regulate acceleration or deceleration of sheets 90 being conveyed along the secondary conveyor 58, and each primary conveyor 54 of the illustrated exemplary construction includes an upstream segment 270 and a downstream segment 274 that may be operated independently to regulate acceleration or deceleration of sheets 90 being conveyed along the primary conveyor 54. While each of the primary conveyor 54, secondary conveyor 58, and tertiary conveyor 62 are illustrated and described has having two segments, more or fewer segments may also be used depending upon the acceleration and deceleration needs of a particular application.
Referring also to
Each discharge zone 74 has a shuttle conveyor 78 associated therewith and positioned to receive two-high or three-high stacks of sheets 90 via the corresponding discharge zone 74 of the first lane 230 or second lane 234 of conveyors 54, 58, 62. The shuttle conveyors 78 are operable to stack the two-high or three-high stacks of sheets one upon the other to form a column of sheets 282. Each shuttle conveyor 78 includes a collecting conveyor 82 upon which the columns of sheets 282 are formed. After the column of sheets 282 has reached the desired number of sheets or weight, the collecting conveyor 82 may operate to move the column of sheets 282 to a corresponding takeaway conveyor 286 configured to transfer the column of sheets 282 to further downstream processing equipment.
Referring also to
The shuttle conveyor 78 includes a frame 290 extending along one side of the shuttle conveyor 78 and having a longitudinal extent that is associated with a conveying direction depicted by the arrow C in
Each of the infeed roller 300, tensioner roller 302, and drive roller 306 have a first end rotatably supported by the frame 290, and a second end rotatably coupled to the subframe 298. The roller assembly 294 also includes support rods 310 that extend laterally between the frame 290 and the subframe 298 and that support the subframe 298 in a cantilever manner from the frame 290. Accordingly, in the illustrated exemplary configuration, the roller assembly 294 is supported exclusively by the frame 290, with all gravity and operating loads applied to the roller assembly passing through the frame 290
The shuttle conveyor 78 also includes a carriage 314 that is reciprocatingly movable relative to the frame 290 in a longitudinal direction. The carriage 314 is movable between an extended position as shown in
The carriage 314 has a first lateral side 318 that is mounted to a longitudinally extending guide tube 322 of the frame 290, and a second lateral side 326 that is supported by a guide rail 330 mounted to the subframe 298. The first lateral side 318 of the carriage 314 includes a first movable support assembly adjacent a proximal end 332 of the carriage 314 in the form of a first pair of concave rollers 334 that engage the outer cylindrical surface of the guide tube 322. The first lateral side 318 of the carriage 314 also includes a second movable support assembly adjacent a distal end 336 of the carriage 314 in the form of a second pair of concave rollers 338 that engage the outer cylindrical surface of the guide tube 322.
The first and second pairs of concave rollers 334, 338 engage the guide tube 322 of the frame 290 support the carriage 314 for substantially linear reciprocating movement along the longitudinal axis of the guide tube 322. In this regard, the concave rollers 334, 338 limit movement of the carriage 314 along and about each ordinal axis except for the longitudinal axis of the guide tube 322. Thus, to limit rotation of the carriage 314 about the axis of the guide tube 322, the second lateral side 326 includes a third movable support assembly in the form of a roller 342 that rolls along the guide rail 330 of the subframe 298 during reciprocating movement of the carriage 314. As best shown in
To move the carriage 314, the shuttle conveyor 78 includes a servo motor 346 mounted to the frame 290 and controlled by the controller 26. A cogged belt 350 extends from the motor 346 to an idler pully 354 positioned below the first pair of concave rollers 334 (see
The distal end 336 of the carriage 314 includes a set of discharge rollers 358 (
The illustrated conveyor web 316 defines a single closed loop of material, it should be appreciated however that the conveyor web 316 of the shuttle conveyor 78 may be formed of multiple closed loops of material, similar to the illustrated configuration of, for example, the tertiary conveyor 62. Regardless of the specific configuration, the conveyor web 316 extends along a conveying path that extends from the infeed roller 300, around the discharge rollers 358 in a first direction (e.g. counterclockwise as viewed in
Referring to
When the tensioner roller 302 is in the engaged position with tension applied to the conveyor web 316, the idler roller 362 is secured to the carriage 314 by way of the conveyor web 316 tension, which urges the ends of the idler roller 362 into engagement with the slotted receptacles 366. When the tensioner roller 302 is in the disengaged position and tension is released from the conveyor web 316, the idler roller is removable from the carriage because the ends of the idler roller 362 can be removed from the slotted receptacles 366. When the idler roller 362 is removed from the carriage 314, the conveyor web 316 becomes removable from the roller assembly 294, the carriage 314, and the subframe 298, thereby allowing the conveyor web 316 and the various components of the shuttle conveyor 78 to be more readily cleaned and sanitized. With the idler roller 362 removed, removing the conveyor web 316 from the subframe 298 involves passing the conveyor web 316 around the outside perimeter of the subframe 298, and as such does not require removing the infeed roller 300, the tensioner roller 302, or the drive roller 306, all of which can remain coupled to the frame 290 and supported therefrom in a cantilever manner.
Referring also to
To enhance the efficiency of an industrial food processing operation, it is desirable that finished columns of sheets 282 be as close to a minimum completed target weight as possible without being below the target weight. However, because food items may have inconsistent shapes, thicknesses, densities, or other properties that cause the weight of individual food items to vary from one to the next, merely counting the number of food items added to the column of sheets 282 may not result in final weights that meet the desired target weights.
To achieve more efficient processing, each collecting conveyor 82 includes a load cell (not shown) that is operable to sense a weight of the column of sheets 282 and to communicate such weight to the controller 26. As the column of sheets 282 is being formed, the controller 26 monitors the rate at which the weight increases as stacks of sheets 90 are added to the column of sheets 282. By monitoring the rate at which the weight of the column of sheets 282 increases, the controller is able to calculate, on a continuous basis, the average weight of a single sheet 90 of food product. Using this average, the controller can then determine an optimum predetermined range for the finished weight of the column of sheets 282 that is equal to the target weight plus the average weight of one sheet 90.
As the column of sheets 282 is formed, the controller 26 updates calculations based on information provided by the load cell and calculates whether one additional sheet 90 will be required for the final weight of the column of sheets 282 to fall within the predetermined range. Stated another way, the controller 26 determines whether the number of sheets 90 required to fall within the predetermined range is an even number of sheets 90 or an odd number of sheets 90. If an even number of sheets 90 is required, then during the formation of the column of sheets 282 in question, the controller 26 will not signal for operation of the corresponding tertiary conveyor 62 during formation of that column of sheets 282 so that only 2-high stacks of sheets are delivered to the respective discharge zone 74. However, if an odd number of sheets 90 is required, then during the formation of the column of sheets 282 in question, the controller 26 will determine that the add-a-sheet condition has been met and operate the tertiary conveyor 62 to deliver a sheet 90 from the waiting zone 254 into the discharge zone 74 at substantially the same time as, and to stack with, the sheets 90 conveyed into the discharge zone 74 via the primary conveyor 54 and the secondary conveyor 58, thereby forming a three-high stack of sheets that is added to the column of sheets 282 by the shuttle conveyor 78. The three-high stack of sheets 90 may be the last stack of sheets 90 added to the column of sheets 282, however if sufficient data is available it may be feasible to add the three-high stack of sheets 90 to the column of sheets 282 before the column of sheets 282 is completed. It should also be appreciated that, although it may reduce the processing rate of the system 10, rather than forming a three-high stack of sheets, if an odd number of sheets is called for to complete a column of sheets 282, the controller 26 may alternatively operate the conveyors 54, 58, 62 so that a single sheet 90 is delivered to the discharge zone74 and added to the column of sheets 282.
To enhance the efficiency and effectiveness of the above-described system 10, the controller 26 controls and coordinates operation of the various conveyors and diverters to form two-high stacks of sheets 90 and, as needed, three-high stacks of sheets 90 that are then delivered to the shuttle conveyors 78 for placement onto the collecting conveyors 82 to form columns of sheets 282 that fall within the predetermined range of weights. In this regard the controller sends operating signals to the various components of the system 10, while also receiving sensor signals, speed information, and position information from the first, second, and third sensors 98, 238, 242, and from the motors that operate the various conveyors and diverters. In some configurations, some or all of the motors used in the system may be servo motors that provide speed and position feedback signals to the controller 26. In other configurations, supplemental speed or position sensors may also or alternatively be used to provide the controller with speed and position information.
Referring to
To facilitate positioning of the sheets 90 to the first discharge path 390 or the second discharge path 394, the lane switch conveyor 48 includes a plurality of laterally extending conveyor rail assemblies 398 that are movable along the conveying path 114 (see
Each laterally extending conveyor rail assembly 398 includes, as shown in
The carriage member 422 is a component that is positioned and configured to support and guide the sheets 90 as the sheets 90 move through the lane switch conveyor 48. The carriage member 422 includes an upper surface 446, a lower surface 450, a first end surface 454 extending between the upper surface 446 and the lower surface 450, and a second end surface 458 opposite the first end surface 454. The upper surface 446 may include a plurality of grooves 460. The lower surface 450 includes a pair of elongated openings 462 and a guide projection 466 that has substantially the same structure and function as the guide projection 150. Each elongated opening 462 communicates with a respective recess 470, of a pair of recesses 470, that extends toward the upper surface 446. The first end surface 454 includes a pair of first openings 474, and the second end surface 458 includes a pair of second openings 478.
In the description that follows, first components of the above-described pairs of components (e.g., the pair of elongated openings 462, the pair of recesses 470, the pair of first openings 474, and the pair of second openings 478) will be described. It should be understood that the description equally applies to second components of the above-described pairs of components.
The first opening 474 communicates with the second opening 478 to define a bore 482 that intersects the recess 470. The bore 482 is sized and configured to receive the elongated body 426 of the conveyor rail 418. To allow a substantial portion of the elongated body 426 to be exposed when extending through the bore 482 and when viewed from an interior of the conveying path 114, the recess 470 may include a length that is greater than 50% of the lateral length of the carriage member 422. In some configurations, the length of the recess 470 may be greater than 65% of the lateral length of the carriage member 422. In still other configurations, the length of the recess 470 may be greater than 75% of the lateral length of the carriage member 422.
Referring also to
During operation of the shuttle assembly 154, the diverter 178 is pivotable about the pivot end 186 between a first position that diverts carriage members 422 toward the first discharge path 390 (shown in
More specifically, as a carriage member 422 moves along the conveying path 114 from the infeed location 382 toward the transition zone 386, the guide projection 466 enters the intake guide 158 and the first and second guide walls 170, 174 align the guide projection 466 with the pivot end 186 of the diverter 178. If the diverter 178 is in the first position as the guide projection 466 travels through the transition zone 386, the guide projection 466 engages the first diverter wall 190 and is guided thereby to the left in
It should be appreciated that the guided movement of the guide projection 466 described above moves the corresponding carriage member 422, and lateral movement of adjacent carriage members 466 in turn moves sheets 90 conveyed by such carriage members 466 toward the first or second discharge path 390, 394. Pivotal movement of the diverter 178 between the first and second positions may be regulated by the controller 26 based at least in part on information received from the first sensor 98 regarding the position of sheets 90 being fed to the lane switch conveyor 48 from upstream equipment. Furthermore, while the lane switch conveyor 48 illustrated and described herein is configured to maneuver sheets 90 toward first and second discharge paths 390, 394, the lane switch conveyor 48 could be configured to maneuver sheets 90 to three or more discharge paths by, for example, reconfiguring, replacing, or supplementing one or more of the intake guide 158, diverter 178, and shuttle guide 198.
Referring also to
By positioning the cleaning nozzles 222, 226 in the manner shown, the lane switch conveyor 48 may be efficiently cleaned by operating the lane switch conveyor 48 to circulate the conveyor rails 418 around the conveying path 114 while spraying cleaning fluid from the cleaning nozzles 222, 226. The above-described configuration of the carriage members 422 and the manner in which they leave a substantial portion of the conveyor rails 418 exposed to the cleaning solution enhances the effectiveness of the cleaning procedure.
To provide a further understanding of the operation of the system 10, an exemplary operating cycle is hereafter described that results in the formation of two columns of sheets 282, one having an even number of sheets 90 and one having an odd number of sheets 90. The example below applies to a system that includes a lane switch conveyor 46, 48, a first lane 230, and a second lane 234. As discussed above however the teachings of the present disclosure may also be used in connection with a system that comprises only a single lane of conveyors. It should be appreciated that the description below represents one possible sequence of operation of the system 10 and that the specific order and sequence of operations may be adjusted to achieve a particular result.
To begin the cycle, an initial sheet 90 arrives at the infeed location 102, 382 and breaks the sensor beam 100, thereby indicating to the controller 26 that a sheet 90 has entered the infeed location 102, 382. The controller 26 may then operate the lane switch conveyor 46, 48 to divert the initial sheet 90 to the first discharge path 106, 390. To account for the potential future need to form a three-high stack of sheets 90, the controller 26 operates the primary diverter 66 to move the initial sheet 90 arriving at the first lane 230 to the tertiary conveyor 62, which decelerates and stops the sheet at the waiting zone 254 where it is held stationary until the add-a-sheet condition is met for the first lane 230.
Similarly, in response to a second sheet 90 arriving at the infeed location 102, 382 and breaking the sensor beam 100, the controller 26 operates the lane switch conveyor 46, 48 (e.g., changes the position of the diverter 178) to divert the second sheet 90 to the second discharge path 108, 394. To account for the potential future need to form a three-high stack of sheets 90 in the second lane 234, the controller 26 operates the primary diverter 66 of the second lane 234 to move the second sheet 90 to the tertiary conveyor 62 where it is decelerated to a stop and held stationary at the second waiting zone 254 until the add-a-sheet condition is met for the first lane 230.
Once the tertiary conveyors 62 both have sheets 90 in their respective waiting zones 254, subsequent sheets arriving at the infeed location 102, 382 are alternatingly diverted by the lane switch conveyor 46, 48 to the first discharge path 106 and the second discharge path 108. For each lane 230, 234, the controller 26 operates the secondary diverter 70 so that the second sheet 90 to arrive at that lane is diverted to the secondary conveyor 58, and the third sheet to arrive at that lane is diverted to the primary conveyor 54.
During continuous operation of the system 10, the controller 26 operates each primary conveyor 54 to convey sheets 90 to the respective discharge zone 74 at a baseline average speed that establishes the overall rate at which the respective lane 230, 234 will stack sheets. While the baseline average speeds of the primary conveyors 54 may be substantially equal, they may also differ or change over time depending on the specifics of a given operation.
To form the stacks of sheets 90 at the discharge zone 74, the secondary conveyors 58 are operated at secondary conveyor average speeds that differ from the baseline average speeds of their respective primary conveyors 54. In some configurations, including the example presently being described, the secondary conveyor average speeds are slower than baseline average speeds at which the primary conveyors 54 are operated. In this way, sheets 90 being conveyed along the primary conveyor 54 “catch up” to the sheets 90 being conveyed along the secondary conveyors 58 so that, for a given lane, the sheets 90 being conveyed via the primary conveyor 54 arrive at the discharge zone 74 at substantially the same time as the sheets 90 being conveyed via the secondary conveyor 58. The shingled arrangement of the distal ends of the primary conveyors 54, secondary conveyors 58, and tertiary conveyors 62 (see
As the newly formed stacks of sheets 90 enter the discharge zone, the shuttle conveyor 78 operates in the manner described above to deposit the stacks of sheets 90 onto the collecting conveyor 82. The collecting conveyor 82 gradually lowers to make room for subsequent stacks of sheets 90 arriving at the shuttle conveyor 78, and to form the column of sheets 282. As the column of sheets 282 is formed the controller 26 continuously monitors the weight of the column of sheets 282 via the collecting conveyor 82 load cell and calculates whether the add-a-sheet condition is met. In this exemplary description, assume that the controller 26 determines that the column of sheets 282 being formed in the first lane 230 will require an odd number of sheets to fall within the predetermined range and the add-a-sheet condition is therefore met, and the column of sheets 282 being formed in the second lane 234 will require an even number of sheets to fall within the predetermined weight range and the add-a-sheet condition is therefore not met.
As the first lane 230 column of sheets 282 approaches completion, the controller 26 operates the first tertiary conveyor 62 to move the sheet 90 being held in the waiting zone 254 into the discharge zone 74 at substantially the same time as the sheets 90 being conveyed via the primary conveyor 54 and the secondary conveyor 58, thereby forming a three-high stack of sheets 90 that will be added to and complete the column of sheets 282. With the column of sheets 282 completed, the controller 26 operates the collecting conveyor 82 to move the column of sheets to the takeaway conveyor 286. As shown in
Once the column of sheets 282 is no longer positioned on the collecting conveyor 82, the collecting conveyor 82 raises back up and prepares to receive the first stack of sheets 90 of the next column of sheets 282 from the shuttle conveyor 78. In addition, because the waiting zone 254 of the tertiary conveyor 62 is now empty, when the next sheet 90 arrives at the first lane 230 the controller 26 operates the primary diverter 66 to divert the sheet to the tertiary conveyor 62 where it is decelerated to a stop in the waiting zone 254 so that, if the add-a-sheet condition is met with the next column of sheets 282 to be formed, the sheet 90 is available to form a three-high stack of sheets 90.
In contrast, as the second lane 234 column of sheets approaches completion, because the add-a-sheet condition has not been met, the final stack of sheets 90 to be added to the column will be a two-high stack of sheets 90, operation of the tertiary conveyor is not required, and the sheet in the waiting zone 254 will remain available to form a three-high stack of sheets if needed upon completion of the next column of sheets 282 formed in the second lane 234
To aid the controller 26 in the consistent operation of the diverter assembly 50 and the conveyors 54, 58, 62, the controller 26 receives signals from the second sensor 238 and the third sensor 242 as the leading edges of subsequent sheets 90 enter the first lane 230 and second lane 234, respectively. In response to signals from the sensors 238, 242 detecting the location of the leading edges of the sheets 90, the controller 26 may adjust timing of movement of the primary and secondary diverters 66, 70 and may adjust the baseline average speed and/or the secondary conveyor average speed.
Referring to
As used herein, “a,” “an,” and a “set” are intended to include one or more items, and may be used interchangeably with “one or more.” Further, as used herein, the article “the” is intended to include one or more items referenced in connection with the article “the” and may be used interchangeably with “the one or more.” Further, the phrase “based on” is intended to mean “based, at least in part, on” unless explicitly stated otherwise. Also, as used herein, the term “or” is intended to be inclusive when used in a series and may be used interchangeably with “and/or,” unless explicitly stated otherwise (e.g., if used in combination with “either” or “only one of”). Further, spatially relative terms, such as “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature’s relationship to another element(s) or feature(s) as illustrated in the figures. The spatially relative terms are intended to encompass different orientations of the apparatus, device, and/or element in use or operation in addition to the orientation depicted in the figures. The apparatus may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly.
Exemplary configurations of the present disclosure are described below, each exemplary configuration being usable alone or in combination with the other exemplary configurations.
Example 1. A food grade classifying conveyor assembly for stacking sheets of food items received at an assembly intake, the food grade classifying conveyor assembly comprising:
a primary conveyor operable to convey sheets from the assembly intake to a discharge zone at a baseline average speed;
a secondary conveyor operable to convey sheets from the assembly intake to the discharge zone at a secondary conveyor average speed that differs from the baseline average speed such that sheets conveyed via the secondary conveyor arrive at the discharge zone at substantially the same time as, and are stacked with, sheets conveyed via the primary conveyor, thereby forming two-high stacks of sheets;
a tertiary conveyor defining a waiting zone upstream of the discharge zone, the tertiary conveyor operable to convey sheets from the assembly intake to the waiting zone where sheets are held stationary until an add-a-sheet condition is met;
a diverter assembly operable to divert sheets received from the assembly intake to one of the primary conveyor, the secondary conveyor, and the tertiary conveyor;
a shuttle conveyor positioned to receive the two-high stacks of sheets via the discharge zone and operable to stack the two-high stacks of sheets one upon another to form a column of sheets, the shuttle conveyor including a load sensor operable to sense a weight of the column of sheets; and,
a controller operably communicating with the load sensor and the tertiary conveyor and operable to calculate an inclusion of one additional sheet to cause a final weight of the column of sheets to fall within a predetermined range, and that the add-a-sheet condition is therefore met, and wherein in response to calculating that the add-a-sheet condition is met, the controller operates the tertiary conveyor to move one sheet from the waiting zone to the discharge zone at substantially the same time as, and to stack with, the sheets conveyed via the primary conveyor and the secondary conveyor, thereby forming a three-high stack of sheets that is added to the column of sheets by the shuttle conveyor.
Example 2. The food grade classifying conveyor assembly of example 1, further comprising:
a reject conveyor having a receiving end and a discharge end; and
a reject diverter positioned upstream of the diverter assembly and operable, in response to a reject signal, to divert reject sheets to the reject conveyor.
Example 3. The food grade classifying conveyor assembly of example 1, further comprising a sensor positioned upstream of the diverter assembly and operable to identify a leading edge of each sheet received by the food grade classifying conveyor assembly, and wherein the controller regulates the secondary conveyor average speed in response to a location of the leading edge of each sheet received by the conveyor assembly.
Example 4. The food grade classifying conveyor assembly of example 1, wherein the controller is operable to independently control the baseline average speed, the secondary conveyor average speed, and the tertiary conveyor.
Example 5. The food grade classifying conveyor assembly of example 1, wherein the secondary conveyor is positioned above the primary conveyor, and wherein the tertiary conveyor is positioned above the secondary conveyor.
Example 6. The food grade classifying conveyor assembly of example 5, wherein the diverter assembly includes a primary diverter operable to divert sheets to the tertiary conveyor, and a secondary diverter operable to divert sheets to either the primary conveyor or the secondary conveyor.
Example 7. The food grade classifying conveyor assembly of example 1, further comprising a lane switch conveyor positioned upstream of the assembly intake, the lane switch conveyor including an infeed location, a transition zone, a first discharge path, and a second discharge path, wherein the lane switch conveyor is operable to divert sheets received at the infeed location between the first discharge path and the second discharge path.
Example 8. The food grade classifying conveyor assembly of example 7, wherein the food grade classifying conveyor assembly includes a first lane that receives sheets from the first discharge path and a second lane that receives sheets from the second discharge path, wherein each lane includes a respective primary conveyor, secondary conveyor, tertiary conveyor, diverter assembly, and shuttle conveyor.
Example 9. The food grade classifying conveyor assembly of example 8, wherein the controller controls and coordinates operation of the lane switch conveyor, the first lane, and the second lane.
Example 10 A food grade sheet stacker for stacking sheets of food items, the food grade sheet stacker comprising:
a lane switch conveyor including an infeed location, a transition zone, a first discharge path, and a second discharge path, the lane switch conveyor operable to divert sheets received at the infeed location between the first discharge path and the second discharge path; and,
a first lane of classifying conveyors positioned to receive sheets via the first discharge path, and a second lane of classifying conveyors positioned to receive sheets via the second discharge path, each of the first lane of classifying conveyors and the second lane of classifying conveyors including:
a discharge zone;
a primary conveyor operable to convey sheets to the discharge zone at a baseline average speed;
a secondary conveyor operable to convey sheets to the discharge zone at a secondary conveyor average speed that differs from the baseline average speed such that sheets conveyed via the secondary conveyor arrive at the discharge zone at substantially the same time as, and are stacked with, sheets conveyed via the primary conveyor, thereby forming two-high stacks of sheets;
a tertiary conveyor operable to convey sheets to a waiting zone where sheets are held stationary; and,
a diverter assembly operable to divert sheets to one of the primary conveyor, the secondary conveyor, and the tertiary conveyor,
wherein, each tertiary conveyor is operable in response to a signal calling for delivery of a three-high stack of sheets to add one of the sheets from the respective waiting zone of the tertiary conveyor to the two-high stack of sheets formed by the corresponding secondary conveyor, thereby forming the three-high stack of sheets.
Example 11. The food grade sheet stacker of example 10, further comprising a pair of shuttle conveyors, each shuttle conveyor positioned to receive stacks of sheets from one of the first lane of classifying conveyors and the second lane of classifying conveyors, each shuttle conveyor operable to stack the received stacks of sheets one upon the other to form a column of sheets.
Example 12. The food grade sheet stacker of example 11, wherein each shuttle conveyor includes a load sensor operable to sense a weight of the column of sheets, and wherein the signal calling for delivery of the three-high stack of sheets is sent in response to the load sensor sensing that the weight of the column of sheets meets a predetermined criteria.
Example 13. The food grade sheet stacker of example 10, further comprising a reject conveyor and a reject diverter operable in response to a reject signal to divert reject sheets to the reject conveyor.
Example 14. The food grade sheet stacker of example 10, further comprising a first sensor positioned upstream of the infeed location and operable to identify a leading edge of each sheet received by the food grade sheet stacker, a second sensor positioned upstream of the diverter assembly and operable to identify a leading edge of each sheet received from the first discharge path, and a third sensor positioned upstream of the diverter assembly and operable to identify a leading edge of each sheet received from the second discharge path.
Example 15. The food grade sheet stacker of example 10, further comprising a controller operable to independently control, for each of the first lane of classifying conveyors and the second lane of classifying conveyors, the baseline average speed, the secondary conveyor average speed, and the tertiary conveyor.
Example 16. The food grade sheet stacker of example 10, wherein for each of the first lane of classifying conveyors and the second lane of classifying conveyors, the secondary conveyor is positioned above the primary conveyor, and the tertiary conveyor is positioned above the secondary conveyor.
Example 17. The food grade sheet stacker of example 10, wherein each diverter assembly includes a primary diverter operable to divert sheets to the tertiary conveyor, and a secondary diverter operable to divert sheets received via the primary diverter to either the primary conveyor or the secondary conveyor.
Example 18. A lane switch conveyor comprising:
a plurality of laterally extending conveyor rails movable along a conveying path, the conveying path having an upper segment, a lower segment, and end segments joining the upper segment and the lower segment, each laterally extending conveyor rail having a substantially C-shaped cross section defining an open section of the conveyor rail and a closed section of the conveyor rail, each laterally extending conveyor rail mounted such that when the laterally extending conveyor rail is positioned along the upper segment, the open section faces toward the lower segment, and when the laterally extending conveyor rail is positioned along the lower segment, the open section faces toward the upper segment;
a plurality of carriage members, each carriage member slidably mounted on a respective one of the plurality of laterally extending conveyor rails for movement therewith along the conveying path, and for movement relative thereto in a lateral direction, each carriage member including a mounting section having a cross section that extends around and at least partially encloses the open section of the substantially C-shaped cross section of the laterally extending conveyor rail to which the carriage member is mounted, and a guiding section that extends over the closed section of the laterally extending conveyor rail to which the carriage member is mounted without covering the open section of the laterally extending conveyor rail to which the carriage member is mounted;
a shuttle assembly operable to engage each of the plurality of carriage members and to move the plurality of carriage members laterally relative to the plurality of laterally extending conveyor rails as the plurality of laterally extending conveyor rails move along the upper segment of the conveying path; and
a plurality of cleaning nozzles positioned between the upper segment and the lower segment of the conveying path, at least some of the plurality of cleaning nozzles oriented to spray cleaning fluid upwardly into the open sections of the plurality of laterally extending conveyor rails.
Example 19. The lane switch conveyor of example 18, wherein the mounting section comprises less than 50% of a lateral length of each carriage member.
Example 20. The lane switch conveyor of example 18, wherein each carriage member includes a guide projection that extends downwardly when the carriage member moves along the upper segment, and wherein the shuttle assembly engages the guide projection to move the carriage member laterally along the laterally extending conveyor rail as the carriage member and the laterally extending conveyor rail move along the upper segment of the conveying path.
Example 21. The lane switch conveyor of example 18, wherein the shuttle assembly includes an intake guide having an upstream end and a downstream end, the intake guide including a first guide wall and a second guide wall that converge toward one another as they extend from the upstream end toward the downstream end, the shuttle assembly including a diverter having a diverting tip positioned adjacent to the downstream end of the intake guide, a pivot end positioned downstream of the diverting tip, and first and second diverter walls extending between the diverting tip and the pivot end and diverging away from one another as they extend from the diverting tip to the pivot end, wherein the diverter is pivotable about the pivot end to move the diverting tip between a first position adjacent to the first guide wall for diverting carriage members toward a first discharge path and a second position adjacent the second guide wall for diverting carriage members toward a second discharge path.
Example 22. The lane switch conveyor of example 18, wherein the plurality of cleaning nozzles is a first plurality of cleaning nozzles, the conveyor assembly further comprising a second plurality of cleaning nozzles positioned below the lower segment of the conveying path, at least some of the second plurality of cleaning nozzles oriented to spray cleaning fluid upwardly onto the closed sections of the laterally extending conveyor rail.
Example 23. A shuttle conveyor for stacking items one upon another, the shuttle conveyor comprising;
a frame having a longitudinal extent associated with a conveying direction;
a roller assembly mounted in a cantilever fashion from the frame, the roller assembly including a subframe laterally spaced from the frame, an infeed roller, and a tensioner roller, each of the infeed roller and the tensioner roller having a first end rotatably supported by the frame and a second end rotatably coupled to the subframe;
a carriage reciprocatingly movable relative to the frame, the carriage having a first lateral side mounted to the frame and a second lateral side supported by the subframe, the carriage including a discharge roller on a distal end thereof, and an idler roller on a proximal end thereof such that, during reciprocating movement of the carriage, the discharge roller and the idler roller move toward and away from the infeed roller; and
a conveyor web defining at least one closed loop of material and extending along a conveying path that extends from the infeed roller, around the discharge roller, around the idler roller, and around the tensioner roller,
wherein the tensioner roller is movable relative to the frame and the subframe between an engaged position that applies tension to the conveyor web such that the idler roller is secured to the carriage by way of the tension applied to the conveyor web, and a disengaged position that releases tension from the conveyor web such that the idler roller is removable from the carriage.
Example 24. The shuttle conveyor of example 23, wherein when the idler roller is removed from the carriage, the conveyor web is removable from the subframe.
Example 25. The shuttle conveyor of example 24, wherein the conveyor web is removable from the subframe by passing the conveyor web around the subframe.
Example 26. The shuttle conveyor of example 25, wherein the conveyor web is removable from the subframe by passing the conveyor web around the subframe without removing the infeed roller or the tensioner roller.
Example 27. The shuttle conveyor of example 23, wherein the first lateral side of the carriage includes a first slotted receptacle that receives a first end of the idler roller, and the second lateral side of the carriage includes a second slotted receptacle that receives a second end of the idler roller, and wherein when the tensioner roller is moved to the engaged position to apply tension to the conveyor web, the first and second ends of the idler roller are urged, respectively, into engagement with the first and second slotted receptacles.
Example 28. The shuttle conveyor of example 27, wherein when the tensioner roller is moved to the disengaged position to release tension from the conveyor web the first and second ends of the idler roller are removable, respectively, from the first and second slotted receptacles.
Example 29. The shuttle conveyor of example 23, wherein the first lateral side of the carriage includes a first movable support assembly adjacent the proximal end of the carriage and a second movable support assembly adjacent the distal end of the carriage, the first and second movable support assemblies engaging the frame to movably support the carriage, and wherein the second lateral side of the carriage includes a third movable support assembly adjacent the proximal end of the carriage and engaging the subframe to movably support the carriage.
Example 30. The shuttle conveyor of example 29, wherein a distal end of the second lateral side of the carriage is supported in a cantilevered manner by the first, second, and third movable support assemblies.
Example 31. The shuttle conveyor of example 23, wherein during operation, the conveyor web defines a conveying surface having a length that extends between the infeed roller and the discharge roller, and wherein the length of the conveying surface changes during reciprocating movement of the carriage relative to the frame.
Example 32. The shuttle conveyor of example 23, wherein the roller assembly further includes a drive roller spaced from the infeed roller and the tensioner roller, the drive roller having one end supported by the frame and a second end coupled to the subframe, the drive roller providing driving rotatable force to the conveyor web during operation of the shuttle conveyor.
Example 33. The shuttle conveyor of example 23, wherein the conveying path includes a serpentine path segment that extends around the discharge roller in a first direction, around the idler roller in a second direction, and around the tensioner roller in the first direction.
Claims
1. A food grade classifying conveyor assembly for stacking sheets of food items received at an assembly intake, the food grade classifying conveyor assembly comprising:
- a first conveyor operable to convey first sheets of food items from the assembly intake to a discharge zone;
- a second conveyor defining a waiting zone upstream of the discharge zone, the second conveyor operable to convey second sheets of food items from the assembly intake to the waiting zone where the second sheets of food items are held until an add-a-sheet condition is met;
- a stacking conveyor positioned downstream of the discharge zone and operable to stack the first sheets of food items received via the discharge zone to form a column of sheets;
- a sensor that is operable to sense a weight of the column of sheets; and,
- a controller operably communicating with the sensor and the second conveyor and operable to determine whether the add-a-sheet condition is met, and wherein in response to determining that the add-a-sheet condition is met, the controller operates the second conveyor to move one of the second sheets of food items from the waiting zone to the discharge zone at substantially the same time as, and to stack with, one of the first sheets of food items conveyed via the first conveyor.
2. The food grade classifying conveyor assembly of claim 1, wherein the controller is operable to determine whether the add-a-sheet condition is met by calculating whether the inclusion of the one of the second sheets of food items in the column of sheets will cause a final weight of the column of sheets to fall within a predetermined range.
3. The food grade classifying conveyor assembly of claim 1, further comprising a diverter assembly operable to divert the sheets of food items received from the assembly intake to one of the first conveyor and the second conveyor.
4. The food grade classifying conveyor assembly of claim 1, further comprising a third conveyor operable to convey third sheets of food items from the assembly intake to the discharge zone.
5. The food grade classifying conveyor assembly of claim 4, wherein the first conveyor operates at a baseline average speed, and the third conveyor operates at a third conveyor average speed that differs from the baseline average speed such that individual ones of the third sheets of food items conveyed via the third conveyor arrive at the discharge zone at substantially the same time as, and are stacked with, individual ones of the first sheets of food items conveyed via the first conveyor, thereby forming two-high stacks of sheets.
6. The food grade classifying conveyor assembly of claim 5, wherein the controller is operable to independently control the baseline average speed, the third conveyor average speed, and the second conveyor.
7. The food grade classifying conveyor assembly of claim 5, wherein a shuttle conveyor receives the two-high stacks of sheets via the discharge zone and is operable to stack the two-high stacks of sheets one upon another to form the column of sheets.
8. The food grade classifying conveyor assembly of claim 4, further comprising a diverter assembly operable to divert sheets of food items received from the assembly intake to one of the first conveyor, the third conveyor, and the second conveyor.
9. The food grade classifying conveyor assembly of claim 4, wherein the third conveyor is positioned above the first conveyor, and wherein the second conveyor is positioned above the third conveyor.
10. The food grade classifying conveyor assembly of claim 1, further comprising a lane switch conveyor positioned upstream of the assembly intake, the lane switch conveyor including an infeed location, a transition zone, a first discharge path, and a second discharge path, wherein the lane switch conveyor is operable to divert sheets of food items received at the infeed location between the first discharge path and the second discharge path.
11. The food grade classifying conveyor assembly of claim 10, wherein the first conveyor and the second conveyor each include: a first lane that receives sheets of food items from the first discharge path, and a second lane that receives sheets of food items from the second discharge path.
12. The food grade classifying conveyor assembly of claim 11, wherein the controller controls and coordinates operation of the lane switch conveyor, the first lane, and the second lane.
13. A food grade classifying conveyor assembly for stacking sheets of food items, the food grade classifying conveyor assembly comprising:
- a primary conveyor operable to convey primary sheets of food items to a discharge zone;
- a secondary conveyor operable to convey secondary sheets of food items to the discharge zone such that individual ones of the secondary sheets of food items arrive at the discharge zone at substantially the same time as, and are stacked with, individual ones of the primary sheets of food items, thereby forming two-high stacks of sheets;
- a tertiary conveyor defining a waiting zone, the tertiary conveyor operable to convey tertiary sheets of food items to the waiting zone where the tertiary sheets of food items are held until an add-a-sheet condition is met;
- a stacking conveyor positioned to receive the two-high stacks of sheets via the discharge zone and operable to stack the two-high stacks of sheets one upon another to form a column of sheets; and,
- a controller operable to determine whether the add-a-sheet condition is met, wherein in response to determining that the add-a-sheet condition is met, the controller operates the tertiary conveyor to move one tertiary sheet of food items from the waiting zone to the discharge zone at substantially the same time as, and to stack with, one of the primary sheets of food items conveyed via the primary conveyor and one of secondary sheets of food items conveyed by the secondary conveyor, thereby forming a three-high stack of sheets.
14. The food grade classifying conveyor assembly of claim 13, further comprising a sensor to sense a weight of the column of sheets, wherein the controller operably communicates with the sensor and the tertiary conveyor, and wherein the controller determines whether the add-a-sheet condition is met by calculating whether inclusion of the one tertiary sheet of food items in the column of sheets will cause a final weight of the column of sheets to fall within a predetermined range.
15. The food grade classifying conveyor assembly of claim 13, wherein the primary conveyor conveys the primary sheets of food items to the discharge zone at a baseline average speed, and wherein the secondary conveyor conveys the secondary sheets of food items to the discharge zone at a secondary conveyor average speed that differs from the baseline average speed.
16. The food grade classifying conveyor assembly of claim 15, further comprising a second sensor positioned upstream of the primary conveyor to identify a leading edge of each sheet of food items received by the food grade classifying conveyor assembly, and wherein the controller regulates the secondary conveyor average speed in response to a location of the leading edge of each sheet of food items received by the food grade classifying conveyor assembly.
17. The food grade classifying conveyor assembly of claim 13, wherein the secondary conveyor is positioned above the primary conveyor, and wherein the tertiary conveyor is positioned above the secondary conveyor.
18. The food grade classifying conveyor assembly of claim 13, further comprising a diverter assembly including a primary diverter that is operable to divert sheets of food items to the tertiary conveyor, and a secondary diverter operable to divert sheets of food items to either the primary conveyor or the secondary conveyor.
19. The food grade classifying conveyor assembly of claim 18, further comprising:
- a reject conveyor having a receiving end and a discharge end; and
- a reject diverter positioned upstream of the diverter assembly and operable, in response to a reject signal, to divert reject sheets of food items to the reject conveyor.
20. A food grade sheet stacker for stacking sheets of food items, the food grade sheet stacker comprising:
- a lane switch conveyor including an infeed location, a transition zone, a first discharge path, and a second discharge path, the lane switch conveyor operable to divert sheets of food items received at the infeed location between the first discharge path and the second discharge path; and,
- a first lane of classifying conveyors positioned to receive sheets of food items via the first discharge path, and a second lane of classifying conveyors positioned to receive sheets of food items via the second discharge path, each of the first lane of classifying conveyors and the second lane of classifying conveyors including: a discharge zone; a primary conveyor operable to convey sheets of food items to the discharge zone at a baseline average speed; a secondary conveyor operable to convey sheets of food items to the discharge zone at a secondary conveyor average speed that differs from the baseline average speed such that individual ones of the sheets of food items conveyed via the secondary conveyor arrive at the discharge zone at substantially the same time as, and are stacked with, individual ones of the sheets of food items conveyed via the primary conveyor, thereby forming two-high stacks of sheets; a tertiary conveyor operable to convey sheets of food items to a waiting zone; and, a diverter assembly operable to divert sheets of food items to one of the primary conveyor, the secondary conveyor, and the tertiary conveyor, wherein each tertiary conveyor is operable in response to a signal to add one of the sheets of food items from the respective waiting zone of the tertiary conveyor to a two-high stack of sheets formed by the corresponding secondary conveyor, thereby forming a three-high stack of sheets.
21. The food grade sheet stacker of claim 20, further comprising a pair of stacking conveyors, each stacking conveyor positioned to receive the two-high stacks of sheets and the three-high stacks of sheets from one of the first lane of classifying conveyors and the second lane of classifying conveyors, each stacking conveyor operable to stack the received two-high stacks of sheets and three-high stacks of sheets one upon the other to form a column of sheets.
22. The food grade sheet stacker of claim 21, wherein each of the first lane of classifying conveyors and the second lane of classifying conveyors includes a sensor that is operable to sense a weight of the column of sheets formed by a respective one of the stacking conveyors, and wherein when one of the sensors senses that the weight of the column of sheets formed by the corresponding stacking conveyor meets a predetermined criteria, a signal is sent to the corresponding tertiary conveyor.
23. The food grade sheet stacker of claim 20, further comprising a first sensor positioned upstream of the infeed location and operable to identify a leading edge of each sheet of food items received by the food grade sheet stacker, a second sensor positioned upstream of the diverter assembly of the first lane of classifying conveyors and operable to identify a leading edge of each sheet of food items received from the first discharge path, and a third sensor positioned upstream of the diverter assembly of the second lane of classifying conveyors and operable to identify a leading edge of each sheet of food items received from the second discharge path.
24. The food grade sheet stacker of claim 20, further comprising a controller operable to independently control, for each of the first lane of classifying conveyors and the second lane of classifying conveyors, the baseline average speed, the secondary conveyor average speed, and the tertiary conveyor.
25. The food grade sheet stacker of claim 20, wherein for each of the first lane of classifying conveyors and the second lane of classifying conveyors, the secondary conveyor is positioned above the primary conveyor, and the tertiary conveyor is positioned above the secondary conveyor.
26. The food grade sheet stacker of claim 20, wherein each diverter assembly includes a primary diverter operable to divert sheets of food items to the tertiary conveyor, and a secondary diverter operable to divert sheets of food items received via the primary diverter to either the primary conveyor or the secondary conveyor.
Type: Application
Filed: Feb 18, 2026
Publication Date: Aug 20, 2026
Applicant: Provisur Technologies, Inc. (Mokena, IL)
Inventors: Ryan M. Torrenga (Bourbonnais, IL), Glen F. Pryor (Manhattan, IL), Michael S. Severns (Naperville, IL)
Application Number: 19/542,958
