Workpiece diverter station, conveyor system, and methods for utilizing the same

1. A workpiece diverter station comprising:

a base frame having a width extending in a Y-direction and a length extending in an X-direction;

an X-direction workpiece transporter subassembly that is axially fixedly supported with respect to the base frame in a Z-direction, wherein the X-direction workpiece transporter subassembly includes a first plurality of rollers extending across the width of the base frame;

a Z-direction lift assembly supported by the base frame;

a Y-direction workpiece transporter subassembly that is:

connected to the Z-direction lift assembly; and

axially movably supported with respect to the base frame in the Z-direction, wherein the Y-direction workpiece transporter subassembly includes a second plurality of rollers extending across a length of the base frame;

a first set of loop members that rotatably couples the first plurality of rollers; and

a second set of loop members that rotatably couples the second plurality of rollers.

2. The workpiece diverter station of claim 1 , wherein the first plurality of rollers of the X-direction workpiece transporter subassembly includes:

at least one roller of a first plurality of proximal rollers, the at least one roller including a proximal powered roller;

at least one roller of a first plurality of distal rollers, the at least one roller including a distal powered roller; and

a plurality of intermediate rollers including at least one passive roller.

3. The workpiece diverter station of claim 2 , wherein the first plurality of rollers of the X-direction workpiece transporter subassembly further includes:

a second plurality of proximal rollers including at least one passive roller; and

a second plurality of distal rollers including at least one passive roller.

4. The workpiece diverter station of claim 3 , wherein the first set of loop members rotatably connects for synchronized rotation all of:

the first plurality of proximal rollers;

the second plurality of proximal rollers;

the first plurality of distal rollers;

the second plurality of distal rollers; and

the plurality of intermediate rollers.

5. A portion of a workpiece diverter station comprising:

a base frame; and

at least one subassembly including:

a plurality of rollers arranged in parallel with one another, the plurality of rollers including:

a first powered roller supported by the base frame;

a second powered roller supported by the base frame;

at least one passive roller supported by the base frame;

a plurality of loop members that rotatably connect the plurality of rollers for synchronized rotation;

at least one servicing access clamp plate that removably-connects at least two rollers of the plurality of rollers to the base frame;

an X-direction workpiece transporter subassembly comprising:

a first panel extension bracket connected to the base frame;

a second panel extension bracket connected to the base frame:

a plurality of intermediate rollers extending between and directly supported by the first panel extension bracket and the second panel extension bracket, wherein the at least one passive roller includes the plurality of intermediate rollers; and

a Y-direction workpiece transporter subassembly,

wherein the plurality of rollers of the Y-direction workpiece transporter subassembly are orthogonally arranged with respect to the plurality of rollers of the X-direction workpiece transporter subassembly.

6. The portion of the workpiece diverter station of claim 5 , wherein a portion of the Y-direction workpiece transporter subassembly includes:

at least one outer bracket connected to the base frame;

at least one inner bracket connected to the base frame; and

at least one plurality of intermediate rollers extending between and directly supported by the at least one outer bracket and the at least one inner bracket, wherein the at least one passive roller includes the at least one plurality of intermediate rollers.

7. The portion of the workpiece diverter station of claim 6 , wherein the at least one servicing access clamp plate includes:

a first servicing access clamp plate that removably-secures a first end of each roller of a first plurality of intermediate rollers of the at least one plurality of intermediate rollers to a first region of the at least one outer bracket; and

a second servicing access clamp plate that removably-secures a first end of each roller of a second plurality of intermediate rollers of the at least one plurality of intermediate rollers to a second region of the at least one outer bracket.

8. The workpiece diverter station of claim 1 , wherein the second plurality of rollers of the Y-direction workpiece transporter subassembly includes:

at least one roller of a plurality of proximal rollers, the at least one roller including a proximal powered roller;

at least one roller of a plurality of distal rollers, the at least one roller including:

a distal powered roller; and

a plurality of intermediate rollers including at least one passive roller.

9. The workpiece diverter station of claim 8 , wherein the second set of loop members rotatably connects for synchronized rotation all of:

the plurality of proximal rollers;

the plurality of distal rollers; and

the plurality of intermediate rollers.

10. The workpiece diverter station of claim 1 , wherein the base frame includes:

at least one support beam arranged within a cavity of the base frame, wherein the Z-direction lift assembly includes:

at least one axial lifter supported by the at least one support beam, wherein the Y-direction workpiece transporter subassembly is supported by the at least one axial lifter.

11. The workpiece diverter station of claim 1 , further comprising:

a fluid source connected to at least one Z-direction lifting actuator of the Z-direction lift assembly.

12. The workpiece diverter station of claim 11 , wherein the at least one Z-direction lifting actuator is an inflatable device.

13. The workpiece diverter station of claim 1 , further comprising:

at least one motor connected to:

at least one roller of the first plurality of rollers of the X-direction workpiece transporter subassembly.

14. The workpiece diverter station of claim 1 , further comprising:

at least one motor connected to:

at least one roller of the second plurality of rollers of the Y-direction workpiece transporter subassembly.

15. The workpiece diverter station of claim 1 , further comprising:

a Y-direction workpiece guiding subassembly connected to the Y-direction workpiece transporter subassembly.

16. The portion of the workpiece diverter station of claim 5 , wherein the at least one servicing access clamp plate includes:

a first servicing access clamp plate that removably-secures a first end of each roller of the plurality of intermediate rollers to the first panel extension bracket; and

a second servicing clamp plate that removably-secures a second end of each roller of the plurality of intermediate rollers to the second panel extension bracket.

17. A method for operating a workpiece diverter station of a conveyor system, the conveyor system including an upstream conveyor line branch, a first downstream conveyor line branch and a second downstream conveyor line branch, the method comprising:

providing a workpiece from the upstream conveyor line branch to the workpiece diverter station, the workpiece diverter station having a width extending in a Y-direction and length extending in an X-direction;

receiving an input at a central processing unit if the workpiece should be directed from the workpiece diverter station to the first downstream conveyor line branch or the second downstream conveyor line branch;

responsive to the received input, transporting the workpiece downstream of the workpiece diverter station by arranging a Y-direction workpiece transporter subassembly of the workpiece diverter station in one of two orientations including:

a down orientation that is axially aligned with a X-direction workpiece transporter subassembly of the workpiece diverter station for transporting the workpiece along a first conveyor path; and

an up orientation that is axially offset from and is not axially aligned with the X-direction workpiece transporter subassembly of the workpiece diverter station for transporting the workpiece along a second conveyor path that is different from the first conveyor path, and

wherein:

the X-direction workpiece transporter subassembly includes a first plurality of rollers extending across the width of the workpiece diverter station;

the Y-direction workpiece transporter subassembly includes a second plurality of rollers extending across a length of the workpiece diverter station;

a first set of loop members that rotatably couples the first plurality of rollers; and

a second set of loop members that rotatably couples the second plurality of rollers.

18. The method of claim 17 , wherein the arranging a Y-direction workpiece transporter subassembly of the workpiece diverter station in the up orientation includes:

sending a signal from the central processing unit to at least one Z-direction lifting actuator of a Z-direction lift assembly that axially offsets the Y-direction workpiece transporter subassembly from the X-direction workpiece transporter subassembly.

19. A method for servicing a portion of a workpiece diverter station, the method comprising:

providing a plurality of loop members having a first set of loop members and a second set of loop members, wherein the first set rotatably couples a first plurality of rollers extending across a width of the workpiece diverter station, and wherein the second set of loop members rotatably couples a second plurality of rollers extending across a length of the workpiece diverter station;

providing at least one servicing access clamp plate that removably-connects at least two rollers of the first plurality of rollers or the second plurality of rollers to a base frame;

determining that a loop member of the plurality of loop members is compromised;

removing the at least one servicing access clamp plate from the base frame;

removing a set of rollers from the base frame;

replacing the compromised loop member with a new loop member; and

re-attaching the at least one servicing access clamp plate to the base frame.

20. The method of claim 19 , wherein the removing the at least one servicing access clamp plate from the base frame includes:

removing one or more fasteners that secures the at least one servicing access clamp plate to the base frame;

lifting the at least one servicing access clamp plate axially away from the base frame; and

discarding the compromised loop member.

21. The method of claim 19 , wherein after replacing the compromised loop member with a new loop member, the method further includes:

arranging the new loop member upon the removed rollers of the set of rollers that were removed from the base frame; and

re-arranging the removed rollers back upon the base frame.

22. A portion of a workpiece diverter station comprising:

a base frame; and

at least one subassembly including:

a plurality of rollers arranged in parallel with one another, the plurality of rollers including:

a first powered roller supported by the base frame;

a second powered roller supported by the base frame;

at least one passive roller supported by the base frame;

a plurality of loop members that rotatably connect the plurality of rollers for synchronized rotation;

at least one servicing access clamp plate that removably-connects at least two rollers of the plurality of rollers to the base frame;

an X-direction workpiece transporter subassembly;

a Y-direction workpiece transporter subassembly;

wherein the plurality of rollers of the Y-direction workpiece transporter subassembly are orthogonally arranged with respect to the plurality of rollers of the X-direction workpiece transporter subassembly;

wherein a portion of the Y-direction workpiece transporter subassembly includes:

at least one outer bracket connected to the base frame;

at least one inner bracket connected to the base frame;

at least one plurality of intermediate rollers extending between and directly supported by the at least one outer bracket and the at least one inner bracket, wherein the at least one passive roller includes the at least one plurality of intermediate rollers; and

wherein the at least one servicing access clamp plate includes:

a first servicing access clamp plate that removably-secures a first end of each roller of a first plurality of intermediate rollers of the at least one plurality of intermediate rollers to a first region of the at least one outer bracket; and

a second servicing access clamp plate that removably-secures a first end of each roller of a second plurality of intermediate rollers of the at least one plurality of intermediate rollers to a second region of the at least one outer bracket.