Modular transfer units, systems, and methods
A modular transfer system with a primary flow system and a diverter system. The primary flow system includes a primary flow belt for conveying an article along a primary flow path from an infeed side of the modular transfer system to a pass-through side of the modular transfer system. The diverter system includes one or more diverter belts for diverting an article from the primary flow path towards a divert side of the modular transfer system. The primary flow belt includes multiple movable components contacting the diverter belt. The movable components can have one or more rotational degrees of freedom.
1. A modular transfer system comprising:
a main belt comprising an upper surface, a lower surface, and a plurality of spherical balls, the spherical balls having an upper portion that protrudes above the upper surface and a lower portion that protrudes below the lower surface, the spherical balls configured to rotate relative to the upper and lower surfaces, the main belt configured to travel in a first direction;
a diverter belt configured to travel in a second direction that is generally perpendicular to the first direction, the diverter belt in contact with the protruding lower portion of the spherical balls such that relative movement of the main and diverter belts causes the spherical balls to rotate; and
a main belt drive unit configured to drive the main belt in the first direction, the main belt drive unit comprising a motor and a motorized drive roller, the motorized drive roller comprising:
a longitudinal axis;
a radially outer surface that is configured to engage with the lower surface of the main belt to provide frictional driving force on the main belt; and
a plurality of recesses having a semi-circular shape from a perspective perpendicular to the longitudinal axis, the recesses configured to receive the lower portion of a respective one of the spherical balls.
2. The modular transfer system of claim 1 , wherein the recesses are longitudinally spaced apart from each other in a direction parallel to the longitudinal axis.
3. The modular transfer system of claim 1 , wherein the recesses are annular.
4. The modular transfer system of claim 1 , wherein, from a perspective parallel to the longitudinal axis, the motorized drive roller is circular in shape.
5. The modular transfer system of claim 1 , wherein the motorized drive roller does not comprise a sprocket.
6. The modular transfer system of claim 1 , wherein the motorized drive roller comprises a plastic base and a rubber coating.
7. The modular transfer system of claim 1 , wherein the radially outer surface of the motorized drive roller further comprises a plastic or rubber coating.
8. The modular transfer system of claim 1 , wherein the radially outer surface of the motorized drive roller further comprises a urethane coating.
9. The modular transfer system of claim 1 , wherein the balls are longitudinally spaced apart by less than or equal to about 1 inch center-to-center.
10. The modular transfer system of claim 1 , wherein the modular transfer system operates at electric voltages of approximately 24 volts or less.
11. A modular transfer system comprising:
a main belt comprising an upper surface, a lower surface, and a plurality of spherical balls, the spherical balls having an upper portion that protrudes above the upper surface and a lower portion that protrudes below the lower surface, the spherical balls configured to rotate relative to the upper and lower surfaces, the main belt configured to travel in a first direction;
a diverter belt configured to travel in a second direction that is generally perpendicular to the first direction, the diverter belt in contact with the protruding lower portion of the spherical balls such that relative movement of the main and diverter belts causes the spherical balls to rotate; and
a motorized drive roller configured to drive the main belt in the first direction, motorized drive roller comprising:
a longitudinal axis;
a radially outer surface comprising a plurality of engagement regions that are configured to engage with the lower surface of the main belt to provide frictional driving force on the main belt,
a plurality of semi-circular recesses that are configured to accommodate the lower portion of a respective one of the spherical balls, the semi-circular recesses being longitudinally spaced apart in a direction parallel to the longitudinal axis, wherein longitudinally neighboring semi-circular recesses are spaced apart by at least one of the engagement regions.
12. The modular transfer system of claim 11 , wherein the motorized drive roller has a circular cross-sectional shape.
13. The modular transfer system of claim 11 , wherein the recesses are annular.
14. The modular transfer system of claim 11 , wherein, from a perspective parallel to the longitudinal axis, the motorized drive roller is circular in shape.
15. The modular transfer system of claim 11 , wherein each of the engagement regions have the same outside diameter.
16. The modular transfer system of claim 11 , wherein the motorized drive roller does not comprise a sprocket.
17. The modular transfer system of claim 11 , wherein the motorized drive roller comprises a plastic base and a rubber coating.
18. The modular transfer system of claim 11 , wherein the radially outer surface of the motorized drive roller further comprises a urethane coating.
19. The modular transfer system of claim 11 , wherein the balls are longitudinally spaced apart by less than or equal to about 1 inch center-to-center.
20. The modular transfer system of claim 11 , wherein the modular transfer system operates at electric voltages of approximately 24 volts or less.