Abstract: A mixed article sortation system and method of sorting the bulk flow of mixed articles being of various sizes and shapes to separate destinations includes at least two bulk flow singulators, each configured to receive a bulk flow of mixed articles and arrange the articles to respective first and second single-file flows. A first article induct arranges the first flow of articles from one of the singulators to a first flow of gapped articles and a first article sensor senses the identity and weight of each article. A second article induct arranges the single-file flow of articles from the other singulator to a second flow of gapped articles and a second article sensor senses the identity and weight of each article in said second single-file flow. A combiner combines the first and second single-file flow of articles into a third single-file flow of articles. A sorter receives the third single-file flow of mixed articles and sorts the articles to separate destinations.

Abstract: A conveyor assembly comprising a main conveyor having a first side frame and a second side frame, with the first and/or second side frames including a side portion and a support surface. One or more input conveyors having a discharge end are joined to the main conveyor with a bottom portion of the discharge end being positioned on the support surface whereby the input conveyors are accurately mounted in close proximity to the main conveyor to promote the conveyance of items from the input conveyors onto the main conveyor.

Abstract: A mixed article sortation system and method of sorting the bulk flow of mixed articles being of various sizes and shapes to separate destinations includes at least two bulk flow singulators, each configured to receive a bulk flow of mixed articles and arrange the articles to respective first and second single-file flows. A first article induct arranges the first flow of articles from one of the singulators to a first flow of gapped articles and a first article sensor senses the identity and weight of each article. A second article induct arranges the single-file flow of articles from the other singulator to a second flow of gapped articles and a second article sensor senses the identity and weight of each article in said second single-file flow. A combiner combines the first and second single-file flow of articles into a third single-file flow of articles. A sorter receives the third single-file flow of mixed articles and sorts the articles to separate destinations.

Abstract: A conveyor assembly comprising a main conveyor having a first side frame and a second side frame, with the first and/or second side frames including a side portion and a support surface. One or more input conveyors having a discharge end are joined to the main conveyor with a bottom portion of the discharge end being positioned on the support surface whereby the input conveyors are accurately mounted in close proximity to the main conveyor to promote the conveyance of items from the input conveyors onto the main conveyor.

Abstract: A conveyor underguard that is adapted for use with a conveyor having a pair of spaced apart side channels, each having a lower flange and a plurality of openings on each flange, includes a guard surface and a pair of mounting members, each extending outwardly generally parallel to the guard surface and defining fastener openings. The fastener openings are spaced apart in a manner that aligns with the through-openings of the conveyor. A pair of side members connect the guard surface with the mounting members in a manner that offsets the guard surface from the mounting members away from each flange. The conveyor underguard is defined by a polymeric material body having a planar body pan integrally connected to opposed first and second side walls and to first and second end walls. A first side flange is integrally connected to the first side wall and extends for an entire length of the first side wall.

Abstract: A conveyor underguard that is adapted for use with a conveyor having a pair of spaced apart side channels, each having a lower flange and a plurality of openings on each flange, includes a guard surface and a pair of mounting members, each extending outwardly generally parallel to the guard surface and defining fastener openings. The fastener openings are spaced apart in a manner that aligns with the through-openings of the conveyor. A pair of side members connect the guard surface with the mounting members in a manner that offsets the guard surface from the mounting members away from each flange. The conveyor underguard is defined by a polymeric material body having a planar body pan integrally connected to opposed first and second side walls and to first and second end walls. A first side flange is integrally connected to the first side wall and extends for an entire length of the first side wall.

Abstract: A conveyor system includes a transport member having a conveying surface that is configured to transport articles in a transport direction, an endless strip and a drive for propelling the endless strip. A power tap off is provided between the strip and the transport member. The power tap off has an input that is driven by the strip and an output that drives the transport member. The power tap off provides a positive transfer of power from the strip to the transport member.

Abstract: A conveying system may include a frame that supports a plurality of rollers which carry articles thereon. At least one of the rollers may be a motorized roller with first and second motors adapted to rotate an outer cylindrical shell of the motorized roller. A controller external to the motorized roller may send speed control commands to the motorized roller to control both the first and second motors in a manner that increases torque of the motorized roller. The motors may be controlled in four quadrant mode, or two quadrant mode, or a combination thereof. The motorized roller may be used in a right angle transfer mechanism, or in other components of a conveying system.

Abstract: A method of replacing a continuous belt on a belt conveyor having a frame assembly includes providing a removable belt module with a removable belt module frame, the removable belt module frame having at one end a rotatably mounted drive pulley and having at an opposite end a rotatably mounted other pulley. The continuous belt is reeved around the drive pulley and the other pulley. The removable belt module is removed from at least one attachment surface of the frame assembly while the continuous belt remains under tension. A replacement removable belt module is then placed at the attachment surface. Optionally, the continuous belt has a low modulus characteristic, and the removable belt module may include at least one pivot arm for mounting at least one of the drive pulley and the other pulley to the removable belt module frame.

Abstract: An article singulating conveyor assembly and method of singulating articles includes providing a conveying surface defining a plurality of tandem zones. The conveying surface travels in a longitudinal direction. Each of the zones includes a pair of laterally spaced side frame members and a plurality of generally parallel elongated driven rollers that are supported at the side frame members. The driven rollers are adapted to provide lateral variation in the longitudinal speed of the conveying surface. Each of the zones includes at least one drive motor that is adapted to drive the driven rollers in that zone. At least one article sensor is provided that is adapted to sensing articles in the zones. The driven rollers may be divided into a plurality of segmented rollers that are separately rotatable with a separate drive motor to drive corresponding segments for a zone. The drive motors for adjacent zones may be activated in a manner that creates a longitudinal gap between longitudinally adjacent articles.

Abstract: A conveyor system includes a transport member having a conveying surface that is configured to transport articles in a transport direction, an endless strip and a drive for propelling the endless strip. A power tap off is provided between the strip and the transport member. The power tap off has an input that is driven by the strip and an output that drives the transport member. The power tap off provides a positive transfer of power from the strip to the transport member.

Abstract: An article singulating conveyor assembly and method of singulating articles includes providing a conveying surface defining a plurality of tandem zones. The conveying surface travels in a longitudinal direction. Each of the zones includes a pair of laterally spaced side frame members and a plurality of generally parallel elongated driven rollers that are supported at the side frame members. The driven rollers are adapted to provide lateral variation in the longitudinal speed of the conveying surface. Each of the zones includes at least one drive motor that is adapted to drive the driven rollers in that zone. At least one article sensor is provided that is adapted to sensing articles in the zones. The driven rollers may be divided into a plurality of segmented rollers that are separately rotatable with a separate drive motor to drive corresponding segments for a zone. The drive motors for adjacent zones may be activated in a manner that creates a longitudinal gap between longitudinally adjacent articles.

Abstract: An article singulating conveyor assembly and method of singulating articles includes providing a conveying surface defining a plurality of tandem zones. The conveying surface travels in a longitudinal direction. Each of the zones includes a pair of laterally spaced side frame members and a plurality of generally parallel elongated driven rollers that are supported at the side frame members. The driven rollers are adapted to provide lateral variation in the longitudinal speed of the conveying surface. Each of the zones includes at least one drive motor that is adapted to drive the driven rollers in that zone. At least one article sensor is provided that is adapted to sensing articles in the zones. The driven rollers may be divided into a plurality of segmented rollers that are separately rotatable with a separate drive motor to drive corresponding segments for a zone. The drive motors for adjacent zones may be activated in a manner that creates a longitudinal gap between longitudinally adjacent articles.

Abstract: A belt conveyor includes at least one belt module defined by at least one drive pulley and at least one other pulley that is generally an idler pulley positioned between opposite sidewalls of the conveyor, and having a continuous belt routed around the drive pulley and the other pulley. The drive pulley is operable to drive the continuous belt around the pulleys to move articles along the zone assembly. The belt conveyor may incorporate features that allow for improved maintenance methods and reduced down time during service intervals. These features may include a removable belt module, at least one pulley mounted on at least one pivot arm, or a combination thereof. The belt may have a low modulus characteristic and may be initially stretched when the belt is reeved or routed around the pulleys and the pivot arms are moved into their operating position.

Abstract: A method of replacing a continuous belt on a belt conveyor having a frame assembly includes providing a removable belt module with a removable belt module frame, the removable belt module frame having at one end a rotatably mounted drive pulley and having at an opposite end a rotatably mounted other pulley. The continuous belt is reeved around the drive pulley and the other pulley. The removable belt module is removed from at least one attachment surface of the frame assembly while the continuous belt remains under tension. A replacement removable belt module is then placed at the attachment surface. Optionally, the continuous belt has a low modulus characteristic, and the removable belt module may include at least one pivot arm for mounting at least one of the drive pulley and the other pulley to the removable belt module frame.

Abstract: A diverter assembly for a positive displacement sorter apparatus having a plurality of interconnected slats that define a conveying surface adapted to convey articles in a longitudinal direction and having a plurality of pusher shoes adapted to move along at least one of the plurality of slats to laterally displace articles on the conveying surface. The diverter assembly includes a diverting track extending diagonally under the conveying surface and an actuator is provided for selectively diverting at least one of the pusher shoes toward the diverting track. A diverter nose is adapted to guide the pusher shoe to the diverting track when diverted by the actuator or to guide the pusher shoe away from said diverting track when not diverted by said actuator. At least a portion of said diverter nose is adapted to move laterally and longitudinally when struck generally head-on by a portion of a pusher shoe.

Abstract: A conveying system may include a frame that supports a plurality of rollers which carry articles thereon. At least one of the rollers may be a motorized roller with first and second motors adapted to rotate an outer cylindrical shell of the motorized roller. A controller external to the motorized roller may send speed control commands to the motorized roller to control both the first and second motors in a manner that increases torque of the motorized roller. The motors may be controlled in four quadrant mode, or two quadrant mode, or a combination thereof. The motorized roller may be used in a right angle transfer mechanism, or in other components of a conveying system.

Abstract: A diverter assembly for a positive displacement sorter apparatus having a plurality of interconnected slats that define a conveying surface adapted to convey articles in a longitudinal direction and having a plurality of pusher shoes adapted to move along at least one of the plurality of slats to laterally displace articles on the conveying surface. The diverter assembly includes a diverting track extending diagonally under the conveying surface and an actuator is provided for selectively diverting at least one of the pusher shoes toward the diverting track. A diverter nose is adapted to guide the pusher shoe to the diverting track when diverted by the actuator or to guide the pusher shoe away from said diverting track when not diverted by said actuator. At least a portion of said diverter nose is adapted to move laterally and longitudinally when struck generally head-on by a portion of a pusher shoe.

Abstract: An article singulating conveyor assembly and method of singulating articles includes providing a conveying surface defining a plurality of tandem zones. The conveying surface travels in a longitudinal direction. Each of the zones includes a pair of laterally spaced side frame members and a plurality of generally parallel elongated driven rollers that are supported at the side frame members. The driven rollers are adapted to provide lateral variation in the longitudinal speed of the conveying surface. Each of the zones includes at least one drive motor that is adapted to drive the driven rollers in that zone. At least one article sensor is provided that is adapted to sensing articles in the zones. The driven rollers may be divided into a plurality of segmented rollers that are separately rotatable with a separate drive motor to drive corresponding segments for a zone. The drive motors for adjacent zones may be activated in a manner that creates a longitudinal gap between longitudinally adjacent articles.

Abstract: A belt conveyor includes at least one belt module defined by at least one drive pulley and at least one other pulley that is generally an idler pulley positioned between opposite sidewalls of the conveyor, and having a continuous belt routed around the drive pulley and the other pulley. The drive pulley is operable to drive the continuous belt around the pulleys to move articles along the zone assembly. The belt conveyor may incorporate features that allow for improved maintenance methods and reduced down time during service intervals. These features may include a removable belt module, at least one pulley mounted on at least one pivot arm, or a combination thereof. The belt may have a low modulus characteristic and may be initially stretched when the belt is reeved or routed around the pulleys and the pivot arms are moved into their operating position.