Abstract: A sideband communication system has been developed for a conveyor system. A controller card controls the operation of a conveyor zone and communicates information about each conveyor in the conveyor zone. The controller card is assigned to control and monitor the operation of one or more of these zones of conveyors. The cards of adjacent zones are daisy-chained together to facilitate communication with one another and with other systems like a programmable logic controller (PLC). In addition to the standard controller area network (CAN) communication protocol, the controller cards further communicate amongst themselves using a sideband communication protocol that is outside the realm of the standard CAN communication protocol. The sideband communication protocol allows the cards to communicate with each other without interfering with normal network communications which provides additional capabilities such as automatic card self-identification.

Abstract: A roller detection system has been developed in which a controller card is configured to automatically detect the type of motorized drive roller being used in the conveyor system. With this automatic detection capability, the controller card is able to automatically control the motorized drive roller without the need for manual reprogramming or reconfiguration. For instance, the controller card can detect whether the motorized drive roller is controlled through an analog or digital signal as well as the voltage required to control or power the motorized drive roller, and based on this roller type detection, the controller card is automatically configured to control the motorized drive roller. The system is further adapted to facilitate a sensor-less or photoeye-less zero pressure (ZP) conveyor system. The controller card is configured to support a secondary power source that allows the motorized drive roller settings during e-stop and other power loss conditions.

Abstract: A data analytics system has been developed for conveyor systems that helps to monitor items along conveyors as well as assist in monitoring the status or health of equipment of the conveyor. Tracking items in conveying systems within a facility can be difficult. Conveyed items can become jammed, lost, or even fall off the conveyor. Based on input from motors and sensors along the conveyor, the data analytics system is able to detect lost or jammed items. With input from the sensors, the data analytics system is also configured to detect equipment wear and damage. The data analytic system further aggregates data from the various conveyor systems to generate statistics as well as other information that can be used for modeling and simulating the conveyor system. The aggregate data can be used to generate measures such as travel efficiency analytics for reporting purposes.

Abstract: A robotic shuttle system includes a rack system and one or more shuttles. The rack system includes a rack and a shuttle frame. The rack has storage locations for containers containing items. The shuttle frame has rails disposed along the rack. The shuttle includes a powertrain, container transfer mechanism, and a robot arm. The power train is configured to move the shuttle along the rails of the rack and on a surface outside of the rack system. The container transfer mechanism is configured to transfer the containers between the rack and the shuttle. The robot arm extends from the shuttle to transfer the items between one of the containers on the shuttle and a container in a container holder of the shuttle.

Abstract: A photoelectric sensor system includes a photoelectric sensor and a retroreflector that is positioned to reflect light emitted by the photoelectric sensor. The photoelectric sensor includes a polarized light source that emits p-polarized light. The photoelectric sensor further includes a Brewster polarizer that is oriented at a Brewster's angle to further polarize the emitted light. The emitted light beam emitted by the photoelectric sensor is reflected off the retroreflector and polarized ninety degrees by the retroreflector to have s-polarization. The reflected light beam is reflected off the Brewster polarizer to a laterally offset light detector.

Abstract: A material handling system includes storage rack configured to store one or more items. An Autonomous Mobile Unit (AMU) is configured to move within the storage rack to service the items. The storage rack includes at least one power rail to charge the AMU when within the storage rack. The AMU includes a wheel assembly with a cogwheel electrically connected to the power rail. The AMU includes a power supply electrically connected to the wheel assembly. The power supply includes a power converter electrically coupled to an Energy Storage System (ESS). The power rail includes a cog track with track teeth. The cogwheel includes cogwheel teeth intermeshed with the track teeth.

Abstract: A material handling system includes storage rack configured to store one or more items. An Autonomous Mobile Unit (AMU) is configured to move within the storage rack to service the items. The storage rack includes at least one power rail to charge the AMU when within the storage rack. The AMU includes a wheel assembly with a cogwheel electrically connected to the power rail. The AMU includes a power supply electrically connected to the wheel assembly. The power supply includes a power converter electrically coupled to an Energy Storage System (ESS). The power rail includes a cog track with track teeth. The cogwheel includes cogwheel teeth intermeshed with the track teeth.