Abstract: An article turner assembly for use with an article handling system such as a palletizer. The article turner assembly selectively turns articles conveyed in a single lane along a particular path so that each article may be turned or not as it is conveyed along that path. The article turner assembly includes a conveyor mechanism, an article turner, and a selector mechanism that acts on either the article turner itself, the conveyed articles, or both. The article turner is designed so that articles are turned without impact against their front or side surfaces or a reduction in their speed. The article turner includes two or more adjacent conveyors, which are run with a speed differential to turn articles. The orientation of and spacing between the conveyors can be adjusted to accommodate articles of different sizes and/or weights. The article turner assembly is well-suited for use with high speed palletizers because it can help form patterns of virtually any desired configuration at very high speeds.

Abstract: A pre-fabricated monorail track section (104, 105) can be bent vertically quickly and easily, without using any special tools, so as to effect any of a number of desired incremental inclination changes in the rail section (104, 105) and without plastically deforming the rail section (104, 105). The rail section (104, 105) incorporates one or more slots 242 about which the rail can be bent to effect the desired inclination change. A filler block (248, 306, 314) is positioned in the slot (242) after bending (and possibly during bending under some circumstances) and mounted in place to maintain rail integrity and to permit conveyance devices to travel over the rail section without interference from the slots (242).

Abstract: A palletizer/depalletizer system includes a palletizer assembly and depalletizer assembly stacked one beneath the other on a common frame assembly. Both assemblies are adapted to handle layers of articles and stacks of pallets. The palletizer loads articles on stacks of empty pallets by transferring layers of articles one at a time onto the uppermost pallet until the pallet is fully loaded, conveying the loaded pallet away from the system using a conventional automated storage and retrieval (ASR) machine, and then loading the next pallet on the stack. The depalletizer creates stacks of empty pallets by repeatedly unloading layers of articles from a pallet to empty the pallet and then accepting a loaded pallet on top of the recently-emptied pallet.

Abstract: A diverter is capable of selectively and alternatively operating in an in-line mode in which it conveys articles along a primary conveyor and in a diverting mode in which it swivels and pops-up to smoothly ramp articles vertically from the primary conveyor and to divert the articles at an angle from the primary conveyor and onto a secondary conveyor or the like. In addition to popping-up and swiveling, the diverter helps to turn the diverted article onto the secondary conveyor by conveying one side of the article faster than the other side. The diverter includes a plurality of laterally spaced diverter wheel assemblies each of which can be swiveled from an in-line orientation to a skewed orientation.

Abstract: An automated order picking system assembled from known, available components and that includes a manager computer to receive orders for goods from a customer and to break the order down into requested full pallets of multiple ordered layers of goods; layers of goods ordered by the customer; compatible ordered layers of goods that can be combined into full pallets; and compatible cases of ordered goods that can be formed into layers and into full pallets of multiple layers of goods; and vertical cells for receiving, storing and delivering cases of the goods. The vertical cells comprise towers having mutually facing tower sections that receive goods delivered to feed conveyors by gantry robots having end effectors capable of handling the goods and the tower sections passing the goods back and forth as the goods are moved downwardly for placement on the discharge conveyor under the control of a programmable logic computer.

Abstract: A zero-pressure accumulating conveyor including a bed defined by rotatable rollers mounted in parallel sidewalls and powered by an endless drive chain. Pneumatic actuators lift the drive chain into engagement with the rollers to empower same. Sensor rollers divide the bed into distinct zones. Sensor rollers are retained in operative position relative to the conveyor bed by unique sensor brackets. A primary sensor roller bracket includes a bore with a piston movable there within; the cooperating secondary sensor roller bracket is spring biased in a first direction. Valves, and pneumatic circuitry controlled by such valves, extend along the length of the conveyor. Such valves are operated by the primary sensor roller brackets to regulate the flow of air pressure into the bores of the brackets and into the actuators. The actuators, when the pressure therein is bled-off, allow the chain in a particular zone to drop out of contact with the rotatable rollers.

Abstract: An automated guided vehicle for carrying a load comprises a mast, a lift carriage, a ball screw drive assembly and a ball screw joint. The ball screw drive assembly has a lift nut and a vertically oriented ball screw. The ball screw joint operatively couples the drive assembly to the lift carriage so as to transmit upward vertical forces from the drive assembly to the lift carriage. The ball screw joint includes first, second, third and fourth shafts which permit the lift nut to move in any horizontal direction and to pivot about any horizontal axis with respect to the lift carriage. As a result, the ball screw joint advantageously prevents the transmission of horizontal forces and angular moments between the ball screw and the lift nut, thereby reducing the wearing out effects of component misalignment on the ball screw assembly.

Abstract: The mounting for a roller shaft in the frame of a conveyor is designed to reduce the vibration of the shaft and the sound produced during conveyor operation. In several embodiments, the end of the shaft is provided with a taper, and a spring which is internal to the roller is used to bias the taper into the mounting hole. The resulting tight fit of the taper in the hole greatly reduces the vibration energy of the shaft. In another embodiment, a bushing separates the shaft and the hole and is designed to grip the shaft as it is pressed into place in the hole.

Abstract: A palletizer has an improved slide plate assembly and an improved indexing hoist. The slide plate assembly incorporates measures to reduce friction between it and the bags or other articles being handled by it. The orientation of the slide plates of the assembly are altered ninety degrees with respect to traditional slide plate orientation to eliminate the deadplate encountered by articles sliding along the slide plates. An air assist mechanism also is incorporated into the slide plate assembly to produce an air cushion between the articles and the top surface of the slide plates. The hoist, which is designed to index upwardly after receiving a layer of articles to compress that layer against the bottom surface of the slide plate assembly to flatten the articles and to force air out of them, incorporates an improved controller that causes the hoist to assuredly impart the desired compressive force to the articles without over-compressing the articles or overloading the hoist's lift motor.

Abstract: A storage and retrieval machine has a telescopically extendible shuttle assembly which includes a plurality of linearly movable plates and a plurality of shuttle guide roller assemblies which accommodate non-linearities in the guide surface and other variations in clearance between the shuttle guide rollers and the corresponding guide surfaces of the shuttle assembly. Each shuttle guide roller assembly includes a spring, preferably a die spring, which biases the guide roller towards the guide surface but which permits limited deflection of the roller when it encounters bows, bumps, or other variations in linearity in the guide surface. The pre-tensioned guide rollers provide wear compensation, center the shuttle plates on their tracks, and assure adequate guidance of the shuttle plates during shuttle telescoping while preventing premature wear of the shuttle guide roller bearings and/or the guide surfaces.

Abstract: An event-driven control system controls movement of a base and carriage of a storage and retrieval machine. The control system is microprocessor-based and includes a motion controller, a machine control task, an input/output interface, an input/output task, and a microprocessor that executes the machine control task and the input/output task. In operation, a plurality of interrupts is issued to the machine control task in response to events which occur in an operating environment of the storage and retrieval machine. To respond to the interrupts, at least one subroutine in response to the reception of each interrupt. The execution of the subroutines controls movement of the base and the carriage of the storage and retrieval machine. Movement of the base and the carriage of the storage and retrieval machine (1) is substantially entirely controlled by issuing and responding to the interrupts as different events occur in the operating environment that cause the interrupts to be issued.

Abstract: A monorail vehicle used for material handling purposes comprises a number of cars which run on a track. The cars are linked together in one or more trains and each train has a master car and several slave cars. An embedded computer in the master car keeps track of the location on the train on the track by means of pulses from a Hall effect sensor in a brushless DC motor which powers the train. A central computer in an off board work station issues commands to the train and by monitoring its position on the track loop, the embedded computer in the master car of the train determines when to execute the command. A special jumper is used to connect the cars of the train together which distributes control signals to the various cars in the train without regard to the position of the cars in the train.

Abstract: A communication system for a storage and retrieval machine comprises a conductor bar, base and carriage electrical devices, a sliding brush, first and second transmitters, and first and second receivers. The sliding brush is mounted to the carriage and is in slidable electrical contact with the conductor bar. The transmitters and receivers are coupled to the conductor bar or the sliding brush, depending on the direction of transmission. The first and second transmitters transmit positive half-waves and negative half-waves, respectively, across the conductor bar in response to inputs. Hence, two one-bit intra SRM communication links are provided between the SRM carriage and base. A communication system for communicating high priority and low priority messages between a base and carriage of an SRM comprises base and carriage electrical devices, and first and second communication links.

Abstract: A storage and retrieval machine has a telescopically extendible shuttle assembly and having spring tensioned shuttle idler pulleys for the slave drive members, preferably chains, of the shuttle assembly. A spring, preferably a die spring, exerts a biasing force on each idler pulley which opposes forces imposed on the idler pulley by the corresponding slave chain. Pre-tensioning the idler pulley in this manner assures adequate tension on the slave chain to prevent or at least inhibit undulations in plate movement which otherwise could occur during telescopic extension and retraction of the shuttle assembly if the slave chain were inadequately tensioned. Use of the spring loaded idler pulley also obviates the need to over-tension the slave chain and prevents or inhibits premature wear and failure of the idler pulley, pulley bearing, and/or chain.

Abstract: A storage and retrieval machine comprises a base, a carriage, and a control system. The control system is used to control the movement of the carriage in the vertical direction and/or the movement of the base in the horizontal direction. The control system includes at least one encoder and at least one optical distance meter. The encoder provides relative position information during a middle portion of the SRM trajectory, i.e., during the implementation of a feedback control scheme. The optical distance meter provides absolute position information to the control system at an endpoint of the SRM trajectory, i.e., to verify that the SRM has in fact reached its destination. If the control system controls both the movement of the carriage and the movement of the base, then two encoders and two optical distance meters are used.

Abstract: A slat sorter having a series of platens slidably mounted on an array of slats driven by an endless chain with each platen having a diverter pin for enabling it to be diverted between a straight-through track and at least one divert track. A switch having an elongated arm having a pivot end and a tip opposite and upstream the pivot end which is urged by a prime mover, that preferably is a limited angle torque electric motor, between a straight-through position directing a diverter pin to travel along the straight-through track and a divert position directing the diverter pin to travel along the divert track. The arm has a cutout which allows the arm to be urged from one position to the another position before the diverter pin is completely downstream and cleared of the arm. Operably associated with the arm is a brake for enabling the arm to be urged toward either the straight-through or divert position by an oncoming divert pin to prevent the divert pin from colliding head-on with the arm.

Abstract: An automated order picking system assembled from known, available components and that includes a manager computer to receive orders for goods from a customer and to break the order down into requested full pallets of multiple ordered layers of goods; layers of goods ordered by the customer; compatible ordered layers of goods that can be combined into full pallets; and compatible cases of ordered goods that can be formed into layers and into full pallets of multiple layers of goods; and vertical cells for receiving, storing and delivering cases of the goods. The vertical cells comprise towers having mutually facing tower sections that receive goods delivered to feed conveyors by gantry robots having end effectors capable of handling the goods and the tower sections passing the goods back and forth as the goods are moved downwardly for placement on the discharge conveyor under the control of a programmable logic computer.

Abstract: An apparatus for optimizing the gap between objects on a roller conveyor is provide which enables independent precise speed and acceleration control of individual rollers and articles carried thereon using small, relatively inexpensive motors and control equipment. The present invention consists of adding a differential drive to the roller, arranged so that the majority of the power is transmitted from a common drive through a low ratio input of the differential drive of each roller. A smaller motor capable of more precise control is connected to the high ratio input of the differential drive of each roller. Thus the speed of an individual roller can be altered by adding to or subtracting from the speed of the main drive.

Abstract: An apparatus for packaging and wrapping a load, and a method for using the same, having an infeed conveyor for receiving bundles from an assembly or production line, positioning conveyors located downstream of the infeed conveyor for arranging the bundles into load layers, and stripper plates downstream of the positioning conveyor for receiving and discharging the load layers. A pair of lifts are located below the stripper plates for raising and lowering a pallet. The second lift is mounted on the first lift, so that the two lifts combine to raise a pallet to receive successive load layers from the stripper plates. A wrap ring including a film dispenser is mounted below the stripper plates, so that the dispenser may orbit and dispense a plastic film material about the load. The second lift raises the pallet above the first lift to position the load adjacent the dispenser for wrapping. Guide plates are mounted above the wrap ring to stabilize the load prior to wrapping.

Abstract: A method of mapping a warehouse rack structure having a plurality of racks comprises the steps of creating a logical matrix and updating the logical matrix. The updating step further includes the steps of causing a moveable device to travel to a first one of the plurality of racks, and producing a first machine-readable distance measurement output. The machine-readable distance measurement output is produced using a first sensor and represents a distance between the first sensor and a first position on the warehouse rack structure. A system for mapping a warehouse rack structure comprises a storage and retrieval machine; a rack structure; a logical matrix; and a computer. The storage and retrieval machine has first and second ultrasonic sensors mounted thereon. The rack structure includes a plurality of racks. The logical matrix stores horizontal position information and vertical position information for each of the plurality of racks.