Abstract: An automatic tray handling system for use with an article or mail sortation system, such as a flats mail sortation system, is operable to automatically remove filled or partially filled trays from individual sorter units and to replenish the sorter units with empty trays. The empty trays and/or filled trays are moved along at least one conveying surface adjacent to the sorter units. The automatic tray handling system includes a plurality of tray moving devices, which are operable to move the empty trays from the conveying surface to the sorter units, whereby the trays are at least partially filled by the sorter units. The tray moving devices are then further operable to move the at least partially filled trays from the sorter units to a conveying surface, whereby the filled trays may be conveyed to downstream operations, such as an automatic labeling station. Preferably, the empty trays are movable in a continuous loop about the mail sortation system.

Abstract: A feed system that is adapted for feeding articles to a sortation system includes at least one feed conveyor upstream of the sortation system feeding articles to the sortation system. The feed conveyor includes a plurality of side rails extending from an initial portion of the feed conveyor to a terminal portion thereof. The side rails are spaced apart a substantially constant distance from the initial portion to the terminal portion to provide a footprint that is substantially the footprint of a transport conveyor. A conveying surface is provided between the side rails. The conveying surface includes at least one article-transporting portion and at least one article-unscrambling portion. The portions are in tandem. The unscrambling portion is made up of a plurality of tapered rollers mounted between the side rails.

Abstract: A roller conveyor belt driver system for a roller conveyor includes a closed loop belt having a continuous driving surface and a non-circular base and a plurality of pulleys which support and engage said non-circular base for at least partially laterally restraining the belt from rotation. A first group of pulleys are constructed and arranged to position the belt in non-orthogonal orientation with respect to the rollers of the conveyor for contacting one or more rollers with the driving surface of the belt. Optionally, the belt driver system includes a lateral restraint associated with a respective pulley of the first group of pulleys to urge the belt to remain engaged with the respective pulley to prevent twisting of the belt and, therefore, increase the life of the belt. For example, the lateral restraint may comprise a bearing which is positioned adjacent the respective pulley and which contacts the belt to maintain the belt in proper orientation in the pulley.

Abstract: A transfer assembly for positioning between conveyor sections and for transferring at least one article laterally with respect to the conveying surface defined by the conveyor sections in a direction angled to the conveying direction of the conveying surface includes at least two conveying devices, which define a conveying surface for at least generally aligning with the conveying surface of the conveyor sections, and a sheave assembly. The sheave assembly includes a support member and a reinforced transfer belt having a belt length and defining a transfer surface. At least two transfer sheaves are mounted to the support member with the transfer sheaves supporting the transfer belt. The support member is adapted to move the transfer belt between a non-transferring position wherein the transfer surface is below the conveying surface of the conveying devices and a transferring position wherein the transfer surface is raised above the conveying surface of the conveying devices.

Abstract: A gravity conveyor includes one or more zones with each zone having at least one brake associated therewith. A controller turns the brakes on for each zone according to various programmable conditions. The downstream-most zone may have its brakes turned on whenever a package is present at the end of the conveyor. Any of the zones may have their brakes turned on in a pulsed manner. The zones may also have their brakes turned on in other situations, such as simultaneous blockage of that zone with another zone, the initial sensing of the leading edge of an article, as well as in other situations.

Abstract: A conveyor induct system includes a control point subsystem for measuring the point at which control of an article transitions from one conveyor to another. The induct system also includes a subsystem for accurately creating or controlling the gaps between articles on the conveyor system. The control point subsystem monitors the location, and changes in the speed, of an article as it passes between two conveyors operating at different speeds. The gap control subsystem provides real time monitoring and measuring of the package gaps. The measured package gaps are fed into a feedback control system which alters the speed of a conveyor in order to change the gapping as desired.

Abstract: A singulator is disclosed for singulating the flow of articles in a conveyor system. The singulator includes a mechanism for actuating a portion of a conveyor to remove one item at a time from the conveyor end. A control system singulates items by selectively actuating portions on the conveyor underlying the items and extending toward the end of the conveyor. After one item has been singulated, another item is singulated when a gap between the trailing edge of the first item and a leading edge of the second hem reaches a predetermined size. This process repeats itself for singulating more articles.

Abstract: A lift assembly for raising and lowering a load includes a first member, which is adapted for resting on a reference surface, and a second member, which defines a support surface for supporting a load. The lift assembly also includes a drive assembly, which selectively moves the second member relative to the first member from an initial position to a final position to raise or lower the second member relative to the first member. The drive assembly is adapted to move the second member from the initial position at a progressively increasing speed to an intermediate position and after which at a progressively decreasing speed until the second member is moved to the final position.

Abstract: A compact article singulation and accumulation conveyor includes a receiving portion which receives articles in random order including clusters of side-by-side articles and a discharge portion from which articles are discharged in a single file singulated stream. A first conveying surface transports articles longitudinally from the receiving portion to the discharge portion. A recirculating bed removes side-by-side articles from a downstream portion of the first conveying surface to an upstream portion of the first conveying surface. The recirculating bed is made up of at least one peel-away conveyor having a second conveying surface adapted to move side-by-side articles laterally off the first conveying surface, at least one coupling conveyor having a third conveying surface adapted to move articles from the second conveying surface upstream and at least one return conveyor having a fourth conveying surface adapted to move articles from the third conveying surface to the first conveying surface.

Abstract: A bolt-together powered belt conveyor assembly includes adjustable tail assemblies which facilitate adjustment of the overall length of the conveyor, while positively securing the position of the end rollers relative to the conveyor sections. The conveyor assembly further includes an adjustable nose-over assembly, which is adjustable to accommodate a change in angle between adjacent conveyor sections. The conveyor assembly further includes a drive assembly which is connectable between end assemblies or slider bed conveyor sections and which is adapted to be installed on a horizontal, inclined or declined conveyor section. The position of the rollers, length of the conveyor sections and angle of incline of the conveyor section may be easily adjusted via adjustment of one or more fasteners of the conveyor assembly, thereby avoiding the need of welding various components of the conveyor assembly together.

Abstract: A positive displacement sorter, preferably of the parallel displacement type, includes a conveying surface, a plurality of pusher shoes capable of travelling laterally of the conveying surface, a plurality of diverting rails extending diagonally under the conveying surface and a plurality of electromagnetic actuators associated with the diverting rails. The pusher shoes include a transfer assembly below the conveying surface including a pilot member made of a magnetically permeable material. A pusher shoe is diverted to one of the diverting rails by the actuator associated with the diverting rail magnetically attracting the pilot member associated with that pusher shoe to magnetically initiate a divert. The transfer member associated with the pusher shoe mechanically completes the divert that is initiated magnetically. This allows actuators to be positioned at a pitch that is no greater than the shoe pitch.

Abstract: An article separation conveyor system includes a plurality of conveyors which are independently and/or collectively operable to destack, separate and/or align articles being conveyed along the article separation conveyor. The conveyor system includes a destacking conveyor, a side by side eliminating conveyor and/or an aligning conveyor. The destacking conveyor includes a plurality of conveying portions, which are inclined to convey articles up and then drop or guide them onto the next adjacent conveyor. The side-by-side eliminating conveyor includes a pair of diverting members and is operable to redirect articles from one side of the conveyor to the other to destack and separate articles as they are continuously conveyed along the conveyor. The aligning conveyor is operable to align articles along one side of the discharge conveyor so the articles are arranged for identification at a downstream scanning device and induction onto a sortation system.

Abstract: A diverter assembly according to the present invention includes a generally horizontal conveying surface, a pair of flipper assemblies, and an actuator for substantially concurrently actuating the flipper assemblies to an actuated position whereby the flipper assemblies are collinear. A driven diverting surface is defined on each flipper assembly wherein an article on the conveying surface is diverted when the article contacts one of the flipper assemblies when the flipper assembly is in its actuated position.

Abstract: A sortation system and method of inducting product are useful with a sorter having a continuous member defining a plurality of transport positions of the continuous member and a plurality of sort destinations for receiving product discharged from the continuous member. At least one induction unit is provided including a plurality of tandem conveying units. Product is received with the at least one induction unit from a product source and discharged from the at least one induction unit to the continuous member. According to one aspect of the invention, the at least one induction unit follows the speed of the continuous member. This includes starting as soon as the continuous member is moving and decreasing in speed substantially only when the continuous member decreases in speed. The invention is useful with linear sorters, such as positive displacement sorters, and the like. The invention is also useful with carousel sorters, such as tilt-tray sorters and cross-belt sorters.

Abstract: A load carrier for supporting, raising or lowering a load includes a frame member, a telescoping mast, and a support frame. The frame member is adapted for being movably supported by a rail. The telescoping mast is supported by the frame member, with the support frame supported by the telescoping mast. The telescoping mast includes at least one fixed mast section and at least one movable mast section, with the support frame being coupled to the movable mast section. The movable mast section is supported for movement between a plurality of extended positions in which the support frame is lowered and raised with respect to the frame member and the fixed mast section with the movable mast section being guided by the fixed mast section when the movable mast section is moved to its extended position. The driver selectively moves the movable mast section to its extended position and includes at least one cord for raising and lowering the movable mast section.

Abstract: An outer extendable boom or extension is implemented on an extendable conveyor of conventional design, which includes at least two extendable units, each of which is nested within the next inwardly positioned unit and adjustably positioned between an extended position and a retracted position. The outer boom includes a pair of opposite side members which extend within an outer conventional extendable unit and a conveying surface. A support system is provided to support the outer boom as it extends and retracts within the outer extendable unit. A forward support member of the support system is laterally aligned with the side members and a cantilever support member is vertically spaced from a rearward end of the side members, such that a reduced range in width and a reduced range in height of the extendable units may be achieved.

Abstract: An automatic tray-handling system for use with a mail sorter (26) having a plurality of tray supporters, comprises a transporter (50) having a conveying surface (56) and an insertion/extraction assembly (58); and respective feed (44a, 44b) and discharge conveyors (46a, 46b) adapted to feed empty trays (38) to the transporter conveying surface (56) and receiving at least partially full trays (38) from the transporter conveying surface. The insertion/extraction assembly (58) is adapted to insert empty trays (38) to tray support areas and remove at least partially full trays (38) from tray support areas. The conveying surface operational is adapted to receive empty trays (38) from the feed conveyor (44a, 44b) and at least partially full trays (38) from the insertion/extraction assembly (58). Moreover from the conveying surface empty trays are dischargeable to the insertion/extraction assembly (58) and to the discharge conveyor (46a, 46b).

Abstract: An automatic tray handling system for use with an article or mail sortation system, such as a flats mail sortation system, is operable to automatically remove filled or partially filled trays from individual sorter units and to replenish the sorter units with empty trays. The empty trays and/or filled trays are moved along at least one conveying surface adjacent to the sorter units. The automatic tray handling system includes a plurality of tray moving devices, which are operable to move the empty trays from the conveying surface to the sorter units, whereby the trays are at least partially filled by the sorter units. The tray moving devices are then further operable to move the at least partially filled trays from the sorter units to a conveying surface, whereby the filled trays may be conveyed to downstream operations, such as an automatic labeling station. Preferably, the empty trays are movable in a continuous loop about the mail sortation system.

Abstract: A crossbelt sortation system is provided which includes a pair of side-by-side carrier belts on each of a plurality of transport units movable along a conveying path. The carrier belts may be operable independently or in a synchronized manner, in order to receive packages from one or more induction stations and either discharge the packages at an appropriate discharge station or transfer the package onto the carrier belt at the other side of the transport unit. A control system is operable to determine the destination side of the packages at the induction station and to further determine the availability and appropriateness of the carrier belts of the approaching transport units, in order to determine if an available carrier belt is proper or compatible to receive the next package at the induction station.

Abstract: A contact assembly for an accumulation conveyor includes a support member having a cavity dimensioned to receive a force producing device. A contact member is positioned between the force producing device and the conveying rollers and reciprocates with respect to the conveying rollers. The contact member includes a wheel assembly which, when vertically reciprocated by the force-producing device, places the drive belt into driving contact with the conveying rollers. The wheel assembly is configured to move in a substantially transverse direction to the direction of movement of the drive belt to maintain alignment between the drive belt and the contact assembly.