Abstract: An extendable gravity loader includes an extendable gravity propelled conveying surface and a user interface section having a driven conveying surface. The sidewalls of the gravity loader define an upper edge which is above a conveying surface of the loader to prevent packages from being laterally dislodged therefrom. The sidewalls allow for a minimal height of the extendable units, while still providing a structurally robust loader with a minimal drop off between the conveying surfaces of the respective units. The user interface section provided at an outer end of the loader may have at least a portion that is vertically adjustable via an actuator at the extendable unit of the loader.

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 conveyor system having an endless conveying surface, a plurality of diverters, and diverting shoes transversely movable across the conveying surface, includes a diverting track network in operational connection with a controller. The controller measures the length of each package, while the diverting track network includes a plurality of upstream diverting tracks and at least one downstream diverting track. The controller selectively actuates a diverter associated with downstream diverting track and at least one diverter along a particular upstream diverting track to engage the package proximate to its leading and trailing end.

Abstract: A transfer assembly for a conveyor system includes a frame, a plurality of rollers mounted to the frame, a plurality of grooved transfer sheaves supported by the frame, and an actuator which selectively moves a group of the transfer conveyors between a retracted position and an extended position such that the transfer belt which is carried by the transfer sheaves is moved between a position below the conveying surface to a position above the conveying surface for lifting an article being conveyed on the rollers and transferring the article in a transfer direction. At least one of the transfer belt and the transfer sheaves are adapted to resist rolling of the transfer belt in the transfer sheaves when the transfer belt is subject to a lateral force from the article being transferred.

Abstract: A method and apparatus for sorting mail to delivery point sequence includes providing a first sortation assembly adapted to performing a first sort pass to mail articles supplied to it and a second sortation assembly adapted to performing a second sort pass to mail articles supplied to it. Mail articles are supplied to the first sortation assembly which identifies the mail articles and performs a first sort pass to sort the mail articles. The mail sorted by the first sortation assembly is conveyed to the second sortation assembly which performs a second sort pass to sort the mail articles to delivery point sequence depth of sort.

Abstract: A belt assembly for a belt turn conveyor includes a belt with a plurality of longitudinal fibers generally aligned or oriented along the curved longitudinal axis of the belt. The belt may comprise a plurality of belt segments which are interconnected to form an endless belt, with each belt segment preferably including a plurality of longitudinal fibers aligned along the longitudinal axis of each respective belt segment. When interconnected, the longitudinal fibers of each belt segment generally align along the curved longitudinal axis of the belt. Alternately, the belt may be woven such that the longitudinal fibers are substantially aligned along the curved longitudinal axis of the curved belt. Thus, a belt assembly for a belt turn conveyor is provided that exhibits a more uniform stiffness along its length, which results in the belt assembly exhibiting reduced forces across its length thus increasing the belt's capacity and longevity.

Abstract: An extendable gravity loader includes an extendable gravity propelled conveying surface and a user interface section having a driven conveying surface. The sidewalls of the conveyor define an upper edge which is above a conveying surface of the loader to prevent packages from being laterally dislodged therefrom. The sidewalls allow for a minimal height of the extendable units, while still providing a structurally robust loader with a minimal drop off between conveying surfaces of the respective units. The user interface section provided at an outer end of the loader may have at least a portion that is vertically adjustable via an actuator at the extendable unit of the loader. The actuator may be mounted to the gravity loader at a pair of compression springs, which function to absorb shock to the actuator when packages or the like are dropped or otherwise impact the user interface section.

Abstract: A freestanding conveyor personnel gate includes a support or base portion and a conveyor portion, which is pivotable and movable relative to the support between a closed position and an open position. The gate includes a latch mechanism which is operable to latch the gate in both the open and close positions. The latch mechanism is operable via a handle which is movable in either direction to disengage the latch mechanism and to raise or lower the conveyor portion toward its open or closed position. The conveyor portion is balanced and supported via a strut member which is pivotally mounted at the conveyor portion and the support portion. A biasing member is provided to bias the conveyor portion toward its closed position when the conveyor portion is moved past a neutral point between the open and close position. The biasing member is further operable to bias the conveyor portion toward its opened position when the conveyor portion is moved past the neutral position toward the open position of the gate.

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: 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.

Abstract: An extendable gravity loader includes an extendable gravity propelled conveying surface and a user interface section having a driven conveying surface. The sidewalls of the conveyor define an upper edge which is above a conveying surface of the loader to prevent packages from being laterally dislodged therefrom. The sidewalls allow for a minimal height of the extendable units, while still providing a structurally robust loader with a minimal drop off between conveying surfaces of the respective units. The user interface section provided at an outer end of the loader may have at least a portion that is vertically adjustable via an actuator at the extendable unit of the loader. The actuator may be mounted to the gravity loader at a pair of compression springs, which function to absorb shock to the actuator when packages or the like are dropped or otherwise impact the user interface section.

Abstract: An improved communications for an electrified monorail includes an off-board programmable logic controller having at least one output electrically coupled to a buss bar of the electrified monorail. At least one other programmable logic controller is mounted on a vehicle that travels on the electrified monorail and includes at least one input in electrical contact with the buss bar. The off-board programmable logic controller is programmed to set its output at a series of high and low voltages corresponding to a message. The on-board programmable logic controller is programmed to detect the series of high and low voltages, store them at least temporarily in memory, and act accordingly upon the transmitted message.

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: An unscrambling and aligning conveyor comprises a plurality of tapered rollers attached to a pair of side supports. The tapered rollers are driven at a single speed and tapered to a minimum diameter to define an alignment region. The tapered rollers create a lateral speed decrease toward the alignment region of the conveyor, causing separation and rotation of the articles, and thereby enabling the articles to be singulated in the alignment region. The tapered rollers are supported by the side supports such that center axis of each roller is horizontal to thereby defining a downwardly sloping article transport surface which increases movement of the articles towards the alignment region. The unscrambling and aligning conveyor is driven at a speed greater than the input conveyor located adjacently upstream thereof to provide articles with a gap therebetween so that articles moving along the unscrambling and aligning conveyor are properly singulated.

Abstract: A transfer assembly of the present invention provides for a low impact transfer of an article between conveyors so that the article can be diverted from a direction of flow without impeding the flow of other articles in the conveyor system. The transfer is done at a relatively fast rate while maintaining the impact on the article to a minimum. The transfer assembly includes a conveying surface and a pusher which is adapted to move across a first portion of the conveying surface from a retracted position adjacent the first portion to an extended position across the first portion adjacent a second portion of the conveying surface for translating an article being conveyed on the conveying surface and for transferring the article from a first conveyor section to a second laterally offset conveyor section.

Abstract: An alignment device for aligning a photo-detector with a target on a conveyor includes a mount for the photo-detector having at least two apertures. Screws are inserted through those apertures into corresponding apertures in a bracket attached to the conveyor. The screws are threadedly secured to one of the mount and bracket and non-threadedly secured to the other of the mount and bracket such that rotation of either of the screws alters the distance between the mount and the bracket. The alteration in distance changes the orientation of the photo-detector. Springs may be mounted between the bracket and the mount.

Abstract: An extendable conveyor has an extendable conveyor section supported in a cantilevered manner including at least one extendable conveyor unit that is extendable between an extended position and a retracted position nested within the extendable conveyor section. The conveyor further includes a user interface section supported in a cantilevered manner from the extendable conveyor unit. The user interface section is vertically adjustable about a horizontal axis and horizontally adjustable about a vertical axis. The extendable conveyor includes a conveying surface defined on the extendable conveyor section and the user interface section. The user interface section is vertically adjustable by an actuator that is preferably an electric motor type linear actuator that is horizontally oriented. This allows the actuator to fit within the side profile of the interface of the user interface section with the extendable conveyor unit.

Abstract: A conveyor system and corresponding method for article volume sharing between conveyor lines includes an overflow handler in operational connection with the alignment conveyor of each conveyor line. The overflow handler receives articles positioned outside of the alignment region of the alignment conveyor and transports the articles to an alignment conveyor positioned within an adjacent conveyor line. Volume sharing between a plurality of conveyor lines increases conveyor system throughput, particularly when one or more of the conveyor lines experiences a high volume of article flow. The conveyor system includes a deflector assembly capable of deflecting articles away from the alignment region of the alignment conveyor and towards the overflow handler, and subsequently to an adjacent conveyor line, when the sortation conveyor is jammed or offline during the performance of maintenance.

Abstract: A shaft support for supporting a shaft end of a conveyor roller is pivotable about an axis extending generally along the direction of conveyance of a conveyor, such that the support may pivot to accommodate a change in vertical positioning of one or both ends of the roller. The shaft support may also be pivotable about a generally vertical axis in order to also accommodate skewed rollers mounted at an angle not perpendicular to the direction of conveyance. Because the shaft support is pivotable about the axis extending in the direction of conveyance, the shaft support simplifies the installation and removal of the motorized roller, while providing for a roller does not require a spring loaded shaft or axle. The roller may thus be a low cost roller which may be easily installed and removed from the conveyor.