Abstract: A tolerance adjuster and wear device, e.g. spring clip, is provided for automatically adjusting the tolerance or clearance between a pusher shoe surface and an adjacent surface of a linear slat of a positive displacement sorter. The spring clip includes an engagement portion to couple the clip to a pusher shoe and a wear portion to automatically bias or adjust a tolerance between the pusher shoe and a corresponding slat. The engagement portion includes a retainer, in the form of a pair of opposing elastic grips or teach that are insertable through a receiver in a surface of the shoe. The wear portion includes a wear surface and spring element, such as a spring arm or convex dome. The spring element is elastic to provide a consistent and automatic bias against the slat surface. Preferably, the spring clip is extruded from a resilient, wear-resistant self-lubricating polymer.

Abstract: A tolerance adjuster and wear device, e.g. spring clip, is provided for automatically adjusting the tolerance or clearance between a pusher shoe surface and an adjacent surface of a linear slat of a positive displacement sorter. The spring clip includes an engagement portion to couple the clip to a pusher shoe and a wear portion to automatically bias or adjust a tolerance between the pusher shoe and a corresponding slat. The engagement portion includes a retainer, in the form of a pair of opposing elastic grips or teach that are insertable through a receiver in a surface of the shoe. The wear portion includes a wear surface and spring element, such as a spring arm or convex dome. The spring element is elastic to provide a consistent and automatic bias against the slat surface. Preferably, the spring clip is extruded from a resilient, wear-resistant self-lubricating polymer.

Abstract: An automatic belt biasing device is provided for biasing a drive belt into frictional contact with rollers of a conveyor. The belt biasing device maintains a drive belt in contact with rollers of a live roller conveyor to provide drive for the rollers to propel items or packages along the conveyor. A spring attached to a pivot arm or pair of scissoring pivot arms adjusts a biasing force applied by guide wheels of the belt biasing device to the drive belt due to changes in drive belt tension. The belt biasing device may be selectively adjustable based on required roller pitch distances. The belt biasing device is pivotably coupled to the roller conveyor allowing the guide wheels to apply equal pressure to the drive belt while allowing the pivot arms to actuate and increase or decrease the biasing force provided by the belt biasing device.

Abstract: A positive displacement sorter and method of diverting articles includes a conveying surface configured to convey articles in a longitudinal direction and at least one diagonal take-away lane, extending diagonally from the conveying surface to receive articles being diverted from said conveying surface. A plurality of pushers are configured to move together in a lateral direction in order to displace an item on the conveying surface to the diagonal take-away lane. A rotational system is configured to rotate a leading portion of a diverted article in the direction of the take-away lane. A belt drive system is provided for driving live roller conveyors about a curved section of a roller conveyor of the sorter. The drive belt is guided along a single conical drive plane that maintains the orientation of the drive belt relative to the single conical drive plane and limits twisting and stress in the drive belt.

Abstract: An automatic belt biasing device is provided for biasing a drive belt into frictional contact with rollers of a conveyor. The belt biasing device maintains a drive belt in contact with rollers of a live roller conveyor to provide drive for the rollers to propel items or packages along the conveyor. A spring attached to a pivot arm or pair of scissoring pivot arms adjusts a biasing force applied by guide wheels of the belt biasing device to the drive belt due to changes in drive belt tension. The belt biasing device may be selectively adjustable based on required roller pitch distances. The belt biasing device is pivotably coupled to the roller conveyor allowing the guide wheels to apply equal pressure to the drive belt while allowing the pivot arms to actuate and increase or decrease the biasing force provided by the belt biasing device.

Abstract: A positive displacement sorter and method of diverting articles includes a conveying surface configured to convey articles in a longitudinal direction and at least one diagonal take-away lane, extending diagonally from the conveying surface to receive articles being diverted from said conveying surface. A plurality of pushers are configured to move together in a lateral direction in order to displace an item on the conveying surface to the diagonal take-away lane. A rotational system is configured to rotate a leading portion of a diverted article in the direction of the take-away lane. A belt drive system is provided for driving live roller conveyors about a curved section of a roller conveyor of the sorter. The drive belt is guided along a single conical drive plane that maintains the orientation of the drive belt relative to the single conical drive plane and limits twisting and stress in the drive belt.

Abstract: A plurality of diverters each selectively divert at least one article moving member having a diverting member from a non-diverting path extending longitudinally along said sorter to a diverting rails in a diverting state. At least one of the diverters has a gate having a diverting surface. The gate is selectively rotatable between the diverting state and a non-diverting state about a generally horizontal axis. An actuator moves the gate between the non-diverting state and the diverting state. The actuator is an electrically operated rotary actuator that is rotatable about another generally horizontal axis of rotation.

Abstract: A plurality of diverters each selectively divert at least one article moving member having a diverting member from a non-diverting path extending longitudinally along said sorter to a diverting rails in a diverting state. At least one of the diverters has a gate having a diverting surface. The gate is selectively rotatable between the diverting state and a non-diverting state about a generally horizontal axis. An actuator moves the gate between the non-diverting state and the diverting state. The actuator is an electrically operated rotary actuator that is rotatable about another generally horizontal axis of rotation.

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 sorter drive for propelling travelling members of a sorter along a path, in which the sorter has a plurality of interconnected travelling members that travel along a path and sortation members carried by the travelling members, with the sortation members adapted to discharge articles to particular destinations, according to an aspect of the invention, includes an endless drive member and an electro-adhesion system. The endless drive member engages the travelling members. The electro-adhesion system increases attraction of the endless drive member and the travelling members.

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 sorter drive for propelling travelling members of a sorter along a path, in which the sorter has a plurality of interconnected travelling members that travel along a path and sortation members carried by the travelling members, with the sortation members adapted to discharge articles to particular destinations, according to an aspect of the invention, includes an endless drive member and an electro-adhesion system. The endless drive member engages the travelling members. The electro-adhesion system increases attraction of the endless drive member and the travelling members.

Abstract: A method of disconnecting a slat from a wheel assembly that is used with a positive displacement sorter having a plurality of parallel laterally extending slats and a pair of wheel assemblies, each interconnecting common end portions of the slats thereby defining an endless web that travels in a longitudinal direction. An upper surface of the web defines an article-conveying surface. The sorter has a plurality of pusher shoes travelling along the slats in order to laterally displace articles on said conveying surface. The sorter further has a plurality of attachment mechanisms, each attaching an end portion of one of the slats to one of the wheel assemblies. Each of the attachment mechanisms includes at least one locking member. The locking member includes a pin on the slat engaging an opening in one of the wheel assemblies. A retraction tool is positioned against one of the wheel assemblies adjacent to the slat to be disconnected.

Abstract: A method of disconnecting a slat from a wheel assembly that is used with a positive displacement sorter having a plurality of parallel laterally extending slats and a pair of wheel assemblies, each interconnecting common end portions of the slats thereby defining an endless web that travels in a longitudinal direction. An upper surface of the web defines an article-conveying surface. The sorter has a plurality of pusher shoes travelling along the slats in order to laterally displace articles on said conveying surface. The sorter further has a plurality of attachment mechanisms, each attaching an end portion of one of the slats to one of the wheel assemblies. Each of the attachment mechanisms includes at least one locking member. The locking member includes a pin on the slat engaging an opening in one of the wheel assemblies. A retraction tool is positioned against one of the wheel assemblies adjacent to the slat to be disconnected.

Abstract: A positive displacement sorter includes a plurality of parallel laterally extending slats and a pair of wheel assemblies, each interconnecting common end portions of the slats thereby defining an endless web that travels in a longitudinal direction. An upper surface of the web defines an article-conveying surface. A plurality of pusher shoes travel along the slats in order to laterally displace articles on the conveying surface. A plurality of attachment mechanisms are provided. Each of the attachment mechanisms attaches an end portion of one of the slats to one of the wheel assemblies. Each of the attachment mechanisms includes a shoulder and a collar and at least one locking member. The collar engages the shoulder thereby providing retention of the slat to the wheel assembly. The locking member provides retention of the collar on the shoulder.

Abstract: A positive displacement sorter includes a plurality of interconnected parallel slats defining an endless web that travels in a longitudinal direction. The web has upper and lower runs and transition sections between the upper and lower runs. An upper surface of the upper run of the web defining an article-conveying surface. A plurality of pusher shoes travels along at least one of the slats in order to laterally divert articles on the conveying surface. Each of the shoes has a diverting member extending below the conveying surface. A plurality of diverting rails below the conveying surface is capable of engaging the diverting member to cause the associated shoe to travel laterally to divert an article. A plurality of diverters selectively diverts at least one of the diverting members from a non-diverting path extending longitudinally along the sorter to one of the diverting rails in a diverting state. A propulsion system propels the web.

Abstract: A positive displacement sorter and method of diverting articles includes providing a plurality of interconnected parallel slats defining an endless web that travels in a longitudinal direction, an upper surface of which defines an article-conveying surface and a plurality of pusher shoes. Each of the shoes travels along at least one of the slats in order to laterally divert articles on the conveying surface. Each of the shoes has a diverting member extending below the conveying surface. A plurality of diverting rails below the conveying surface are each capable of engaging the diverting member to cause the associated shoe to travel laterally to divert an article. A plurality of diverters are provided for selectively diverting at least one of the diverting members from a non-diverting path extending longitudinally along the sorter to one of said diverting rails in a diverting state. At least one of the diverters has a gate having a diverting surface.

Abstract: A positive displacement sorter includes a plurality of interconnected parallel slats defining an endless web that travels in a longitudinal direction. The web has upper and lower runs and transition sections between the upper and lower runs. An upper surface of the upper run of the web defining an article-conveying surface. A plurality of pusher shoes travels along at least one of the slats in order to laterally divert articles on the conveying surface. Each of the shoes has a diverting member extending below the conveying surface. A plurality of diverting rails below the conveying surface is capable of engaging the diverting member to cause the associated shoe to travel laterally to divert an article. A plurality of diverters selectively diverts at least one of the diverting members from a non-diverting path extending longitudinally along the sorter to one of the diverting rails in a diverting state. A propulsion system propels the web.

Abstract: A positive displacement sorter and method of diverting articles includes providing a plurality of interconnected parallel slats defining an endless web that travels in a longitudinal direction, an upper surface of which defines an article-conveying surface and a plurality of pusher shoes. Each of the shoes travels along at least one of the slats in order to laterally divert articles on the conveying surface. Each of the shoes has a diverting member extending below the conveying surface. A plurality of diverting rails below the conveying surface are each capable of engaging the diverting member to cause the associated shoe to travel laterally to divert an article. A plurality of diverters are provided for selectively diverting at least one of the diverting members from a non-diverting path extending longitudinally along the sorter to one of said diverting rails in a diverting state. At least one of the diverters has a gate having a diverting surface.

Abstract: A material handling system, and method of controlling the material handling system, includes a conveying surface with a plurality of individually controlled zones and a plurality of motors. At least one of the motors propelling the conveying surface at each zone. A plurality of motor controller circuits adapted to control the plurality of motors. An upper-level control circuit in communication with the plurality of motor controller circuits and adapted to send communications to the motor controller circuits for controlling at least one motor. An integrated control card defining the upper-level control circuit and the plurality of motor controller circuits, wherein the upper-level control circuit and the plurality of motor controller circuits are integrated onto the integrated control card.