Conveyor Controllers

• US 20120290126A1
• Filed: 05/09/2011
• Published: 11/15/2012
• Est. Priority Date: 05/09/2011
• Status: Active Grant

• Current Assignee: Insight Automation, Inc.
• Original Assignee: Insight Automation, Inc.
• Inventors: Combs, Charles R., Knaple, James P., Petrov, Dimitar ivanov, Barnes, Timothy A., Sellers, David W.
• Granted Patent: US 8,757,363 B2
• Time in Patent Office: Days
• US Class Current: 700/230
• CPC Class Codes: B65G 13/02 having driven rollers
• CPC Class Codes: B65G 23/08 with self-contained driving mechanisms, e.g. motors and associated gearing
• CPC Class Codes: B65G 43/00 Control devices, e.g. for safety, warning or fault-correcting
• CPC Class Codes: B65G 43/10 Sequence control of conveyors operating in combination
• CPC Class Codes: B65G 47/261 Accumulating articles
• CPC Class Codes: G05B 19/4189 characterised by the transport system
• CPC Class Codes: G05B 2219/25081 Clone, copy configuration from first device, in teach mode, to second identical device
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

Various methods, apparatuses, and program products that are used to control at least a portion of a conveyor, determine information about an article conveyed by the conveyor, or otherwise operate a conveyor are provided. One method includes detecting whether a second conveyor controller is connected to the first conveyor controller and, in response to detecting that there is a second conveyor controller connected to the first conveyor controller, identifying whether the second conveyor controller is connected to a predetermined network interface of the first conveyor controller. The method further includes configuring the first conveyor controller to rotate a motorized roller in a first predetermined direction if a second conveyor controller is connected to the predetermined network interface and configuring the first conveyor controller to rotate the motorized roller in a second predetermined direction if a second conveyor controller is not connected to the predetermined network interface.

Claims

1. A method of controlling at least a portion of a conveyor with a first conveyor controller, the method comprising:

detecting whether a second conveyor controller is connected to the first conveyor controller;

in response to detecting that there is a second conveyor controller connected to the first conveyor controller, identifying whether the second conveyor controller is connected to a predetermined network interface of the first conveyor controller;

if a second conveyor controller is connected to the predetermined network interface, configuring the first conveyor controller to rotate a motorized roller in a first predetermined direction; and

if a second conveyor controller is not connected to the predetermined network interface, configuring the first conveyor controller to rotate the motorized roller in a second predetermined direction.

2. The method of claim 1, further comprising:

in response to detecting that there is not a third conveyor controller connected to the first conveyor controller, determining that the first conveyor controller is an initial conveyor controller of a linear conveyor.

3. The method of claim 1, wherein the first conveyor controller detects whether there is a second conveyor controller connected thereto in response to user interaction to initiate an automatic configuration procedure.

4. The method of claim 1, wherein the first conveyor controller detects whether there is a second conveyor controller connected thereto in response to receiving a command to initiate an automatic configuration procedure.

5. The method of claim 1, further comprising:

if the second conveyor controller is connected to the predetermined network interface, setting a flag to indicate the second conveyor controller is connected to the predetermined network interface.

6. The method of claim 1, further comprising:

if the second conveyor controller is not connected to the predetermined network interface, clearing a flag to indicate that the second conveyor controller is connected to the predetermined network interface.

7. The method of claim 1, wherein the first conveyor controller includes a first and second network interfaces, and wherein the predetermined network interface is one of the first and second network interfaces.

8. The method of claim 1, further comprising:

transmitting a configuration message to the second conveyor controller that includes configuration data associated with the first conveyor controller.

9. The method of claim 8, further comprising:

receiving a confirmation message from the second conveyor controller indicating that the configuration data was received.

10. The method of claim 9, wherein the confirmation message is a first confirmation message, the method further comprising:

in response to receiving a second confirmation message from a third conveyor controller, indicating that an error has occurred.

11. The method of claim 9, wherein the confirmation message is a first confirmation message, the method further comprising:

in response to receiving a second confirmation message from a third conveyor controller, transmitting an error message to the second conveyor controller indicating that an error has occurred.

12. The method of claim 8, wherein the configuration data includes a network address for the first conveyor controller.

13. The method of claim 1, further comprising:

receiving and storing configuration data associated with the second conveyor controller.

14. The method of claim 1, further comprising:

detecting a photo-eye sensor connected to the conveyor controller, including whether the photo-eye sensor is light-operated or dark-operated;

detecting the motorized roller connected to the conveyor controller, including information about the motorized roller; and

automatically configuring at least one of a speed to operate the motorized roller, a rate at which to accelerate the motorized roller, a rate at which to decelerate the motorized roller, or combinations thereof.

15. The method of claim 14, wherein detecting the photo-eye sensor includes:

querying the photo-eye sensor to determine whether it is light-operated or dark-operated.

16. A conveyor controller, comprising:

a plurality of network interfaces;

at least one processing unit;

a memory; and

program code resident in the memory, the program code configured to be executed by the at least one processing unit to detect whether a second conveyor controller is connected to the conveyor controller, identify whether the second conveyor controller is connected to a predetermined network interface of the conveyor controller in response to detecting that the second conveyor controller is connected to the conveyor controller, configure the conveyor controller to rotate a motorized roller in a predetermined direction if the second conveyor controller is connected to the predetermined network interface, and configure the conveyor controller to rotate the motorized roller opposite the predetermined direction if the second conveyor controller is not connected to the predetermined network interface.

17. The conveyor controller of claim 16, wherein the program code is further configured to determine that the conveyor controller is an initial conveyor controller of a linear conveyor in response to detecting that there is not a third conveyor controller connected to the conveyor controller.

18. The conveyor controller of claim 16, further comprising:

a user interface, wherein the program code detects whether the second conveyor controller is connected to the conveyor controller in response to user interaction at the user interface to initiate an automatic configuration procedure.

19. The conveyor controller of claim 16, wherein the program code detects whether the second conveyor controller is connected to the conveyor controller in response to receiving a command to initiate an automatic configuration procedure.

20. The conveyor controller of claim 16, wherein the program code is further configured to set a flag to indicate the second conveyor controller is connected to the predetermined network interface if the second conveyor controller is connected to the predetermined network interface.

21. The conveyor controller of claim 16, wherein the program code is further configured to clear a flag to indicate that the second conveyor controller is connected to the predetermined network interface if the second conveyor controller is not connected to the predetermined network interface.

22. The conveyor controller of claim 16, wherein the plurality of network interfaces includes a first and second network interface, and wherein the predetermined network interface is one of the first and second network interfaces.

23. The conveyor controller of claim 16, wherein the program code is further configured to transmit a configuration message to the second conveyor controller that includes configuration data associated with the conveyor controller.

24. The conveyor controller of claim 23, wherein the program code is further configured to receive a confirmation message from the second conveyor controller indicating that the configuration data was received.

25. The conveyor controller of claim 24, wherein the confirmation message is a first confirmation message, and wherein the program code is further configured to indicate that an error has occurred in response to receiving a second confirmation message from a third conveyor controller.

26. The conveyor controller of claim 24, wherein the confirmation message is a first confirmation message, and wherein the program code is further configured to transmit an error message to the second conveyor controller indicating that an error has occurred in response to receiving a second confirmation message from a third conveyor controller.

27. The conveyor controller of claim 23, wherein the configuration data includes a network address for the conveyor controller.

28. The conveyor controller of claim 16, wherein the program code is further configured to receive and store configuration data associated with the second conveyor controller.

29. The conveyor controller of claim 16, wherein the program code is further configured to detect a photo-eye sensor connected to the conveyor controller, including whether the photo-eye sensor is light-operated or dark-operated, detect the motorized roller connected to the conveyor controller, including information about the motorized roller, and automatically configure at least one of a speed to operate the motorized roller, a rate at which to accelerate the motorized roller, a rate at which to decelerate the motorized roller, or combinations thereof.

30. The conveyor controller of claim 16, wherein the program code is further configured to query the photo-eye sensor to determine whether it is light-operated or dark-operated.

31. A program product, comprising:

program code configured to be executed by at least one processing unit to detect whether a second conveyor controller is connected to the conveyor controller, identify whether the second conveyor controller is connected to a predetermined network interface of the conveyor controller in response to detecting that the second conveyor controller is connected to the conveyor controller, configure the conveyor controller to rotate a motorized roller in a predetermined direction if the second conveyor controller is connected to the predetermined network interface, and configure the conveyor controller to rotate the motorized roller opposite the predetermined direction if the second conveyor controller is not connected to the predetermined network interface; and

a non-transitory computer readable medium bearing the program code.

32. A method of controlling at least a portion of a conveyor, the method comprising:

in response to receiving first configuration data from a first conveyor controller at a second conveyor controller, detecting whether a third conveyor controller is connected to the second conveyor controller;

if a third conveyor controller is connected to the second conveyor controller, transmitting a configuration message to the third conveyor controller that includes second configuration data associated with the second conveyor controller; and

if a third conveyor controller is not connected to the second conveyor controller, determining that the second conveyor controller is a final conveyor controller of a linear conveyor.

33. The method of claim 32, further comprising:

determining a network address for the second conveyor controller based on the first configuration data.

34. The method of claim 33, further comprising:

determining a first network address for the first conveyor controller from the first configuration data;

incrementing the first network address to generate a second network address; and

assigning the second network address to the second conveyor controller.

35. The method of claim 34, further comprising:

including the second network address in the second configuration data.

36. The method of claim 32, further comprising:

in response to receiving the first configuration data, transmitting a confirmation message to the first conveyor controller indicating that the first configuration data was received.

37. The method of claim 32, further comprising:

receiving a confirmation message from the third conveyor controller indicating that the second configuration data was received.

38. The method of claim 37, wherein the confirmation message is a first confirmation message, the method further comprising:

in response to receiving a second confirmation message from a fourth conveyor controller, indicating that an error has occurred.

39. The method of claim 37, wherein the confirmation message is a first confirmation message, the method further comprising:

in response to receiving a second confirmation message from a fourth conveyor controller, transmitting an error message to the first conveyor controller indicating that an error has occurred.

40. The method of claim 32, further comprising:

receiving and storing the first configuration data;

sending the second configuration data to the first conveyor controller.

41. The method of claim 32, further comprising:

if a third conveyor controller is connected to the second conveyor controller, receiving and storing third configuration data associated with the third conveyor controller.

42. A conveyor controller, comprising:

at least one processing unit;

a memory; and

program code resident in the memory, the program code configured to be executed by the at least one processing unit to, in response to receiving first configuration data from a second conveyor controller at the conveyor controller, detect whether a third conveyor controller is connected to the conveyor controller, transmit a configuration message to the third conveyor controller that includes second configuration data associated with the conveyor controller if the third conveyor controller is connected to the conveyor controller, and determining that the conveyor controller is a final conveyor controller of a linear conveyor if the third conveyor controller is not connected to the conveyor controller.

43. The conveyor controller of claim 42, wherein the program code is further configured to determine a network address for the conveyor controller based on the first configuration data.

44. The conveyor controller of claim 43, wherein the program code is further configured to determine a first network address for the second conveyor controller from the first configuration data, increment the first network address to generate a second network address, and assign the second network address to the conveyor controller.

45. The conveyor controller of claim 44, wherein the program code is further configured to include the second network address in the second configuration data.

46. The conveyor controller of claim 42, wherein the program code is further configured to transmit a confirmation message to the second conveyor controller indicating that the first configuration data was received in response to receiving the first configuration data.

47. The conveyor controller of claim 42, wherein the program code is further configured to receive a confirmation message from the third conveyor controller indicating that the second configuration data was received.

48. The conveyor controller of claim 47, wherein the confirmation message is a first confirmation message, and wherein the program code is further configured to indicate that an error has occurred in response to receiving a second confirmation message from a fourth conveyor controller

49. The conveyor controller of claim 47, wherein the confirmation message is a first confirmation message, and wherein the program code is further configured to transmit an error message to the second conveyor controller indicating that an error has occurred in response to receiving a second confirmation message from a fourth conveyor controller.

50. The conveyor controller of claim 42, wherein the program code is further configured to receive and store the first configuration data, and wherein the program code is further configured to send the second configuration data to the second conveyor controller.

51. The conveyor controller of claim 42, wherein the program code is further configured to receive and store third configuration data associated with the third conveyor controller if the third conveyor controller is connected to the conveyor controller.

52. A program product, comprising:

program code configured to be executed by at least one processing unit to, in response to receiving first configuration data from a second conveyor controller at the conveyor controller, detect whether a third conveyor controller is connected to the conveyor controller, transmit a configuration message to the third conveyor controller that includes second configuration data associated with the conveyor controller if the third conveyor controller is connected to the conveyor controller, and determining that the conveyor controller is a final conveyor controller of a linear conveyor if the third conveyor controller is not connected to the conveyor controller; and

a non-transitory computer readable medium bearing the program code.

53. A method of controlling at least a portion of a conveyor with a first conveyor controller, the method comprising:

receiving and storing configuration data associated with a second conveyor controller connected to the first conveyor controller;

in response to a first request for data from a third conveyor controller intended to replace the second conveyor controller, transmitting the configuration data to the third conveyor controller.

54. The method of claim 53, further comprising:

in response to a second request for data from the third conveyor controller, transmitting a network address associated with the first conveyor controller to the third conveyor controller.

55. The method of claim 53, further comprising:

in response to a second request for a network address for each conveyor controller connected in a network with a fourth conveyor controller, transmitting a network address associated with the first conveyor controller to the fourth conveyor controller.

56. A conveyor controller, comprising:

at least one processing unit;

a memory; and

program code resident in the memory, the program code configured to be executed by the at least one processing unit to receive and store configuration data associated with a second conveyor controller connected to the conveyor controller, transmit the configuration data to a third conveyor controller intended to replace the second conveyor controller in response to a first request for data from the third conveyor controller.

57. The conveyor controller of claim 56, wherein the program code is further configured to transmit a network address associated with the conveyor controller to the third conveyor controller in response to a second request for data from the third conveyor controller.

58. The conveyor controller of claim 56, wherein the program code is further configured to transmit a network address associated with the conveyor controller to the fourth conveyor controller in response to a second request for a network address for each conveyor controller connected in a network with a fourth conveyor controller.

59. A program product, comprising:

program code configured to be executed by at least one processing unit to receive and store configuration data associated with a second conveyor controller connected to the conveyor controller, transmit the configuration data to a third conveyor controller intended to replace the second conveyor controller in response to a first request for data from the third conveyor controller; and

a non-transitory computer readable medium bearing the program code.

60. A method of controlling at least a portion of a conveyor, the method comprising:

in response to user input to a first conveyor controller to automatically configure the first conveyor controller, requesting configuration data from a second conveyor controller connected to the first conveyor controller; and

in response to receiving the configuration data, storing the configuration data in the first conveyor controller.

61. The method of claim 60, wherein the first conveyor controller includes a first and second network interface, the second conveyor controller connected to the first network interface and a third conveyor controller connected to the second network interface.

62. The method of claim 60, further comprising:

in response to the user input to the first conveyor controller to automatically configure the first conveyor controller, broadcasting a request for a network address for each conveyor controller connected in a network with the first conveyor controller.

63. The method of claim 62, further comprising:

receiving a plurality of network addresses associated with a plurality of conveyor controllers connected in the network to the first conveyor controller; and

determining a first network address to assign to the first conveyor controller based on the plurality of network addresses.

64. The method of claim 60, further comprising:

in response to the user input to the first conveyor controller to automatically configure the first conveyor controller, transmitting a request for a second network address associated with the second conveyor controller to the second conveyor controller; and

generating a list of potential network addresses for the first conveyor controller based on at least the second network address.

65. The method of claim 64, further comprising:

broadcasting a request for a network address for each conveyor controller connected in a network with the first conveyor controller; and

selecting a first network address from the list of potential network addresses that does not match any other network address for another conveyor controller connected in the network with the first conveyor controller.

66. A conveyor controller, comprising:

a plurality of network interfaces connected to a network;

at least one user interface;

at least one processing unit;

a memory; and

program code resident in the memory, the program code configured to be executed by the at least one processing unit to request configuration data from a second conveyor controller connected to the conveyor controller in response to user input with the at least one user interface to automatically configure the conveyor controller, and store the configuration data in the conveyor controller in response to receiving the configuration data.

67. The conveyor controller of claim 66, wherein the plurality of network interfaces includes a first and second network interface, the second conveyor controller connected to the first network interface and a third conveyor controller connected to the second network interface.

68. The conveyor controller of claim 66, wherein the program code is further configured to broadcast a request for a network address for each conveyor controller connected in the network with the conveyor controller in response to user input with the at least one user interface to automatically configure the conveyor controller.

69. The conveyor controller of claim 68, wherein the program code is further configured to receive a plurality of network addresses associated with a plurality of conveyor controllers connected in the network to the conveyor controller, and determine a first network address to assign to the first conveyor controller based on the plurality of network addresses.

70. The conveyor controller of claim 66, wherein the program code is further configured to transmit a request for a second network address associated with the second conveyor controller to the second conveyor controller in response to user input with the at least one user interface to automatically configure the conveyor controller, and generate a list of potential network addresses for the first conveyor controller based on at least the second network address.

71. The conveyor controller of claim 70, wherein the program code is further configured to broadcast a request for a network address for each conveyor controller connected in the network with the conveyor controller, and select a first network address from the list of potential network addresses that does not match any other network address for another conveyor controller connected in the network with the conveyor controller.

72. A program product, comprising:

program code configured to be executed by at least one processing unit to request configuration data from a second conveyor controller connected to the conveyor controller in response to user input with the at least one user interface to automatically configure the conveyor controller, and store the configuration data in the conveyor controller in response to receiving the configuration data; and

a non-transitory computer readable medium bearing the program code.

73. A method of controlling at least a portion of a conveyor, comprising:

monitoring a motorized roller for at least partial rotation thereof;

in response to detecting the at least partial rotation of the motorized roller, determining a length of time for the at least partial rotation;

in response to determining that the length of time is greater than a target time, activating the motorized roller.

74. The method of claim 73, wherein activating the motorized roller includes:

supplying a voltage signal to the motorized roller.

75. The method of claim 73, further comprising:

transmitting a message to a conveyor controller indicating that the motorized roller has been activated.

76. The method of claim 73, further comprising:

deactivating the motorized roller after a target period of time.

77. The method of claim 73, further comprising:

deactivating the motorized roller after a target period of time during which an article is not detected on the conveyor.

78. The method of claim 73, further comprising:

in response to receiving a message from a conveyor controller downstream a predefined direction of travel indicating that there is jam, deactivating the motorized roller.

79. The method of claim 78, wherein deactivating the motorized roller includes:

gradually reducing a rate of rotation of the motorized roller.

80. The method of claim 73, further comprising:

deactivating the motorized roller by gradually reducing a rate of rotation of the motorized roller.

81. The method of claim 73, wherein activating the motorized roller includes:

gradually increasing a rate of rotation of the motorized roller.

82. A conveyor controller, comprising:

at least one user interface;

at least one processing unit;

a memory; and

program code resident in the memory, the program code configured to be executed by the at least one processing unit to monitor a roller for at least partial rotation thereof, determine a length of time for at least partial rotation of the roller in response to detecting the at least partial rotation of the roller, and activating the motorized roller in response to determining that the length of time is greater than a target time.

83. The conveyor controller of claim 82, the program code further configured to supply a voltage signal to the motorized roller.

84. The conveyor controller of claim 82, the program code further configured to transmit a message to a conveyor controller indicating that the motorized roller has been activated.

85. The conveyor controller of claim 82, the program code further configured to deactivate the motorized roller after a target period of time.

86. The conveyor controller of claim 82, the program code further configured to deactivate the motorized roller after a target period of time during which an article is not detected on the conveyor.

87. The conveyor controller of claim 82, the program code further configured to, in response to receiving a message from a conveyor controller downstream a predefined direction of travel indicating that there is jam, deactivate the motorized roller.

88. The conveyor controller of claim 87, the program code further configured to gradually reduce a rate of rotation of the motorized roller.

89. The conveyor controller of claim 82, the program code further configured to deactivate the motorized roller by gradually reducing a rate of rotation of the motorized roller

90. The conveyor controller of claim 82, the program code further configured to gradually increase a rate of rotation of the motorized roller.

91. A program product, comprising:

program code configured to be executed by at least one processing unit to monitor a roller for at least partial rotation thereof, determine a length of time for at least partial rotation of the roller in response to detecting the at least partial rotation of the roller, and activating the motorized roller in response to determining that the length of time is greater than a target time; and

a non-transitory computer readable medium bearing the program code.

92. A method of controlling a conveyor, comprising:

in response to a determination to prevent rotation of a motorized roller, identifying a rotational position associated with the motorized roller when the motorized roller is stopped; and

in response to an external force on the motorized roller, applying a voltage signal to the motorized roller to maintain the roller at the identified rotational position.

93. The method of claim 92, wherein applying the voltage signal comprises:

applying a voltage signal to cause the motorized roller to rotate at least partially against a predefined direction corresponding to a direction of travel.

94. The method of claim 92, wherein applying the voltage signal comprises:

applying a voltage signal to cause the motorized roller to rotate at least partially in a predefined direction corresponding to a direction of travel.

95. The method of claim 92, wherein the voltage signal energizes one winding of a motor of the motorized roller.

96. The method of claim 92, wherein the voltage signal energizes two windings of a motor of the motorized roller.

97. The method of claim 92, further comprising:

storing the rotational position of the motorized roller; and

in response to the external force on the motorized roller, analyzing the rotation of the motorized roller to determine whether to cause the motorized roller to rotate at least partially against a predefined direction corresponding to a direction of travel or at least partially in the predefined direction corresponding to the direction of travel.

98. The method of claim 92, further comprising:

controlling a brake to halt rotation of the motorized roller.

99. The method of claim 92, wherein the voltage signal maintains the roller at the identified rotational position to maintain an article on at least a portion of the conveyor at a predetermined position.

100. A conveyor controller, comprising:

at least one processing unit;

a memory; and

program code resident in the memory, the program code configured to be executed by the at least one processing unit to identify a rotational position associated with the motorized roller when the motorized roller is stopped in response to a determination to prevent rotation of a motorized roller and apply a voltage signal to the motorized roller to maintain the roller at the identified rotational position in response to an external force on the motorized roller.

101. The conveyor controller of claim 100, wherein the program code is further configured to apply a voltage signal to cause the motorized roller to rotate at least partially against a predefined direction corresponding to a direction of travel.

102. The conveyor controller of claim 100, wherein the program code is further configured to apply a voltage signal to cause the motorized roller to rotate at least partially in a predefined direction corresponding to a direction of travel.

103. The conveyor controller of claim 100, wherein the voltage signal energizes one winding of a motor of the motorized roller.

104. The conveyor controller of claim 100, wherein the voltage signal energizes two windings of a motor of the motorized roller.

105. The conveyor controller of claim 100, wherein the program code is further configured to store the rotational position of the motorized roller and, in response to the external force on the motorized roller, analyze the rotation of the motorized roller to determine whether to cause the motorized roller to rotate at least partially against a predefined direction corresponding to a direction of travel or at least partially in the predefined direction corresponding to the direction of travel.

106. The conveyor controller of claim 100, wherein the program code is further configured to control a brake to halt rotation of the motorized roller.

107. The conveyor controller of claim 100, wherein the voltage signal maintains the roller at the identified rotational position to maintain an article on at least a portion of the conveyor at a predetermined position.

109. A program product, comprising:

program code configured to be executed by at least one processing unit to identify a rotational position associated with the motorized roller when the motorized roller is stopped in response to a determination to prevent rotation of a motorized roller and apply a voltage signal to the motorized roller to maintain the roller at the identified rotational position in response to an external force on the motorized roller; and

a non-transitory computer readable medium bearing the program code.

110. A method of controlling at least a portion of a conveyor with a conveyor controller, comprising:

querying a motorized roller for data associated therewith;

in response to receiving the data, analyzing the data to determine an operational characteristic associated with the motorized roller; and

controlling the motorized roller based at least in part upon the determined operational characteristic.

111. The method of claim 110, wherein the operational characteristic is a gear ratio of a gear box for the motorized roller, the method further comprising:

determining, from the gear ratio, a distance the motorized roller rotates in response to a voltage signal.

112. The method of claim 111, wherein the voltage signal is a momentary voltage signal.

113. The method of claim 110, wherein the operational characteristic indicates a power rating of the motorized roller, the method further comprising:

determining a current threshold associated with the motorized roller that indicates a level of current above which the motorized roller should not be operated.

114. A conveyor controller, comprising:

at least one processing unit;

a memory; and

program code resident in the memory, the program code configured to be executed by the at least one processing unit to query a motorized roller for data associated therewith, in response to receiving the data, analyze the data to determine an operational characteristic associated with the motorized roller, and control the motorized roller based at least in part upon the determined operational characteristic.

115. The conveyor controller of claim 114, wherein the operational characteristic is a gear ratio of a gear box for the motorized roller, the program code further configured to determine, from the gear ration, a distance the motorized roller rotates in response to a voltage signal.

116. The conveyor controller of claim 115, wherein the voltage signal is a momentary voltage signal.

117. The conveyor controller of claim 114, wherein the operational characteristic indicates a power rating of the motorized roller, the program code further configured to determine a current threshold associated with the motorized roller that indicates a level of current above which the motorized roller should not be operated.

118. A program product, comprising:

program code configured to be executed by at least one processing unit to query a motorized roller for data associated therewith, in response to receiving the data, analyze the data to determine an operational characteristic associated with the motorized roller, and control the motorized roller based at least in part upon the determined operational characteristic; and

a non-transitory computer readable medium bearing the program code.

119. A method of controlling at least a portion of a conveyor with a conveyor controller, comprising:

operating a motorized roller to rotate in a first direction corresponding to a direction of travel; and

in response to detecting that a jam has occurred, operating the motorized roller to rotate in a second direction opposite the first direction.

120. The method of claim 119, wherein the motorized roller is operated to rotate in the second direction for a target period of time.

121. The method of claim 119, wherein detecting that the jam has occurred includes:

determining that a sensor indicates that an article is present on the at least a portion of the conveyor for a target period of time.

122. The method of claim 119, wherein detecting that the jam has occurred includes:

determining that a current level of a voltage signal used to operate the motorized roller has exceeded a high target level for a target period of time.

123. A conveyor controller, comprising:

at least one processing unit;

a memory; and

program code resident in the memory, the program code configured to be executed by the at least one processing unit to operate a motorized roller to rotate in a first direction corresponding to a direction of travel and, in response to detecting that a jam has occurred, operate the motorized roller to rotate in a second direction opposite the first direction.

124. The conveyor controller of claim 123, wherein the program code is further configured to operate the motorized roller in the second direction for a target period of time.

125. The conveyor controller of claim 123, wherein the program code is further configured to determine that a sensor indicates that an article is present on the at least a portion of the conveyor for a target period of time.

126. The conveyor controller of claim 123, wherein the program code is further configured to detect that a jam has occurred in response to determining that a current level of a voltage signal used to operate the motorized roller has exceeded a high target level for a target period of time.

127. A program product, comprising:

program code configured to be executed by at least one processing unit to operate a motorized roller to rotate in a first direction corresponding to a direction of travel and, in response to detecting that a jam has occurred, operate the motorized roller to rotate in a second direction opposite the first direction; and

a non-transitory computer readable medium bearing the program code.

128. A method of determining information about an article being conveyed upon at least a portion of a conveyor, the method comprising:

sensing a current of a signal used to operate a motorized roller; and

determining a weight associated with the article based upon the sensed current.

129. The method of claim 128, further comprising:

determining a number of rotations during which the signal used to operate the motorized roller is at the sensed current; and

determining a length of the article based upon the determined number of rotations.

130. The method of claim 128, further comprising:

determining a time during which the signal used to operate the motorized roller is at the sensed current; and

determining a length of the article based upon the determined time.

131. The method of claim 130, wherein determining the length of the article includes:

determining the length of the article based additionally upon the speed of the operation of the motorized roller.

132. A conveyor controller, comprising:

at least one processing unit;

a memory; and

program code resident in the memory, the program code configured to be executed by the at least one processing unit to sense a current of a signal used to operate a motorized roller and determine a weight associated with the article based upon the sensed current.

133. The conveyor controller of claim 132, wherein the program code is further configured to determine a number of rotations during which the signal used to operate the motorized roller is at the sensed current and determine a length of the article based upon the determined number of rotations.

134. The conveyor controller of claim 132, wherein the program code is further configured to determine a time during which the signal used to operate the motorized roller is at the sensed current and determine a length of the article based upon the determined time.

135. The conveyor controller of claim 134, wherein the program code is further configured to determine the length of the article based additionally upon the speed of the operation of the motorized roller.

136. A program product, comprising:

program code configured to be executed by at least one processing unit to sense a current of a signal used to operate a motorized roller and determine a weight associated with the article based upon the sensed current; and

a non-transitory computer readable medium bearing the program code.

137. A method of determining information about an article being conveyed upon at least a portion of a conveyor, the method comprising:

as the article is conveyed along the at least a portion of the conveyor, determining a time during which a photo-eye detects the article; and

determining a length associated with the article based upon the determined time.

138. The method of claim 137, further comprising:

determining the length of the article additionally based upon the speed of the operation of a motorized roller utilized to convey the article along the at least a portion of the conveyor.

139. A conveyor controller, comprising:

at least one processing unit;

a memory; and

program code resident in the memory, the program code configured to be executed by the at least one processing unit to determine a time during which a photo-eye detects an article as the article is conveyed along the at least a portion of the conveyor and determine a length associated with the article based upon the determined time.

140. The conveyor controller of claim 139, wherein the program code is further configured to determine the length of the article additionally based upon the speed of the operation of a motorized roller utilized to convey the article along the at least a portion of the conveyor.

141. A program product, comprising:

program code configured to be executed by at least one processing unit to determine a time during which a photo-eye detects an article as the article is conveyed along the at least a portion of the conveyor and determine a length associated with the article based upon the determined time; and

a non-transitory computer readable medium bearing the program code.

142. A method of controlling at least a portion of a conveyor with a conveyor controller, comprising:

determining a rate of rotation associated with a motorized roller;

if the rotation of the motorized roller does not exceed a target speed, connecting a first voltage signal generated by the rotation of the motorized roller to a power supply of the conveyor controller to supply the power supply with energy generated by the motorized roller; and

if the rotation of the motorized roller exceeds the target speed, supplying a second voltage signal to the motorized roller to reduce the rate of rotation thereof.

143. A conveyor controller, comprising:

at least one processing unit;

a memory; and

program code resident in the memory, the program code configured to be executed by the at least one processing unit to determine a rate of rotation associated with a motorized roller, connect a first voltage signal generated by the rotation of the motorized roller to a power supply of the conveyor controller to supply the power supply with energy generated by the motorized roller if the rotation of the motorized roller does not exceed a target speed, and supply a second voltage signal to the motorized roller to reduce the rate of rotation thereof if the rotation of the motorized roller exceeds the target speed.

144. A program product, comprising:

program code configured to be executed by at least one processing unit to determine a rate of rotation associated with a motorized roller, connect a first voltage signal generated by the rotation of the motorized roller to a power supply of the conveyor controller to supply the power supply with energy generated by the motorized roller if the rotation of the motorized roller does not exceed a target speed, and supply a second voltage signal to the motorized roller to reduce the rate of rotation thereof if the rotation of the motorized roller exceeds the target speed; and

a non-transitory computer readable medium bearing the program code.

145. A method of controlling at least a portion of a conveyor with a conveyor controller, comprising:

determining whether a current through a motorized roller is associated with a low level to indicate that the motorized roller is conveying a first article;

in response to determining that the motorized roller is conveying the first article, determining whether the current through the motorized roller is associated with a high level to indicate that the first article has encountered a second article; and

in response to determining that the first article has jammed or encountered a second article, conveying the first and second articles simultaneously and without substantial gap there between during such conveyance.

146. The method of claim 145, further comprising:

supplying a voltage signal to the motorized roller; and

deactivating the motorized roller after a target period of time during which a current level of the voltage signal has not reached a low target level and a high target level.

147. The method of claim 145, further comprising:

supplying a voltage signal to the motorized roller; and

deactivating the motorized roller after a target period of time during which a current level of the voltage signal has reached a low target level.

148. The method of claim 145, further comprising:

supplying a voltage signal to the motorized roller; and

deactivating the motorized roller when a current level of the voltage signal has reached a high target level.

149. A conveyor controller, comprising:

at least one processing unit;

a memory; and

program code resident in the memory, the program code configured to be executed by the at least one processing unit to determine whether a current through a motorized roller is associated with a low level to indicate that the motorized roller is conveying a first article, determine whether the current through the motorized roller is associated with a high level to indicate that the first article has encountered a second article in response to determining that the motorized roller is conveying the first article, and, in response to determining that the first article has jammed or encountered a second article, convey the first and second articles simultaneously and without substantial gap there between during such conveyance.

150. The conveyor controller of claim 149, wherein the program code is further configured to supply a voltage signal to the motorized roller and deactivate the motorized roller after a target period of time during which a current level of the voltage signal has not reached a low target level and a high target level.

151. The conveyor controller of claim 149, wherein the program code is further configured to supply a voltage signal to the motorized roller and deactivate the motorized roller after a target period of time during which a current level of the voltage signal has reached a low target level.

152. The conveyor controller of claim 149, wherein the program code is further configured to supply a voltage signal to the motorized roller and deactivate the motorized roller when a current level of the voltage signal has reached a high target level.

153. A program product, comprising:

program code configured to be executed by at least one processing unit to determine whether a current through a motorized roller is associated with a low level to indicate that the motorized roller is conveying a first article, determine whether the current through the motorized roller is associated with a high level to indicate that the first article has encountered a second article in response to determining that the motorized roller is conveying the first article, and, in response to determining that the first article has jammed or encountered a second article, convey the first and second articles simultaneously and without substantial gap therebetween during such conveyance; and

a non-transitory computer readable medium bearing the program code.

154. A method of controlling at least a portion of a conveyor with a conveyor controller in a conveyor system having at least one downstream conveyor controller and at least one upstream conveyor controller to the conveyor controller, the method comprising:

sending a message to the downstream conveyor controller to request data to determine whether at least a portion of the conveyor controlled thereby is occupied by an article;

if the at least a portion of the conveyor controlled by the downstream conveyor controller is not occupied by an article, operating a motorized roller to convey an incoming article at a target speed; and

if the at least a portion of the conveyor controlled by the downstream conveyor controller is occupied by an article, operating the motorized roller to convey an incoming article at an adjusted target speed that is slower than the target speed.

155. The method of claim 154, wherein the message is sent in response to a notification from the upstream conveyor controller indicating the transfer of control of the incoming article from the upstream conveyor controller to the conveyor controller.

156. The method of claim 154, further comprising:

receiving a message from the downstream conveyor controller that includes data indicating whether the at least a portion of the conveyor controlled by the downstream conveyor controller is occupied by an article.

157. The method of claim 154, further comprising:

determining whether a first portion or a second portion of the conveyor controlled by the downstream conveyor controller is occupied by the article; and

setting the adjusted target speed to a first target speed when the first portion of the conveyor is occupied by the article; and

setting the adjusted target speed to a second target speed when the first portion of the conveyor is not occupied by the article but the second portion of the conveyor is occupied by the article, wherein the first target speed is lower than the second target speed.

158. A conveyor controller, comprising:

at least one processing unit;

a memory; and

program code resident in the memory, the program code configured to be executed by the at least one processing unit to sending a message to a downstream conveyor controller to request data to determine whether at least a portion of a conveyor controlled thereby is occupied by an article, operating a motorized roller to convey an incoming article at a target speed if the at least a portion of the conveyor controlled by the downstream conveyor controller is not occupied by an article, and operating the motorized roller to convey an incoming article at an adjusted target speed that is slower than the target speed if the at least a portion of the conveyor controlled by the downstream conveyor controller is occupied by an article.

160. The conveyor controller of claim 158, wherein message is sent in response to a notification from an upstream conveyor controller indicating the transfer of control of the incoming article from the upstream conveyor controller to the conveyor controller.

161. The conveyor controller of claim 158, wherein the program code is further configured to receiving a message from the downstream conveyor controller that includes data indicating whether the at least a portion of the conveyor controlled by the downstream conveyor controller is occupied by an article

162. The conveyor controller of claim 158, wherein the program code is further configured to determine whether a first portion or a second portion of the conveyor controlled by the downstream conveyor controller is occupied by the article, set the adjusted target speed to a first target speed when the first portion of the conveyor is occupied by the article, and set the adjusted target speed to a second target speed when the first portion of the conveyor is not occupied by the article but the second portion of the conveyor is occupied by the article, wherein the first target speed is lower than the second target speed.

163. A program product, comprising:

program code configured to be executed by at least one processing unit to sending a message to a downstream conveyor controller to request data to determine whether at least a portion of a conveyor controlled thereby is occupied by an article, operating a motorized roller to convey an incoming article at a target speed if the at least a portion of the conveyor controlled by the downstream conveyor controller is not occupied by an article, and operating the motorized roller to convey an incoming article at an adjusted target speed that is slower than the target speed if the at least a portion of the conveyor controlled by the downstream conveyor controller is occupied by an article; and

a non-transitory computer readable medium bearing the program code.