Method and apparatus for sorting articles using a matrix of conveyor cells

• US 6,230,872 B1
• Filed: 02/25/1999
• Issued: 05/15/2001
• Est. Priority Date: 02/02/1996
• Status: Expired due to Term

• Current Assignee: United Parcel Service Of America Incorporated (United Parcel Service Incorporated)
• Original Assignee: United Parcel Service Of America Incorporated (United Parcel Service Incorporated)
• Inventors: Cai, Chunsheng, Lecko, John, Janik, Jaroslav, Huang, Pao-Ter
• Primary Examiner(s): Bidwell, James R.
• Application Number:
  US09/257,111
• Time in Patent Office: 810 Days
• Field of Search: 198/345.3, 198/367, 198/367.2, 198/368, 198/370.09, 198/370.06, 198/370.1, 193/35.A
• US Class Current: 198/368
• CPC Class Codes: B07C 3/02 Apparatus characterised by the means used for distribution
• CPC Class Codes: B07C 3/08 using arrangements of conveyors transport of sheets B65H; transport in general B65G
• CPC Class Codes: B65G 2207/18 Crossing conveyors
• CPC Class Codes: B65G 47/643 in a vertical plane
• CPC Class Codes: Y10S 209/939 Video scanning

Abstract

An efficient package sorting system in which a stationary matrix of multi-directional conveyor cells sorts packages to a plurality of destination locations. In a preferred embodiment, the matrix delivers sorted packages to a plurality of lift assemblies that further transfer the packages to receiving conveyors or chutes on different levels. According to another preferred aspect of the system, a selectively elevating stop bar is provided to control side transfer between conveyor cells. A controller is operative to plan a path for each of the objects from the input cell to a destination location, to monitor availability of successive conveyor cells along the path, and to cause an object to be moved to the next conveyor cell along its path only when the next conveyor cell is available. The system may include a plurality of sensors positioned to sense the passage of objects from one conveyor cell to another, the sensors being connected to the controller. The sensor input is used to guide the packages through the matrix, and to optimize the speed at which a plurality of packages can be sorted.

Claims

1. In a conveyor unit including a plurality of spaced apart rollers extending to a unit edge extending perpendicular to a longitudinal axis of said rollers, a side stop plate assembly, comprising:

an elongate stop plate configured for pivoting movement and when in its stopping position extending parallel to said unit edge and spaced inwardly from said unit edge above said rollers, and defining a pair of arms extending downwardly from said stop plate between said rollers to be pivotally attached to a support member of said conveyor unit;

said stop plate being pivotable about a fixed point from an elevated, substantially nonhorizontal position above said rollers to a horizontal position along said unit edge; and

a moving device for moving said stop plate between said elevated position and said horizontal position.

2. The conveyor unit of claim 1, wherein said means for moving said stop plate comprises a foldable linkage attached to a linear actuator, said foldable linkage including a folding pivot point which moves when said stop plate is moved between said elevated position and said horizontal position, wherein said linkage locks against pressure on said stop plate when said stop plate in said elevated position.

3. The conveyor unit of claim 2, wherein said linear actuator comprises a fluid-actuated cylinder including a piston rod pivotally attached intermediate the ends of said foldable linkage.

4. The conveyor unit of claim 3, wherein said foldable linkage comprises a shaft pivotally connected at one end thereof to said support member, said shaft slidably mounted within a bearing pivotally connected to said piston rod, and pivotally connected at the other end of said shaft to a link arm, said link arm pivotally connected to said stop plate.

5. The conveyor unit of claim 4, said unit further comprising a low-friction material mounted on said stop plate.

6. In a conveyor unit including a frame, a plurality of spaced apart conveying rollers defining a conveying support plane, said rollers extending to a unit edge extending perpendicular to a longitudinal axis of said rollers, and a side stop plate assembly for use with said conveying rollers, said side stop assembly itself comprising:

A) a stop plate configured for pivoting movement between a stopping position and a cleared position, said stop plate itself comprising;

1) a stopping portion configured to provide a stop; and

2) at least one arm extending relative to said stopping portion and terminating at a free end;

B) a pivoting connection between said free end of said arm and said frame, said pivoting connection configured to cause said stopping portion to be pivoted about a fixed point between said stopping position and said cleared position, said stopping position being an elevated, substantially nonhorizontal position above said conveying support plane and spaced inwardly from said unit edge, and said cleared position being retracted below said conveying support plane and spaced outwardly of from said unit edge; and

C) a moving device for moving said stopping portion between said elevated position and said horizontal position.

7. In the conveyor unit of claim 6, wherein said moving device is a linear actuator.

8. In the conveyor unit of claim 7, wherein said linear actuator is a fluid cylinder.

9. In a conveyor unit including a frame, a plurality of spaced apart conveying rollers defining a conveying support plane, said rollers extending to a unit edge extending perpendicular to a longitudinal axis of said rollers, and a side stop plate assembly for use with said conveying rollers, said side stop assembly itself comprising:

A) a stop plate configured for pivoting movement between a stopping position and a cleared position, said stop plate itself comprising;

1) a stopping portion configured to provide a stop; and

2) at least one arm extending relative to said stopping portion and terminating at a free end;

B) a pivoting connection between said free end of said arm and said frame, said pivoting connections configured to cause said stopping portion to be pivoted about a fixed point between said stopping position and said cleared position, said stopping position being an elevated, substantially nonhorizontal position above said conveying support plane, and said cleared position being retracted below said conveying support plane; and

C) a moving device for moving said stopping portion between said elevated position and said horizontal position.

10. In the conveyor unit of claim 9, wherein said moving device is a linear actuator.

11. In the conveyor unit of claim 10, wherein said linear actuator is a fluid cylinder.

19. In the conveyor unit of claim 11, wherein all of said recited pivoting connections have substantially parallel pivoting axes.

20. In the conveyor unit of claim 11, wherein said stop plate portion when in said cleared position provides an upwardly-directed support surface substantially parallel to said conveying support plane.

21. In the conveyor unit of claim 11, wherein said stop plate portion when in said cleared position provides an upwardly-directed support surface substantially coplanar to said conveying support plane.

12. In a conveyor unit including a frame having a frame pivot point, a plurality of spaced apart conveying rollers defining a conveying support plane, said rollers extending to a unit edge extending perpendicular to a longitudinal axis of said rollers, and a side stop plate assembly for use with said conveying rollers, said side stop assembly itself comprising:

A) a stop plate configured for pivoting movement between a stopping position and a cleared position, said stop plate including a plate-linkage pivot point and itself comprising;

1) a stopping portion configured to provide a stop; and

2) at least one arm extending relative to said stopping portion and terminating at a free end;

B) a pivoting connection between said free end of said arm and said frame, said pivoting connection configured to cause said stopping portion to be pivoted about a fixed point between said stopping position and said cleared position, said stopping position being an elevated, substantially nonhorizontal position above said conveying support plane, and said cleared position being retracted below said conveying support plane; and

C) a moving device for moving said stopping portion between said stopping position and said cleared position, said moving device itself comprising;

1) a linkage assembly linking said plate-linkage pivot point and said frame pivot point, said linkage assembly including first and second linkage members, said first linkage member having one end pivotably attached to said plate-linkage pivot point of said stop plate and the other end attached to said second linkage member at a common linkage pivot point, said second linkage member having one end pivotably attached to said first linkage member at said common linkage pivot point and the other end attached to said frame pivot point, said linkage assembly itself movable from a stopping position to a cleared position; and

2) a moving device for moving said linkage assembly from said stopping position to said cleared position such that said stop plate assembly is pivoted from said stopping position to said cleared position, such that when said linkage assembly is in said stopping position said common linkage pivot point is substantially coaligned with said frame pivot point and said plate-linkage pivot point, such that said linkage assembly locks against pressure when said stop plate assembly is providing its stopping function when in said stopping position.

13. In the conveyor unit of claim 12, wherein said moving device is a linear actuator.

14. In the conveyor unit of claim 13, wherein said linear actuator is a fluid cylinder.

15. In the conveyor unit of claim 13, wherein said linear actuator and said linkage assembly are connected by a sliding connection.

16. In the conveyor unit of claim 12, wherein said moving device is configured to provide force relative to one of said linkages sufficient to assist said pivoting.

17. In the conveyor unit of claim 16, wherein said linkage receiving said force is said second linkage.

18. In the conveyor unit of claim 17, wherein said linear actuator and said linkage assembly are connected by a sliding connection.

22. A conveying system for moving items along a conveyor path, said system comprising;

a first conveyor bed defining an upwardly-directed conveyor support plane partially defining said conveyor path;

a second conveyor bed defining an upwardly-directed conveyor support plane also partially defining said conveyor path; and

a pivoting stop plate assembly pivotable between a stopping position and a retracted position, said plate when in said stopping position configured to stop items from being conveyed from said first conveyor bed to said second conveyor bed, and said plate when in said retracted position configured to at least partially bridge a gap between said two beds and to provide a flat sliding surface portion to allow items to be slid across said pivoting stop plate and across said gap from said first conveyor bed to said second conveyor bed.

23. The conveyor system as claimed in claim 22, wherein said flat sliding surface portion of said pivoting stop plate is substantially parallel to said support surfaces of said first and second conveyors.

24. The conveyor system as claimed in claim 22, wherein said flat sliding surface portion of said pivoting stop plate is substantially coplanar with said support surfaces of said first and second conveyors.