Bilateral sorter

• US 6,264,042 B1
• Filed: 11/15/1999
• Issued: 07/24/2001
• Est. Priority Date: 11/15/1999
• 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: Cossey, James R. Jr., Prutu, Victor N., Tew, Richard J.
• Primary Examiner(s): Walsh, Donald P.
• Assistant Examiner(s): Beauchaine, Mark J.
• Application Number:
  US09/439,398
• Time in Patent Office: 617 Days
• Field of Search: 209/559, 209/651, 198/890, 198/570, 198/571, 198/572, 198/575, 198/577, 198/597
• US Class Current: 209/559
• CPC Class Codes: B07C 5/362 Separating or distributor mechanisms switches for postal sorting B07C3/065; particular discharging devices for B65G47/74
• CPC Class Codes: B65G 1/00 Storing articles, individually or in orderly arrangement, in warehouses or magazines conveyor combinations in warehouses, magazines or workshops B65G37/00; stacking of articles B65G57/00; removing articles from stacks B65G59/00; loading machines B65G65/02
• CPC Class Codes: B65G 47/53 between conveyors which cross one another

Abstract

A system for sorting objects includes an upstream and a downstream conveyor positioned to sequentially receive and convey an object along a first path, and a sorting conveyor belt positioned transversely in a gap between the upstream and downstream conveyors. The sorting conveyor is tilted with respect to the plane of the other conveyors, and carries flexible projections that lift one edge of the object and push it The operation of the sorting belt reduces static friction between the object and the main conveyors as the object is pushed. The system also includes a measuring device operatively linked to provide dimensions and position information about the object to a sorting conveyor controller.

Claims

1. A system for sorting objects, comprising:

an upstream and a downstream conveyor positioned to sequentially receive and convey an object along a first path, said conveyors defining a gap transverse to the first path;

an elongate sorting member positioned in said transverse gap, said sorting member including an elongate carrier strip defining at least one diverter section comprising a plurality of flexible, spaced apart projections extending upwardly from said carrier strip, and at least one generally planar section adjacent to said diverter section; and

an actuator connected selectively to move said projections against and under an object travelling across said sorting member to carry the object off the conveyors, and selectively to position said planar section in the path of an object to allow the object to pass over the sorting member without being diverted.

2. The sorting system of claim 1, wherein said carrier strip slopes upwardly from said upstream conveyor across said gap toward said downstream conveyor, such that a leading portion of the object is raised above said upstream conveyor as the object crosses said gap.

3. The sorting system of claim 2, wherein said downstream conveyor is positioned higher than said upstream conveyor.

4. The sorting system of claim 1, wherein said actuator moves said sorting member in either of two directions to divert objects off a selected one of two sides of said conveyors.

5. The sorting system of claim 4, further comprising a measuring device positioned to determine a transverse position on said upstream conveyor of a side edge of the object opposite the selected side of said conveyor to which the object is to be diverted.

6. The sorting system of claim 5, wherein said measuring device comprises a light curtain positioned above said upstream conveyor.

7. The sorting system of claim 5, wherein said actuator comprises a controller configured to move said sorting member in response to a signal from said measuring device indicating an approaching object.

8. The sorting system of claim 7, wherein said controller receives from said measuring device the transverse position on said upstream conveyor of the side edge of the object opposite the selected side of said conveyor to which the object is to be diverted, and causes said actuator to position said diverter section of said sorting member adjacent to the path of said side edge of the object prior to the object reaching the sorting member.

9. The sorting system of claim 8, wherein said sorting member comprises an endless belt, said controller being a programmable servo motor connected to reversibly drive said belt.

10. The sorting system of claim 7, wherein said controller receives from said measuring device longitudinal positions of the leading and trailing edges of the object, and causes said actuator to move said projections against and under the object at a selected location along its length.

11. The sorting system of claim 1, further comprising a sensor positioned to detect an object on said upstream conveyor, and wherein said actuator comprises a controller configured to move said sorting member in response to a signal from said sensor.

12. The sorting system of claim 11, wherein said sensor measures the longitudinal position, length, height and width of the object, and wherein said actuator comprises a controller configured to calculate a speed and acceleration of movement of said sorting member based on dimensions of the object.

13. The sorting system of claim 12, wherein said sorting member comprises an endless belt, said controller being a programmable servo motor connected to reversibly drive said belt.

14. A system for sorting objects, comprising:

an upstream and a downstream conveyor positioned to sequentially receive and convey an object along a first path, said conveyors defining a gap transverse to said first path;

a measuring device positioned to determine a transverse position on said upstream conveyor of a side edge of the object opposite a side of said conveyor to which the object is to be diverted;

an elongate sorting member positioned in said transverse gap, said sorting member including at least one projection extending upwardly from said carrier strip;

an actuator connected selectively to move said projection adjacent to the path of said side edge of the object prior to the object reaching the sorting member; and

to move said projection to engage the object and move the object off the conveyors when the object is over the sorting member, and selectively to allow the object to pass over the sorting member without being diverted.

15. The sorting system of claim 14, wherein said sorting member includes an elongate carrier strip defining at least one diverter section comprising a plurality of flexible, spaced apart projections extending upwardly from said carrier strip, and at least one generally planar section adjacent to said diverter section.

16. The sorting system of claim 15, wherein said carrier strip slopes upwardly from said upstream conveyor across said gap toward said downstream conveyor, such that a leading portion of the object is raised above said upstream conveyor as the object crosses said gap.

17. The sorting system of claim 16, wherein said downstream conveyor is positioned higher than said upstream conveyor.

18. The sorting system of claim 15, wherein said actuator moves said sorting member in either of two directions to divert objects a selected one of two sides of said conveyors.

19. A system for sorting objects, comprising:

an upstream and a downstream conveyor positioned to sequentially receive and convey an object along a first path, said conveyors defining a gap transverse to said first path;

an elongate member positioned in said transverse gap, said elongate member including a generally planar portion sloping upwardly from said upstream conveyor across said gap toward said downstream conveyor, such that a leading portion of the object is raised above said upstream conveyor as the object crosses said gap;

a diverter movable to intersect the object moving along said first path; and

an actuator connected selectively to move said diverter to move the object off the conveyors, and selectively to allow the object to pass over the gap without being diverted.

20. The sorting system of claim 19, wherein said elongate member is movable transversely with respect to said gap, and said diverter comprises upwardly projecting cleats movable with said elongate member.

21. A method for sorting objects, comprising:

moving an object along a first path;

determining whether the object should be sorted;

if the object is to be sorted, then

measuring the transverse position of the object relative to the first path;

pre-positioning a sorting device based on the transverse position of the object;

sorting the object with the sorting device by lifting an edge of the object and pushing the object along a sort direction away from said first path;

if the object is not to be sorted, then moving the object across the sorting device onto a third path; and

moving the object along the third path away from said first path.

22. The method of claim 21, further comprising measuring the length, width, and height dimensions of the object;

and pushing the object at a speed and acceleration based on said dimensions.

23. The method of claim 22, wherein the step of measuring the dimensions of the object further comprises measuring the length of the object by detecting a leading edge and trailing edge of the object;

and further comprising;

measuring a velocity of the object along the first path based on detection of the leading and trailing edges; and

timing the pushing of the object based on the velocity of the object.

24. A system for sorting objects, comprising:

a first conveyor positioned to convey an object along a first direction toward a sorting position, said object having a pair of peripheral points transverse to said first direction;

a second conveyor positioned to receive said object from said first conveyor in a selected portion of said second conveyor,

a measuring device positioned to detect at least one of said peripheral points of said object on said first conveyor; and

a controller configured to adjust a speed of at least one of said conveyors in response to said detected peripheral points to cause said object to be delivered to said selected portion of said second conveyor.

25. The sorting system of claim 24, wherein said second conveyor is positioned substantially transverse to said first conveyor.

26. The sorting system of claim 24, wherein said measuring device comprises a light curtain positioned above said first conveyor to detect at least one of said peripheral points of said object.

27. The sorting system of claim 24, wherein said measuring device detects a plurality of said peripheral points, and said controller calculates at least one dimension of said object in response to said detected peripheral points.

28. The sorting system of claim 27, wherein said controller adjusts a speed of at least one of said conveyors based at least in part on said dimension of said object.

29. The sorting system of claim 27, wherein said peripheral points include a leading edge and a trailing edge of said object, wherein said dimension is a length of said object, and wherein said controller calculates an approximate longitudinal center of gravity of said object based at least in part on said length of said object and adjusts a speed of at least one of said conveyors based at least in part on said center of gravity.

30. The sorting system of claim 27, wherein said controller selects an acceleration profile from a look up table based at least in part on said dimension of said object and uses said acceleration profile to adjust a speed of at least one of said conveyors.

31. The sorting system of claim 24, wherein said controller receives from said measuring device transverse position information for one of said detected peripheral points, and is configured to position said second conveyor with respect to said transverse position information.

32. The sorting system of claim 24, wherein said controller adjusts a speed of at least one of said conveyors based at least in part on a weight of said object.

33. The sorting system of claim 24, wherein said controller adjusts a speed of at least one of said conveyors based at least in part on a center of gravity of said object.

34. The sorting system of claim 24, wherein said controller adjusts a speed of said second conveyor.

35. The sorting system of claim 24, wherein said second conveyor comprises a plurality of upwardly extending projections adjacent to said selected portion.