Decentralized tracking of packages on a conveyor

• US 8,284,993 B2
• Filed: 06/18/2009
• Issued: 10/09/2012
• Est. Priority Date: 06/18/2009
• Status: Active Grant

• Current Assignee: Hytrol Conveyor Company, Inc.
• Original Assignee: Hytrol Conveyor Company, Inc.
• Inventors: Taylor, Bryan Dale, Mullis, Clifford Allen, Prince, Cole Jeremiah
• Primary Examiner(s): Seth, Manav
• Application Number:
  US12/487,439
• Publication Number:
  US 20100322473A1
• Time in Patent Office: 1,209 Days
• Field of Search: None
• US Class Current: 382/103
• CPC Class Codes: B65G 43/10 Sequence control of conveyors operating in combination

Abstract

A decentralized tracking system is discussed herein. The decentralized tracking system can be comprised of two or more tracking elements and be used to track packages moving on a conveyor system. Each tracking element can operate independently, despite being highly sophisticated and dynamically coordinated with one or more other tracking elements. The conveyor system can be a modular and/or accumulation conveyor system that has sorting functionality. The decentralized tracking system can be used to divert packages for sortation by, for example, embedding a destination zone into the package'"'"'s tracking data and/or preprogramming conveyor zones to sort specific packages based on a package identifier.

Claims

1. A method of tracking packages on a multi-zone conveyor having a subject zone and a downstream zone, the method comprising:

receiving, with subject zone circuitry that is dedicated to the subject zone, first package tracking data, wherein the first package tracking data represents a first package;

in response to receiving the first package tracking data, storing the first package tracking data in a subject zone loading registry;

detecting the presence of the first package in the subject zone;

in response to detecting the first package in the subject zone,

reassigning the first package tracking data from the subject zone loading registry to a subject zone registry;

receiving, with the subject zone circuitry, second package tracking data, wherein the second package tracking data represents a second package; and

storing the second package tracking data in the subject zone loading registry.

2. The method of claim 1 further comprising receiving the first package in the downstream zone.

3. The method of claim 2 further comprising:

in response to detecting the first package in the subject zone, sending a notification to the downstream zone of the first package; and

receiving, with downstream zone circuitry dedicated to the downstream zone, the notification of the first package.

4. The method of claim 3 further comprising:

sending the first package tracking data from the subject zone to the downstream zone, wherein the downstream zone circuitry receives the first package tracking data directly from the subject zone circuitry; and

storing the first package tracking data in a downstream zone loading registry that is dedicated to storing data about a package that is at least partially physically located in the subject zone.

5. The method of claim 1 further comprising:

detecting the presence of the second package in the subject zone; and

in response to detecting the second package in the subject zone;

deleting the first package tracking data from the subject zone registry; and

reassigning the second package tracking data from the subject zone loading registry to the subject zone registry.

6. The method of claim 5 comprising, prior to deleting the first package tracking data and prior to reassigning the second package tracking data, determining that the detecting of the second package occurred within a predetermined period of time from when the storing the second package tracking data in the subject zone loading registry occurred.

7. The method of claim 6 further comprising:

determining that an error occurred prior to the first package being detected in the downstream zone; and

in response to determining that the error occurred, deleting the first package tracking data from the downstream zone loading registry.

8. The method of claim 7 further comprising:

in response to determining that the error occurred, replacing the first package tracking data with error tracking data.

9. The method of claim 1 further comprising:

outputting the first package tracking data to a display device; and

displaying first package information that corresponds with the first package tracking data.

10. The method of claim 1, wherein detecting the presence of the first package comprises detecting a leading edge of the first package in the subject zone.

11. The method of claim 1, wherein receiving the first package tracking data comprises receiving data from one or more input components.

12. The method of claim 1 further comprising:

in response to receiving the first package tracking data, generating a redirecting command; and

sending the redirecting command to a mechanical transducer.

13. The method of claim 1, wherein receiving the first package tracking data comprises receiving a unique package identifier associated with the first package.

14. The method of claim 13, further comprising:

parsing the unique package identifier;

determining that a portion of the unique package identifier matches a diversion zone identifier; and

in response to determining that the portion of the unique package identifier matches the diversion zone identifier, generating an output that causes a diversion zone associated with the diversion zone identifier to be activated.

15. A package tracking element for a conveyor system, comprising:

a sensor configured to sense a package;

a data storage component, wherein the data storage component includes a loading registry and a zone registry;

communications circuitry configured to receive tracking data that represents a package; and

decentralized tracking circuitry that is configured to;

receive the tracking data;

store the tracking data in the loading registry;

receive position data from the sensor that indicates the package is being detected by the sensor; and

in response to receiving the position data, reassign the tracking data from the loading registry to the zone registry.

16. The tracking element of claim 15, wherein the sensor is a photo eye that generates the position data in response to detecting the package.

17. The tracking element of claim 15 further comprising a data port that receives upstream tracking data from an upstream tracking element, wherein the upstream tracking data is associated with an upstream package.

18. The tracking element of claim 17, wherein the upstream tracking data is received subsequent to an upstream sensor detecting the upstream package.

19. The tracking element of claim 18, wherein the upstream position data is stored in the loading registry subsequent to the upstream position data being received by the tracking element.

20. The tracking element of claim 18, wherein the upstream tracking data is sent to the tracking element by upstream communications circuitry of the upstream tracking element.

21. The tracking element of claim 15, in response to the sensor sensing the package, determining that package is nearing a downstream portion of a conveyor area being monitored by the tracking element.

22. The tracking element of claim 21, in response to determining the package is nearing the downstream portion of the conveyor area, the tracking element sends a notification signal to a downstream tracking element.

23. The tracking element of claim 22, wherein the notification signal comprises the tracking data to the downstream tracking element.

24. A redirection apparatus for a conveyor system, comprising:

a sensor that detects a package;

a data storage component, wherein the storage component includes a loading registry and a zone registry;

communications circuitry configured to facilitate downloading of tracking data that represents the package;

decentralized tracking circuitry that is configured to;

receive the tracking data;

store the tracking data in the loading registry;

receive position data from the sensor that indicates the package is being detected by the sensor; and

in response to receiving the position data;

delete the tracking data from the loading registry; and

store the tracking data in the zone registry; and

redirection circuitry that is configured to;

determine whether the package is to be redirected by parsing the tracking data; and

in response to determining that the package is to be redirected, send a redirection command to a mechanical transducer.

25. The redirection apparatus of claim 24, wherein:

the decentralized tracking circuitry is further configured to cause the communications circuitry to send the tracking data to an external device in response to the package being redirected to the new zone.