US 12,077,389 B2
System and method for controlling an accumulation conveyor
Kevin Klueber, Monroe, OH (US); and Randolph T. Skanse, Mason, OH (US)
Assigned to Intelligrated Headquarters, LLC, Mason, OH (US)
Filed by Intelligrated Headquarters, LLC, Mason, OH (US)
Filed on Apr. 27, 2023, as Appl. No. 18/308,006.
Application 18/308,006 is a continuation of application No. 17/113,705, filed on Dec. 7, 2020, granted, now 11,667,478.
Application 17/113,705 is a continuation of application No. 16/162,923, filed on Oct. 17, 2018, granted, now 10,889,451, issued on Jan. 12, 2021.
Prior Publication US 2024/0076139 A1, Mar. 7, 2024
Int. Cl. B65G 43/08 (2006.01); B65G 43/10 (2006.01); B65G 47/26 (2006.01); G05B 19/418 (2006.01)
CPC B65G 43/08 (2013.01) [B65G 43/10 (2013.01); B65G 47/261 (2013.01); B65G 47/268 (2013.01); G05B 19/4189 (2013.01); B65G 47/263 (2013.01)] 19 Claims
OG exemplary drawing
 
1. A method for controlling an accumulation conveyor, the accumulation conveyor comprising a plurality of zones, the plurality of zones comprising at least a first zone, a second zone and a third zone, wherein the first zone is upstream of the second zone and the second zone is upstream of a third zone, the method comprising:
receiving, by a second control module associated with the second zone, a third feedback signal from a third control module associated with the third zone, wherein the third feedback signal indicates that a third sensor in the third zone is blocked;
setting, by the second control module, a second drive assembly associated with the second zone to a disengaged state;
receiving, by the second control module, a first signal from a first control module associated with the first zone, wherein the first signal indicates that one of a first article having an irregular boundary or a second article having a regular boundary exits from the first zone;
controlling, by the second control module, the second drive assembly and a second brake assembly associated with the second zone based on the indication of the exit of the one of the first article or the second article from the first zone by the first signal received from the first control module,
wherein the controlling of the second drive assembly and the second brake assembly further comprises:
setting the second drive assembly to an engaged state until a first sensor is blocked by the first article; and
setting the second drive assembly to the disengaged state and the second brake assembly to an engaged state when the first article blocks a second sensor in an instance in which the first signal indicates that the first article having the irregular boundary exits from the first zone and the first article enters the second zone.
 
9. A material handling system, comprising:
an accumulation conveyor comprising:
a plurality of zones comprising at least a first zone, a second zone, and a third zone, wherein the first zone is upstream of the second zone, wherein the second zone is upstream of the third zone;
a plurality of sensors, comprising at least a first sensor, a second sensor, and a third sensor, wherein the first sensor is located at an exit portion of the first zone, the second sensor is located at an exit portion of the second zone, and the third sensor is located at an exit portion of the third zone; and
a plurality of control modules comprising at least a first control module, a second control module, and a third control module, wherein the first control module is communicably coupled with the first sensor, the first zone, and second control module, wherein the second control module is communicably coupled with the second sensor, the second zone, and third control module, wherein the third control module is communicably coupled with the third sensor and the third zone,
wherein the second control module is configured to:
receive a third feedback signal from the third control module, wherein the third feedback signal indicates that the third sensor in the third zone is blocked;
set a second drive assembly associated with the second zone to a disengaged state;
receive a first signal from the first control module associated with the first zone, wherein the first signal indicates that one of a first article having an irregular boundary or a second article having a regular boundary exits from the first zone;
control the second drive assembly and a second brake assembly associated with the second zone based on the indication of the exit of the one of the first article or the second article from the first zone by the first signal received from the first control module; and
a main controller communicably coupled with the accumulation conveyor to perform operations to receive data indicating conditions for each zone of the plurality of zones,
wherein the controlling of the second drive assembly and the second brake assembly further comprises:
setting the second drive assembly to an engaged state until the first sensor is blocked by the first article; and
setting the second drive assembly to the disengaged state and the second brake assembly to an engaged state when the first article blocks the second sensor in an instance in which the first signal indicates that the first article having the irregular boundary exits from the first zone and the first article enters the second zone.
 
19. A material handling system, comprising:
an accumulation conveyor comprising:
a plurality of zones comprising at least a first zone, a second zone, and a third zone, wherein the first zone is upstream of the second zone, wherein the second zone is upstream of the third zone;
a plurality of sensors, comprising at least a first sensor, a second sensor, and a third sensor, wherein the first sensor is located at an exit portion of the first zone, the second sensor is located at an exit portion of the second zone, and the third sensor is located at an exit portion of the third zone; and
a plurality of control modules comprising at least a first control module, a second control module, and a third control module, wherein the first control module is communicably coupled with the first sensor, the first zone, and second control module, wherein the second control module is communicably coupled with the second sensor, the second zone, and third control module, wherein the third control module is communicably coupled with the third sensor and the third zone,
wherein the second control module is configured to:
receive a third feedback signal from the third control module, wherein the third feedback signal indicates that the third sensor in the third zone is blocked;
set a second drive assembly associated with the second zone to a disengaged state;
receive a first signal from the first control module associated with the first zone, wherein the first signal indicates that one of a first article having an irregular boundary or a second article having a regular boundary exits from the first zone;
control the second drive assembly and a second brake assembly associated with the second zone based on the indication of the exit of the one of the first article or the second article from the first zone by the first signal received from the first control module; and
a main controller communicably coupled with the accumulation conveyor to perform operations to receive data indicating conditions for each zone of the plurality of zones,
wherein the controlling of the second drive assembly and the second brake assembly further comprises maintaining the second drive assembly in the disengaged state in an instance in which the first signal indicates that the second article having the regular boundary exits from the first zone and the second article enters the second zone, wherein the second article entering the second zone coasts to stop exhibiting zero pressure accumulation due to the disengaged state of the second drive assembly.