Abstract:
A product handling system includes a product conveyor capable of transporting a plurality of products. An overhead diverter assembly includes a flighted conveyor situated substantially orthogonal to the product conveyor that includes a flight. A transport containment device is located at least partially below the flighted conveyor. A control system operates the overhead diverter such that the flighted conveyor has a diverting mode and a cassette filling mode. When the flighted conveyor is in the diverting mode, the flight moves in a profiled motion to acquire the product from the product conveyor at a location beneath the overhead diverter and transports the product along the transport containment device.

Description:
TECHNICAL FIELD 
     The present invention is generally directed to apparatuses for diverting products and methods of handling products. 
     BACKGROUND 
     Various systems may be provided between a product supply and a packaging apparatus. For example, it is known to utilize conveyors and motorized systems to automatically transport product between processing operations. However, in some instances there may be a need to divert at least some of the product to a different processing operation. For example, guide rails or walls may be used to divert some product travelling along a conveyor line to a different conveying line. However, such systems may have limited control over how much product is being diverted and the arrangement or orientation of the product, once diverted. 
     SUMMARY 
     In one embodiment, a product handling system includes a product conveyor capable of transporting a plurality of products. An overhead diverter assembly includes a flighted conveyor situated substantially orthogonal to the product conveyor that includes a flight. A transport containment device is located at least partially below the flighted conveyor. A control system operates the overhead diverter such that the flighted conveyor has a diverting mode and a cassette filling mode. When the flighted conveyor is in the diverting mode, the flight moves in a profiled motion to acquire the product from the product conveyor at a location beneath the overhead diverter and transports the product along the transport containment device. 
     In another embodiment, a product handling system includes a product conveyor capable of transporting a plurality of products. An overhead diverter assembly includes at least three or more flighted conveyors. The overhead diverter includes a first flighted conveyor situated substantially orthogonal to the product conveyor. The first flighted conveyor includes a first train of first flights for diverting products from the product conveyor. A second flighted conveyor is situated substantially orthogonal to the product conveyor. The second flighted conveyor includes a second train of second flights for diverting products from the product conveyor. A third flighted conveyor is situated substantially orthogonal to the product conveyor. The third flighted conveyor includes a third train of third flights for diverting products from the product conveyor. A cassette conveyor includes a cassette conveyor belt that moves cassettes toward a transfer location. A control system operates the overhead diverter such that each of the first, second and third flighted conveyors has a diverting mode and a cassette filling mode. When at least one of the first, second and third flighted conveyors is in the cassette filling mode product diverted from the product conveyor is transferred to a cassette at the transfer location. 
     In another embodiment, a product handling system includes a flighted conveyor for transferring a collection of individual products having variable speed. A cassette conveyor has a substantially constant speed. A plurality of cassettes are disposed on the cassette conveyor. Each of the plurality of cassettes includes receptacles for receiving the collection of individual products from the flighted conveyor during a transfer operation. A synchronizing system includes an engaging structure that engages one or more of the plurality of cassettes to synchronize the speed and position of the one or more cassettes and the flighted conveyor during the transfer operation. The speed and positioning of the cassettes are controlled by the cassette conveyor at a point before and after the transfer operation. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The following detailed description of specific embodiments of the present invention can be best understood when read in conjunction with the drawings enclosed herewith. 
         FIG. 1  is a diagrammatic plan view of an embodiment of a product handling system including an overhead diverter assembly; 
         FIG. 2  is a perspective view of an embodiment of an overhead diverter assembly for use in the product handling system of  FIG. 1 ; 
         FIG. 3  is another perspective view of the overhead diverter assembly of  FIG. 2 ; 
         FIG. 4  is a top view of the overhead diverter assembly of  FIG. 2 ; 
         FIG. 5  is a perspective view of an embodiment of a flight for use with the overhead diverter assembly of  FIG. 2 ; 
         FIG. 6  is a section view of an embodiment of a train of multiple flights of  FIG. 5 ; 
         FIG. 7  is a perspective view of an embodiment of a cassette for use in the product handling system of  FIG. 1 ; 
         FIG. 8  is a section view of the cassette of  FIG. 7  along line  8 - 8 ; 
         FIG. 9  is a side view of the overhead diverter assembly of  FIG. 2 ; 
         FIG. 10  illustrates an embodiment of a diverting process using the overhead diverter assembly of  FIG. 2 ; 
         FIG. 11  illustrates an embodiment of a cassette filling process using the overhead diverter assembly of  FIG. 2 ; and 
         FIG. 12  illustrates an embodiment of a product handling system for handling multiple product types. 
     
    
    
     The embodiments set forth in the drawings are illustrative in nature and not intended to be limiting of the invention defined by the claims. Moreover, individual features of the drawings and invention will be more fully apparent and understood in view of the detailed description. 
     DETAILED DESCRIPTION 
     The following text sets forth a broad description of numerous different embodiments of the present invention. The description is to be construed as exemplary only and does not describe every possible embodiment since describing every possible embodiment would be impractical, if not impossible, and it will be understood that any feature, characteristic, component, composition, ingredient, product, step or methodology described herein can be deleted, combined with or substituted for, in whole or part, any other feature, characteristic, component, composition, ingredient, product, step or methodology described herein. Numerous alternative embodiments could be implemented, using either current technology or technology developed after the filing date of this patent, which would still fall within the scope of the claims. All publications and patents cited herein are incorporated herein by reference. 
     It should also be understood that, unless a term is expressly defined in this specification using the sentence “As used herein, the term ‘_’ is hereby defined to mean . . . ” or a similar sentence, there is no intent to limit the meaning of that term, either expressly or by implication, beyond its plain or ordinary meaning, and such term should not be interpreted to be limited in scope based on any statement made in any section of this patent (other than the language of the claims). No term is intended to be essential to the present invention unless so stated. To the extent that any term recited in the claims at the end of this patent is referred to in this patent in a manner consistent with a single meaning, that is done for sake of clarity only so as to not confuse the reader, and it is not intended that such a claim term be limited, by implication or otherwise, to that single meaning. Finally, unless a claim element is defined by reciting the word “means” and a function without the recital of any structure, it is not intended that the scope of any claim element be interpreted based on the application of 35 U.S.C. §112, sixth paragraph. 
     Embodiments described herein generally relate to systems and methods for handling products that utilize an overhead diverter assembly for use in diverting some, but in some instances not all, product provided from a product supply. In other instances, all or none of the products may be diverted using the overhead diverter assembly. The products may be provided using a supply conveyor that includes a continuous conveyor belt that passes underneath the overhead diverter assembly. A flighted conveyor of the overhead diverter assembly may be controlled to allow either the passing of the product along the supply conveyor or the diverting of the product by engaging the product to transport the product away from the supply conveyor. The passing product may be delivered to a first packaging location and the diverted product may be delivered to a second packaging location that is different from the first packaging location. In other instances, all of the product may be diverted and delivered to the second packaging location. 
     The systems and methods described herein may be useful in handling mass quantities of a number of products, particularly relatively lightweight products of less than about 1000 grams, such as less than about 100 grams, such as less than about 12 grams, such as absorbent articles that include a wrapper, such as wrapped tampons for feminine hygiene. Often times, lightweight products, such as wrapped tampons, may be somewhat easily damaged during mass product handling. Damage can be to the tampon itself and/or to the wrapper. In various embodiments, the systems and methods described herein may be useful in handling quantities of products having a mass of over 1000 grams. 
     By “tampon” it is meant herein an absorbent article, in some embodiments, a disposable one, comprising absorbent material usually being compressed into a self-sustaining, generally oblong, typically essentially cylindrical shape. In most cases the absorbent material comprises fibrous material, e.g. rayon, wood pulp fluff, cotton or the like. 
     By “length” of a tampon it is meant herein the linear extension of a tampon along its largest dimension. 
     “Wrapper” as used herein refers to a structure, which is formed of a wrapper material and which substantially encloses an individual absorbent article, in some embodiments, an individual tampon, for packaging purposes. The wrapper may be constituted of one connected piece of wrapper material, though a wrapper can also be made from multiple pieces of material sufficiently joined together such that it substantially acts as one connected piece of wrapper material. 
     By “wrapper material” it is meant herein any material suitable to be used for hygienically wrapping tampons. Various wrappers and wrapper materials are described in, for example, U.S. Pat. No. 6,955,665. 
     Referring to  FIG. 1 , a product handling system  10  for use packing a product (e.g., a wrapped tampon) includes a product supply  12 , a product feed system  14  and an overhead diverter assembly  16  that is located between the product feed system  14  and one or more packaging locations where the product is packaged. A product conveyor  18  delivers products from the product feed system  14  to the overhead diverter assembly  16 . The product conveyor  18  may be any suitable conveyor type, such as a continuous belt-type vacuum conveyor. The product feed system  14  is capable of providing the product to the product conveyor  18  in an orderly lengthwise fashion, one product at a time. In some embodiments, between about 2 and about 1200 wrapped tampons or other product per minute, such as between about 100 and 800 wrapped tampons or other product per minute may be delivered to the product conveyor  18  from the product feed system  14  in a single file stream. The product conveyor  18  may deliver the product to the overhead diverter assembly  16  single file with one product in front of another product. 
     A cassette supply  20  provides cassettes  22  to a cassette conveyor  24 , which is used to deliver the cassettes  22  to the overhead diverter assembly  16 . As can be seen, the cassette conveying path represented by arrow  25  provided by the cassette conveyor  24  may be substantially perpendicular to a conveying path represented by arrow  27  provided by the product conveyor  18 . However, non-perpendicular arrangements for the cassette conveyor  24  and the product conveyor  18  may be employed. The cassette conveyor  24  may be any suitable conveyor type, such as a continuous belt-type conveyor. 
     As will be described in greater detail below, the product that is diverted from the product conveyor  18  using the overhead diverter assembly  16  is delivered from the product conveyor  18  to a transfer location where the products are transferred to the cassettes  22  in a controlled fashion. The overhead diverter assembly  16  includes multiple axes that are controlled by servo motors  32 ,  34  and  36  and a control system  45 . The control system  45 , based at least in part on input from a product detecting sensor  65 , utilizes each axis of the 3-axis diverter assembly  16  is used to control movement of a flighted conveyor assembly  38 ,  40  and  42  that is used to pick product from the product conveyor  18  and deliver the product to the cassettes  22 . The cassettes  22  with product may then be delivered to a packaging location  29 , for example, for packaging multiple product types into a package. The empty cassettes  22  may then recycle through a loop back to the overhead diverter assembly  16  for delivery of product. Product that is allowed to pass through the overhead diverter assembly  16  may continue to move along the product conveyor  18  or multiple product conveyors to a different packaging location  31  (or some other location-type other than for packaging) where the product of a single type is packaged in a package. 
     Referring to  FIGS. 2 and 3 , the overhead diverter assembly  16  includes a frame  33  through which drive shafts  26 ,  28  and  30  of servo motors  32 ,  34  and  36  extend. Each servo motor  32 ,  34  and  36  is used to drive the respective flighted conveyor assembly  38 ,  40  and  42  and is controlled by the control system  45  ( FIG. 1 ). Each flighted conveyor assembly  38 ,  40  and  42  includes a timing belt pair  44   a  and  44   b ,  46   a  and  46   b , and  48   a  and  48   b  and trains  54 ,  56  and  58  of flights. The timing belt pairs,  44   a  and  44   b ,  46   a  and  46   b , and  48   a  and  48   b  may each be separately driven by its respective servo motor  32 ,  34  and  36 . 
     The servo motors  32 ,  34  and  36  may move their respective flighted conveyor assembly  38 ,  40  and  42  using idler sprockets and drive sprockets, each having teeth that mesh with teeth integrally formed in the timing belts  44   a ,  44   b ,  46   a ,  46   b ,  48   a  and  48   b . Idler sprockets and drive sprockets may be arranged concentric to their drive shafts. The drive sprockets may be connected to their drive shafts by a key or other torque transmitting feature. The idler sprockets may spin freely around their drive shafts due to a bearing or bushing between the idler sprocket and the drive shaft. As one example, the servo motor  32  may drive the timing belts  44   a  and  44   b . Drive sprockets may be keyed to the drive shaft  26  for rotation therewith which are used to move the timing belts  44   a  and  44   b . The timing belts  44   a  and  44   b  may also routed over idler sprockets associated with the other drive shafts  28  and  30  to allow the timing belts  44   a  and  44   b  to move independently of the other drive shafts  28  and  30 . Likewise, the servo motor  34  may drive the timing belts  46   a  and  46   b . Drive sprockets may be keyed to the drive shaft  28  for rotation therewith which are used to move the timing belts  46   a  and  46   b . The timing belts  46   a  and  46   b  may also be trained over idler sprockets associated with the other drive shafts  26  and  30  to allow the timing belts  46   a  and  46   b  to move independently of the other drive shafts  26  and  30 . Likewise, the servo motor  36  may drive the timing belts  48   a  and  48   b . Drive sprockets may be keyed to the drive shaft  30  for rotation therewith which are used to move the timing belts  48   a  and  48   b . The timing belts  48   a  and  48   b  may also be trained over idler sprockets associated with the other drive shafts  26  and  28  to allow the timing belts  48   a  and  48   b  to move independently of the other drive shafts  26  and  28 . It should be noted that while timing belts are described above, other mechanisms may be used, such as smooth flat belts, V-type belts, cables, chains, and the like. 
     Trains  54 ,  56  and  58  of flights  60  are each directly connected to a respective pair of timing belts  44   a  and  44   b ,  46   a  and  46   b , and  48   a  and  48   b . Train  54  of flights  60  is connected directly to timing belts  44   a  and  44   b  for movement therewith, train  56  of flights  60  is connected directly to timing belts  46   a  and  46   b  for movement therewith, and train  58  of flights  60  is connected directly to timing belts  48   a  and  48   b  for movement therewith. Movement of each train  54 ,  56  and  58  may be independently controlled by their associated servo motor  32 ,  34  and  36 . 
     It should be noted that while each servo motor  32 ,  34  and  36  may independently control movement of its respective flighted conveyor assembly  38 ,  40  and  42  and associated timing belts  44   a  and  44   b ,  46   a  and  46   b , and  48   a  and  48   b , a single servo motor  32 ,  34  and  36  may also control movement of multiple flighted conveyor assemblies  38 ,  40  and  42 , for example, to lock movement of two or more of the flighted conveyor assemblies  38 ,  40  and  42  together. For example, the drive sprockets and idler sprockets may have differing states to allow one of the servo motors  32 ,  34  and  36  to control multiple ones of the flighted conveyor assemblies  38 ,  40  and  42 . In some embodiments, more or less timing belts and servo motors than those illustrated may be used. Additionally, a train may be connected to a single timing belt, or more than a pair of timing belts, such as three or four or more timing belts. 
       FIG. 4  illustrates exemplary trains  54  and  58  of flights  60  connected to their respective flighted conveyor assemblies  38  and  42  and  FIG. 5  illustrates a single flight  60  in isolation. While only trains  54  and  58  are shown in  FIG. 4 , the other train  56  may include similar components as trains  54  and  58 . As used herein, the term “train of flights” is meant to include a series of flights that are connected directly to one of the flighted conveyor assemblies  38 ,  40  and  42  for movement therewith. Each flight  60  may be separately connected to its respective flighted conveyor assembly  38 ,  40  and  42  or multiple flights  60  may be connected directly together (e.g., using a hinged connection) and then connected to the respective flighted conveyor assembly  38 ,  40  and  42 . 
     Referring particularly to  FIG. 5 , each flight  60  is U-shaped in cross section and includes a forward retaining flight member  62  and a rearward retaining flight member  64  that are connected together by a base member  66  extending between the forward retaining flight member  62  and the rearward retaining flight member  64 . In some embodiments, the base member  66  includes connection structure (e.g., openings  68  and  70 ) that are located to connect to the timing belts  44   a  and  44   b ,  46   a  and  46   b , or  48   a  and  48   b  associated with the respective flighted conveyor assembly  38 ,  40  and  42 . In an alternative embodiment, the flights may not be U-shaped. For example, the flights may include a forward retaining flight member and a rearward retaining flight member that are both connected directly to their respective timing belts without a base member. The flights may also be constructed by using the forward retaining member  62  or the rearward retaining member  64  and may optionally include the base member  66  to form an L-shaped construction. The flights may also include the forward retaining member  62  or the rearward retaining member  64  without the base member  66 . The flights  60  may be connected to the timing belts  44   a  and  44   b ,  46   a  and  46   b , or  48   a  and  48   b  using any suitable connection such as screws, rivets, snaps, adhesive, welding, magnets, etc. or could me molded integrally to their respected belts. In some embodiments, the attachment may be configured to break or shear away in the event of jamming or malfunction. 
     The flights  60  include a first open end  72  and an opposite, second open end  74 . The first open end  72  allows for ingress of the product and the second open end  74  allows for egress of the product during a pass through operation. At the first open end  72  and the second open end  74  the forward retaining flight member  62  and the rearward retaining flight member  64  each taper outwardly away from each other, increasing in width (in the conveying direction) from a central portion  76  of the flights  60 . In some embodiments, the base member  66  may increase in thickness from the first open end  74  toward the central portion  76  and the second open end  74  to the central portion  76  (e.g., at portions  77  and  79 ). With this arrangement, a cross sectional entrance area at the first open end  72  and a cross sectional exit area at the second open end  74  may be greater than a cross sectional area at the central portion  76  of the flights  60 . In other embodiments, the cross sectional areas at the first and second open ends may be about the same as the cross sectional area at the central portion  76 . In some embodiments, the cross-sectional area may be largest at the first open end  72  and substantially smaller at the central portion  76  and the second open end  74 . 
     As can be seen particularly by  FIG. 4 , the trains  54  and  58  may include flights  60  having about the same dimensions and may be substantially equally spaced in the conveying direction. In some embodiments, the flights  60  of the trains  54  and  58  have about the same length in the cross conveying direction such that, while they may be connected directly only to timing belts  44   a  and  44   b  for train  54  and timing belts  48   a  and  48   b  for train  58 , they extend across and over each of the timing belts  44   a  and  44   b ,  46   a  and  46   b , and  48   a  and  48   b . By this arrangement, the timing belts  46   a ,  46   b ,  48   a  and  48   b  can move relative to the train  54  and timing belts  44   a ,  44   b ,  46   a  and  46   b  can move relative to the train  58 , allowing for movement of each train of flights  60  relative to the other trains of flights  60 . This arrangement also allows two or more of the trains  54 ,  56  and  58  to align their flights  60  in single file, one flight  60  adjacent the next in the conveying direction. 
       FIG. 6  illustrates a section view through a center of the train  54  of flights  60 . Any suitable number of flights  60  per train  54 ,  56  and  58  may be used. Additionally, each train  54 ,  56  and  58  may include the same number of flights  60  or at least one, two or three trains may include different numbers of flights  60 . In one exemplary embodiment, each train  54 ,  56  and  58  includes 14 flights. However, more or less than 14 flights may be utilized. In some embodiments, the train  56  of flights  60  has a substantially constant pitch P 1  between the adjacent flights  60 . The pitch P 1  may be measured between equivalent points on adjacent flights  60 . The pitch P 1  may be between about 30-60 millimeters, such as about 40 millimeters, or such as about 50 millimeters. In some embodiments, a clearance distance D between adjacent flights is maintained at about four millimeters or more, which can provide space between adjacent trains  54  and  58  and avoid collisions during operation. The clearance distance D may be less than four millimeters in some embodiments. The clearance distance D may be about zero, in some embodiments. 
     The flights  60  may be formed using any suitable process or combination of processes, such as casting, molding, machining, etc. Any suitable material may be used to form the flights  60 , such as various metals and plastics. One exemplary plastic material having low-frictional properties is polyoxymethylene (POM). 
     Referring to  FIG. 7 , the flights  60  are used to divert product to the cassettes  22 . The cassettes  22  may include a front wall  78 , a rear wall  80  and side walls  82  and  84  extending between the front wall  78  and the rear wall  80 . The cassettes  22  have a closed bottom  86  with multiple product receptacles (e.g., holding trays  88 ) arranged side-by-side from the front wall  78  to the rear wall  80 . Retaining walls  90  extend substantially transverse to and between the side walls  82  and  84 . Each product holding tray  88  is shaped to retain a product within the individual product holding tray  88 . While a single column of multiple rows of holding trays  88  are illustrated, the cassettes  22  may include multiple columns and multiple rows of holding trays  88 . In some embodiments, cartons or boxes may be provided having a volume for holding one or more products therein (e.g., in a stacked fashion). 
       FIG. 8  illustrates a section view through a center of the cassette  22 . Any suitable number of product holding trays  88  may be used. Additionally, each cassette  22  may include the same number of product holding trays  88 , or at least some of the cassettes may include different numbers of product holding trays  88 . In one exemplary embodiment, each cassette  22  includes four product holding trays  88 . However, more or less than four product holding trays  88  may be utilized. In some embodiments, the cassettes  22  have a substantially constant pitch P 2  between adjacent product holding trays  88 . The pitch P 2  of the cassettes  22  may be measured between equivalent points on adjacent product holding trays  88 . The pitch P 2  may be between about 30-60 millimeters, such as about 40 millimeters, such as about 50 millimeters. In some embodiments, the pitch of the cassettes  22  matches the pitch of the trains  54 ,  56  and  58  of flights  60 . In other embodiments, the pitch of the cassettes  22  may be different than the pitch of the trains  54 ,  56  and  58  of flights  60 . 
     The flighted conveyor assemblies  38 ,  40  and  42  and their respective trains may each have four primary product handling modes: (1) a diverting mode, (2) a cassette filling mode, (3) a transition from diverting mode to cassette filling mode, and (4) a transition from cassette filing mode to diverting mode constituting a complete cycle through the overhead diverter assembly  16 . Referring to  FIG. 9 , the trains  56 ,  58  and  54  are illustrated in the various modes with the train  56  in the diverting mode, the train  58  in the cassette filling mode and the train  54  in the transition from the cassette filling mode to the diverting mode. Referring also to  FIG. 10 , a diverting operation is illustrated where a trailing retaining flight member  64  of the train  56  is used in diverting a product  92  from the product conveyor  18 . In this instance, the train  56  may be referred to as the diverting train  56 . The product conveyor  18  conveys the product  92  into a tunnel  93  that is formed between a leading retaining flight member  62  and the trailing retaining flight member  64 . The diverting train  56  is controlled by input from a sensor  65  ( FIG. 1 ), e.g., an optical eye, laser sensor, etc. that whose output (or lack thereof) is used in indexing the diverting train  56  with a profiled move that is equal to the flight pitch for each product  92 . The terms “profiled move” and “profiled motion” broadly refer to a controlled motion, such as a controlled motion having varying velocity. In some embodiments, the profiled move is an indexing motion (e.g., a start and stop type motion). The product  92  is then picked or stripped from the product conveyor  18  and pushed by the overhead flight  60  of the diverting train  56  to a transport containment device  94 . In this embodiment, the transport containment device  94  is in the form of a smooth dead plate. The dead plate  94  angles downwardly from an elevation adjacent the product conveyor  18  to an elevation slightly above the cassettes  22 . Other transport containment devices include vacuum nozzles, grippers, etc. that are used to retain the products  92  within their respective overhead flights  60 . 
     Products  92  can be diverted on demand by rapidly indexing the flights  60  of the diverting train  56  as the product  92  is carried by the product conveyor  18 . Timing of the indexing motion can be selected for gaining control of the product  92  (e.g., using the sensor  65 ) and pushing it substantially perpendicular to the original direction of travel on the product conveyor  18 . The indexing flight  60  drags on the side of the product  92  and the friction between the flight  60  and the product  92  reduces the speed of the product  92  traveling along the product conveyor  18 . The high acceleration of the indexing flight  60  generates enough frictional force to completely stop the product before the product travels the entire length of the flight  60  and exits the open end  74 . In these embodiments, no stop plates are needed to stop the conveying motion of the product  92 . This can reduce damage due to a collision by the product  92  into the stop plate. In some embodiments, the product may be slowed down by friction with the flight  60  and the motion of the product can be arrested upon collision with a guide rail  95  ( FIG. 3 ) that extends along a length of the transport containment device  94 . 
     Referring to  FIGS. 9 and 11 , as the diverting train  56  of the flights  60  diverts the products  92  using the indexing motion (or allows products  92  to pass by the train  56 ), the train  58  of flights  60  transitions from the diverting mode to the cassette filling mode, traveling to a transfer location  96 . (As shown, the train  58  has already transitioned from the diverting mode to the cassette filling mode.) In this instance, the train  58  may be referred to as the cassette filling train  58 . In some embodiments, the cassette filling train  58  of flights  60  carrying the diverted product  92  may be moved in synch behind the train  54  which may be nearly complete with cassette filling. The cassette filling train  58  deposits the products  92  diverted into the cassettes  22  at the transfer location  96 . In some embodiments, the motion of the cassettes  22  may be electronically geared to the motion of the cassette filling train  58  carrying the diverted products  92  along the dead plate  94 , which can allow products  92  to drop (e.g., due to gravity) one at a time into respective product holding trays  88 . In some embodiments, additional mechanisms may be employed to aid in the transfer of the product  92  from the flight  60  to the cassette  22 , such as a mechanical stripper bar that pulls the product  92  from the flight  60 . A jet of compressed air may be used to push product  92  from the flight  60 . A vacuum can be used to pull product  92  into the cassette  22  and may be used to hold the product in the cassette  22 . 
     A synchronizing system (e.g., a timing belt assembly  98 ) may be used to control the motion of the cassettes  22  during the transfer operation of products  92  from the cassette filling train  58  of flights  60  to the cassettes  22 . The timing belt assembly  98  includes a timing belt  100  and a motor  102  ( FIG. 9 ) that controls movement of the timing belt  100 . The motor  102  may be controlled by the control system  45 , for example. The cassettes  22  are conveyed by the cassette conveyor  24  prior to cassette  22  engagement with the timing belt assembly  98 . The cassette conveyor  24  may be operating at a higher speed V 1  than the cassette motion due to the speed V 2  of the timing belt  100  at the transfer location  96 , which can allow empty cassettes  22  to cue up against each other in a line upstream of the timing belt assembly  98  and then decouple or distance apart from each other once released by the timing belt assembly  98 . 
     The pitch between the flights  60  and the cassettes  22  need not be the same. As one example, the flight pitch may be 50 mm and the cassette pitch may be 40 mm. The cassettes  22  may be driven synchronously with the flights  60  above such that the flight  60  containing product  92  is above (e.g., directly above) the cassette holding tray at the point of transfer where the transport containment device  94  ends. 
     During filling of cassettes  22 , the speed of the cassette filling train  58  of flights  60  may be proportional to a distance between the cassette filling train  58  and the diverting train  56  diverting the product  92 . As the distance between the cassette filing train  58  filling the cassettes  22  and the diverting train  56  diverting the product  92  increases, the cassette filling train  58  may decelerate. Alternatively, if the distance between the cassette filling train  58  and the diverting train  56  decreases, the cassette filling train  58  may accelerate. The maximum positive acceleration of the cassette filling train  58  and timing belt assembly  98  may be limited to avoid creating gaps between cued cassettes  22  entering the timing belt assembly  98 . This maximum acceleration may be limited to less than the coefficient of kinetic friction between the cassettes  22  and the cassette conveyor belt  24  multiplied by gravitational acceleration. The kinetic coefficient of friction between the cassette conveyor belt  24  and the cassettes  22  may be determined as follows: The conveyor belt  24  is driven at full production speed. The cassette  22  riding on top of the moving conveyor belt  24  is fed into a linear force gauge that is held rigid with respect to the moving conveyor belt  24 . The frictional force generated between the cassette  22  and belt  24  is measured directly by the force imparted by the cassette on the force gauge. The coefficient of friction is determined by dividing the measured friction force by the normal force. In this case, the normal force between the cassette and belt is the mass of cassette multiplied by gravitational acceleration. 
     The train  54  of flights  60  ( FIG. 9 ), once finished with the cassette filling operation, transitions from the cassette filling mode to the diverting mode. In some embodiments, the train  54  of flights  60  is moved in coordination with the movement of the diverting train  56  so that constant spacing is maintained between the trains  54  and  56 . In this instance, the train  54  may be referred to as the cued train  54 , which is awaiting its turn to divert product  92 . In some embodiments, the cued train  54  may move adjacent (i.e., catch up to) the diverting train  56  such that the pitch between the leading most flight  60  of the cued train  54  and the trailing most flight  60  of the diverting train  56  is substantially equal to the pitch P 1  between adjacent flights  60  of the individual trains  54  and  56 . 
     Referring to  FIG. 12 , an exemplary embodiment of a product handling system  120  includes multiple product lines (e.g., a Product 1 product line  122 , a Product 2 product line  124  and a Product 3 product line  126 ). The Product 1, Product 2 and Product 3 may be provided at product source locations  128 ,  130  and  132 . The product source locations  128 ,  130  and  132  may be, for example, a product converting line or a feeder system that supplies the product from bulk, cassettes, surge supply, etc. The Products 1, 2 and 3 may then be delivered to one or more overhead diverter assemblies  146 ,  148  and  150 , each of which may be the same as or similar to the overhead diverter assembly  16  described above. The overhead diverter assemblies  146 ,  148  and  150 , depending on operator instructions, may divert at least some or all of their respective Product 1, 2 or 3 and the cassettes of diverted products may be sent to a multi-pack cartoner  160 , where a mix of the various products may be packaged together into a package. One or more of the diverter assemblies  146 ,  148  and  150  may also allow their respective Product 1, 2 or 3 to pass through the overhead diverter assemblies  146 ,  148  and  150 . Such pass through of the Products 1, 2 or 3 may be sent to a single pack cartoner  152 ,  154  and  156 , which can be used to pack a single type of the Products 1, 2 or 3 into its own carton. 
     In some embodiments, the single pack cartoners  152 ,  154  and/or  156  may be replaced by other equipment having a demand for non-diverted product. For example, additional downstream equipment such as a wrapper, printer, perforator, shrink wrapping, perfume addition, followed by other steps may be employed. Thus, the overhead diverter assemblies  146 ,  148  and/or  150  may be used to divert products in work on a converting line to enable producing products with varying stages of completion. The single pack cartoners  152 ,  154  and/or  156  may also be replaced with other packaging equipment, such as baggers, tray loaders, bundlers, etc. The multi-pack cartoner  160  may also be replaced by other packaging equipment, bulk storage, etc. In some embodiments, multiple overhead diverter assemblies may be placed in series to divert product to multiple, downstream stations packing and/or otherwise. 
     It should be noted that while cassettes  22  are described above, in alternative embodiments, the cassettes could be a tray with no separate or divided holding trays to separate products. In some embodiments, the cassettes may be replaced by a continuous chain or belt. The diverted products could be transported by other means after the transport containment device  94  such as conveyor, air conveying, vibratory feed, etc. The diverted products could also be fed into bulk or directly loaded into cartons, bags, or other packaging. Also, the diverted products could be fed into another downstream process or packaging step such as printing, perforating, wrapping, banding, shrink wrapping, perfume addition, etc. 
     The above-described systems and methods for handling products utilize an overhead diverter assembly for use in diverting some, but in some instances not all, product provided from a product supply. The passing product may be delivered to a first packaging location and the diverted product may be delivered to a second packaging location that is different from the first packaging location. The overhead diverter assemblies may utilize a rapid indexing action that picks the product from a supply conveyor while reducing damage to the product during the diverting process. 
     The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as “40 mm” is intended to mean “about 40 mm.” 
     Every document cited herein, including any cross referenced or related patent or application, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern. 
     While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.