Cart coupling assembly

Various embodiments described herein relate to a sortation conveyer system including a cart coupling assembly for coupling two adjacent carts. The cart coupling assembly includes a coupling disc having a control slot, a bearing slot, and one or more arcuately shaped mounting slots. The coupling disc is mounted on a cart such that, upon rotation of the coupling disc, a control slot cavity defined by the control slot slidably moves about a position register screw along the control slot cavity, and a cavity defined by a respective mounting slot slidably moves relative to a respective mounting pin received in the mounting slot. Cavities defined by the control slot facilitate a continual translation of a center of rotation of the coupling disc linearly, to adjust a gap between the two carts. The control slot includes position registers that restrict a sliding movement of the control slot cavity.

BACKGROUND

1. Technical Field

The present disclosure generally relates to sortation conveyors that sort discrete articles to one of multiple destinations, and more specifically a cart coupling assembly used in a sorter cart train.

2. Description of the Related Art

A distribution center for a set of products is a warehouse or other specialized building that is stocked with products (goods) to be redistributed to retailers, to wholesalers, or directly to consumers. A distribution center is a principal part, order processing element, of an entire order fulfillment process. A distribution center can also be called a warehouse, a DC, a fulfillment center, a cross-dock facility, a bulk break center, and a package handling center. The name by which the distribution center is known is commonly based on the purpose of the operation. For example, a “retail distribution center” normally distributes goods to retail stores, an “order fulfillment center” commonly distributes goods directly to consumers, and a “cross-dock facility” stores little or no product but distributes goods to other destinations. Some organizations operate both retail distribution and direct-to-consumer out of a single facility, sharing space, equipment, labor resources, and inventory as applicable.

Distribution centers are the foundation of a supply network, allowing a single location to stock a vast number of products. A large retailer might sell tens of thousands of products from thousands of vendors. Sortation conveyors are an important aspect of distribution centers (DCs). Typically, goods are received in bulk and need to be immediately or eventually routed to one or more different storage or shipping locations within the DC. The sortation conveyor receives a singulated stream of articles, such as parcels, cartons, totes, shrink wrapped products, bags, etc. The individual articles are identified and a particular divert destination, selected from multiple divert destinations, is assigned to each article. In many instances, the divert destination is a conveyor, chute, Gaylord or other apparatus that can receive and accumulate a number of articles that constitute an order for shipping to a specific recipient. The accumulated order can then be moved to a transportation conveyance.

Without prejudice to above identified problems, Applicant has identified a number of deficiencies and problems associated with the foregoing. Through applied effort, ingenuity, and innovation, many of these identified problems have been solved by developing solutions that are included in embodiments of the present invention, many examples of which are described in detail herein.

BRIEF SUMMARY

Various embodiments described herein, relates to a mechanism for coupling multiple linked carts in a sortation conveyor system. In an embodiment, the sortation conveyor system includes at least one cart coupling assembly that is adapted to engage two adjacent carts. The cart coupling assembly includes: (i) a coupling disc that is configured to engage a first cart with an adjacent cart. In this regard, a structure of the coupling disc includes a control slot having one or more position registers defined along a control slot cavity of the control slot. The one or more position registers, herein, are configured to engage and lock, a position register screw, to restrict a sliding movement of the control slot cavity relative to the position register screw along the control slot cavity of the control slot, in a first direction, in an instance, while the coupling disc rotates. Further, the one or more position registers, herein, are also configured to allow sliding movement of the control slot cavity relative to the position register screw in a second direction opposite to the first direction along the control slot cavity of the control slot, in an instance, while the coupling disc rotates. The coupling disc, as described herein, also includes multiple mounting slots and a bearing slot. In this aspect, the bearing slot is adapted to hold a bearing and is located circumferentially at a center of the coupling disc. The bearing, herein, is configured to engage a bearing hub assembly of a second cart that may be positioned adjacent to the first cart. The cart coupling assembly further includes, (ii) a set of mounting pins attached at an end of the first cart. In accordance with said embodiment, as the coupling disc is engaged on the first cart, the control slot is configured to receive the position register screw and each mounting slot is configured to receive one of the mounting pins. Further, in this aspect, when the coupling disc rotates, the control slot and each of the mounting slots, slide on each respective one of, the position register screw and the set of mounting pins. In this regard, upon rotation of the coupling disc, the control slot cavity and the mounting slot cavities slid ably moves relative to the position register screw and each mounting pin respectively to produce a translational movement of the bearing. This translation movement of the bearing changes a gap between the first cart and the second cart, as in, when the carts are engaged together, by the cart coupling assembly. To this extent, in accordance with said embodiment, cavities defined by a structure of the control slot and each of the mounting slots respectively, facilitates a continual linear translation of a center of rotation about the bearing of the coupling disc, when the coupling disc is rotated.

According to another embodiment, a system including a plurality of carts on a conveyor, is described. In this regard, at least two carts, from amongst the plurality of carts includes: (i) a front hitch plate mounted on a primal end of the at least two carts and (ii) a rear hitch plate mounted on a distal end of the at least two carts. In accordance with said embodiment, the rear hitch plate also includes a bearing hub assembly. To engage adjacent carts together, the system further includes a cart coupling assembly configured to engage a front plate of one of the at least two carts with the rear hitch plate of another of the at least two carts. In this regard, the cart coupling assembly includes a coupling disc having a control slot with one or more position registers defined along a control slot cavity of the control slot. The one or more position registers, herein, are configured to engage and lock, a position register screw, to restrict a sliding movement of the control slot cavity relative to the position register screw along the control slot cavity in a first direction, in an instance, while the coupling disc rotates. Further, the one or more position registers, herein, are also configured to allow sliding movement of the control slot cavity relative to the position register screw in a second direction opposite to the first direction along the control slot cavity. The coupling disc further includes multiple mounting slots and a bearing slot. In this aspect, the bearing slot is adapted to hold a bearing and is located circumferentially at a center of the coupling disc. In this aspect, the bearing is configured to engage a bearing hub assembly of a second cart adjacent to the first cart. The cart coupling assembly further includes, a set of mounting pins attached at an end of the first cart. In accordance with said embodiment, upon engagement of the coupling disc on the first cart: (a) the control slot is configured to receive the position register screw and (b) each mounting slot is configured to receive one of the mounting pins. Further, in this aspect, in an instance, when the coupling disc rotates, the control slot and each of the mounting slots slide on each respective one of, the position register screw and the set of mounting pins to produce translational movement of the bearing to change a gap between the first cart and the second cart, via the cart coupling assembly.

According to said embodiment, upon engagement of the coupling disc to the first cart, each of the mounting slots of the coupling disc receives one of the respective of mounting pins. In this aspect, the set of mounting pins, as described herein, are engaged on the front hitch plate of the first cart. As the bearing slot of the coupling disc receives the bearing hub assembly on the rear hitch plate of the second cart, the first cart is engaged with the second cart.

According to another embodiment, a method for adjusting length of a cart assembly in a conveyor system, is described. The method includes, engaging a first cart of the cart assembly with a second cart of the cart assembly, via a cart coupling assembly. To this extent, the cart coupling assembly herein, comprises a coupling disc that includes a control slot with at least one position register. The coupling disc also includes, a bearing slot configured to hold a bearing that engages a bearing hub assembly on an end of the second cart. Further, the coupling disc also includes one or more mounting slots. Upon engaging the first cart of the cart assembly with the second cart, the method includes, rotating the coupling disc in a second direction with respect to the first cart and about a center axis of the coupling disc. In this regard, the rotation of the coupling disc provides a sliding movement of a control slot cavity of the control slot relative to a position register screw along the circular control slot cavity of the control slot. Also, rotation of the coupling disc, provides a sliding movement of one or more mounting slot cavities defined by defined by each of the one or more mounting slots respectively, relative to a mounting pin that is received respectively in the one or more mounting slot cavities, in the second direction. Further, upon rotating the coupling disc, the method includes, pausing the rotation of the coupling disc, based on a locking of the position register screw, by the at least one position register as the control slot cavity of the control slot slid ably moves with respect to the position register screw along the control slot cavity. In this regard, the position register is configured to lock the position register screw to restrict a sliding movement of the control slot cavity relative to the position register screw in a first direction opposite to the second direction, thereby restricting the rotation of the coupling disc in the first direction.

DETAILED DESCRIPTION

An example material handling system includes a sortation conveyor for transporting different articles or products from a source location to a destination location. The sortation conveyor includes a conveyor bed, commonly referred as, conveyor frame in a conveyor system or a sorter frame in the sortation conveyor, on which multiple carts moves along with respective carriers for carrying various items. In this regard, the sortation conveyor, usually comprises, multiple carts (e.g., a cart along with a respective carrier engaged to the cart) that are placed adjacent to each other, in a manner such that, one cart after another of the multiple carts together forms a sorter cart train, which runs on the conveyor bed. The conveyor carts, in some examples, are like totes, carrier buckets or cross belt carriage usually meant for carrying or loading different products or articles from one location, such as a source location to another location, such as a destination location within a distribution center, an inventory store or warehouse unit. In some cases, the sortation conveyor is a loop sortation conveyor that may be installed within the material handling environment, for sorting different articles or products to one of many possible destination locations. In this regard, the loop sortation conveyor (also called as “loop sorter”) is a category of sortation equipment having multiple carts sequentially engaged in a cart train that endlessly conveys around a loop formed by a conveyor bed or track. Each cart supports one or more carriers for carrying and discharging articles. In this aspect, depending on an installation, the loop can be designed and installed with a desired length and the loop can also be designed and installed with various changes in lateral and vertical direction to fit within a desired footprint and with other material handling equipment. Typically, in such sortation conveyors, a connection including an engagement means between the carts may securely couple two adjacent carts, as the adjacent carts move through these changes in relative directions. In this aspect, an overall length of the cart train needs to be capable of matching a running length of the loop sorter. Usually, these multiple carts are engaged adjacently to each other by means of various engagement mechanisms.

To this extent, in operation, where such sortation conveyors having multiple carts are adjacently engaged with each other, often, there are undesired-gaps which are created along a sorter cart train of the sortation conveyor, as the carts move operationally for transporting the articles. These gaps are often created due to multiple reasons, like, slack-ups occurred during running of sorter chain that may be due to tensions created along the sorter chain, or variances on floor and the sorter bed on which the sorter is placed, or sometimes during installation of the sortation system itself. For smooth movement and operation of the carts along the sortation conveyor, formation of such gaps is to be minimalized or removed. Further, such gaps along the sortation conveyor increases chances of falling off the articles from the carts or improper diverting of the articles by the sorter. Accordingly, for smooth movement of multiple carts along a sortation system such as, a loop sorter or a tilt-tray sorter, multiple carts are to be effectively installed adjacent to each other over a sorter frame. Error free installation and timely maintenance of installed carts over a sorter frame prevents and resolves, in some examples, any formation of gaps or slacks formed between the carts in a sorter train over an operational period.

According to present invention, systems and methods described herein, relates to a sortation conveyor system comprising one or more carts, that are configured to carry one or more carts holding various items on a conveyor and engagement mechanisms for engaging adjacently placed carts. In this regard, for coupling two adjacent carts together along a conveyor bed, a cart coupling assembly, is described. In accordance with some embodiments, one or more carts of the sortation conveyor system may include a front hitch plate and a rear hitch plate that may be mounted on a front or primal end and a rear or a distal end of each of the cart, respectively. In this regard, the cart coupling assembly, in accordance with various embodiments described herein, includes: a coupling disc, a bearing hub assembly, and a set of mounting pins. To this extent, for engaging two carts together, the coupling disc is mounted on the front hitch plate of the cart and is adapted to receive the bearing hub assembly that is on the rear hitch plate of an adjacent cart. Accordingly, when the two adjacent carts are engaged together, the bearing hub assembly on the rear hitch plate of a first cart is engaged via a bearing slot of the coupling disc on the front hitch plate of a second cart which is positioned adjacent to the first cart.

In accordance with various embodiments described herein, the cart coupling assembly including the coupling disc and the bearing hub assembly, may be installed between each pair of adjacent carts together along a sorter cart train. To this extent, upon engaging the two adjacent carts together, the coupling disc is rotatable in any of a clockwise or counterclockwise direction relative to its center, such that rotation of the coupling disc is performed to adjust distance between two adjacent carts, in order to overcome any gaps that may be formed during an operation of the sortation conveyor.

In accordance with various embodiments described herein, the coupling disc includes a control slot having at least one position register that is defined along a cavity defined by the control slot. Also, the coupling disc includes one or more mounting slots. To this extent, in some embodiments, a lateral surface defined by cavities of each of the control slots and the one or more mounting slots may be of a circular shape. However, in other embodiments, the cavities defined by each of the control slots and the one or more mounting slots may be such that, a curvature defined by these slots is circular and does not changes with respect to a central axis of the coupling disc. In this regard, the rotation of the coupling disc, causes sliding movement of the one or more mounting slot cavities (of respective one or more mounting slots) with respect to a set of mounting pins on an end of a cart and sliding movement of a control slot cavity of the control slot, relative to, a position register screw into the control slot cavity of the control slot. In the control slot, as the coupling disc rotates causing sliding of the control slot cavity about a position register screw and the sliding of the mounting slot cavities relative to one or more mounting pins, the position register, facilitates engaging and locking the position register screw, in such a manner, that an adjustment of a cart length and/or distance between the two carts happens only in one direction, for instance, an upstream direction of the sortation conveyor system or a downstream direction of the sortation conveyor system, at an instance of time. In this aspect, in an instance, when the coupling disc rotates, the control slot and each of the mounting slots slide on each respective one of the position register screw and a set of mounting pins, to produce translational movement of a bearing in the bearing slot of coupling disc, to change a gap between a first cart and a second cart of the sortation conveyor system. Accordingly, in accordance with various example embodiments described herein, a rotational motion of the coupling disc is translated into a linear motion that causes movement or displacement of the coupling disc over the front hitch plate, so as to, adjust the distance between a front end of a cart and a rear end of an adjacent cart.

Accordingly depending on rotation of the coupling disc, an adjustment in the length of the cart may be performed along the sortation conveyor system to overcome formation of any gaps that are formed during an operational course of the sortation conveyor system. Various aspects of the sortation conveyor system including the cart coupling assembly and operations of the cart coupling assembly, are described in more details in reference to description ofFIGS. 1-8hereinafter. Various aspects related to the coupling disc are described herein, with reference to sortation conveyor system, however, the coupling disc may be used in various other application areas for engagement of other mechanical structures, without departing from scope and spirit of described subject matter.

FIG. 1illustrates a material handling system100that includes a sortation conveyor102that provides induction of items (for example, articles, cartons, parcels, boxes, products, and/or the like) from different source locations and discharging of the items to a destination location. According to various embodiments illustrated herein, the sortation conveyor102may be any of: a cross belt (CB) loop sorter, a tilt tray sorter or a pusher-carriage, or any other sorter type, conventionally known in state of art. As illustrated herein, one or more induction conveyors104may transfer articles106to respective locations of the sortation conveyor102, such as inbound direction indicated by arrow108. The sortation conveyor102, in this regard, may comprise of multiple carts which runs via rails along a conveyor bed114such as, a conveyor frame or a sorter frame. In this regard, multiple cart frames, (also referred herein as carts, hereinafter throughout the description) are covered with a moving carriage or a moving carrier cart, such as a cart112that runs along with the carts, via engagement of rails associated with the carts along the conveyor bed114. Accordingly, for transportation of articles from a source (e.g., inventory location) to a destination (e.g., chutes, a container, downstream conveyors, and/or the like), the articles106are positioned on a carriage110such as, but not limited to, a cross-belt carriage on the moving carrier cart, such as the cart112that endlessly conveys on a conveyor bed114in a looping direction indicated by arrow115. Illustratively, an indicia reader120may also be provided along the sortation conveyor102to read coded information placed on the articles106, while the articles106are in transit on the sortation conveyor102.

Illustratively, the sortation conveyor102, along with transporting the articles106, may also sort the articles106, as these articles106moves along a length of the sortation conveyor102. In this aspect, the sortation conveyor may transport the articles106into various downstream lanes, for instance, via transfer chutes122into different picking units124. As illustrated, different adjacent carts along the cross-belt carriage110may be connected together over an engagement means118of respective carts, via a cart coupling assembly126. Various embodiments with reference toFIGS. 2-8hereinafter, describe further details of the cart coupling assembly126for engaging adjacent carts on a sorter system, like the sortation conveyor102as illustrated inFIG. 1.

FIG. 2illustrates fragmentary cutaway perspective views of the front of a sortation conveyor system200, comprising the cart coupling assembly126, for engaging adjacent carts, such as the cart112and a subsequent cart, of the sortation conveyor102, as illustrated inFIG. 1. In this regard, the fragmentary cutaway perspective view illustrates a depiction of the cart coupling assembly126of one cart from amongst the multiple carts on the sortation conveyor102, where each of the cart112, moves along in a direction one after another in a sorter cart train fashion, according to one or more exemplary embodiments. In some examples and in accordance with a front view of the sortation system200, which provides the cutaway perspective view of the sortation conveyor, a cart would move in a direction outwards of a viewing screen towards a user viewing theFIGS. 2 and 3upon movement of the sortation conveyor.

In an aspect, the perspective view of the sortation system illustrates a cross-sectional view of a cross belt sorter carrier, such as the cross-belt carriage110described inFIG. 1, which on installation of the sortation conveyor102, sits on a top of the cart112. In some examples, multiple items may be placed on the cross-belt sorter carrier for transportation from a source location to a destination location by a sorter conveyor train of the sortation system200. Illustratively, the cart112, includes two cart arms202-1and202-2, each of which includes a cart wheel assembly (not shown herein) which moves along a conveyor bed frame204by means of the respective cart wheel assembly. In this regard, the cart112includes a cart frame having a carrier support structure with a longitudinal portion and a transverse portion, such that the longitudinal portion terminates at horizontally-extending front and rear hitch plates (not shown) and the transverse portion terminates in left and right ends connected to wheel assemblies (not shown) for moving the cart along the conveyor bed frame204. Details of the structure of the cart112are described in reference toFIGS. 4 and 5.

In this context, the cart112includes a main profile having two cart arms202-1and202-2which extends outwardly from a cart main profile206. In operation, the cart main profile206maintains a pre-determined distance above a seating or lower end of the conveyor bed frame204due to induction maintained by a dual linear induction motor (not shown herein) which runs the carts112along the conveyor bed frame204. As described, in an aspect, the cart112includes hitch plates (rear and front hitch plates) at two ends front and back end of a longitudinal portion of the cart112, for engaging the cart coupling assembly126by means of various fastening bolts. Details of the hitch plate and engagement of the cart coupling assembly on the hitch plate of the respective cart112is described with respect toFIGS. 4 and 5.

As illustrated, several I/O cables210runs through the conveyor bed frame204, communicating power and control commands from a carrier control card (CCC) (not shown herein) (e.g., a controller unit) for driving various operations of the cart112. In this regard, each cart112of the sortation conveyor102, in some examples, includes a type of the CCC. The CCC is mounted on each cart and receives instructions from a sortation control card (SCC) for execution of various operations of the cart112. Illustratively, the CCC provides commands like, ‘run’, ‘discharge’, ‘induct’, etc. for performing various operations like moving in a direction, discharging the articles, etc. by the cart112.

As illustrated, the cart coupling assembly126includes a coupling disc214mounted on a mounting plate216which is engaged to a main profile of the cart112. In this regard, the coupling disc214is engaged on the mounting plate216via one or more mounting pins218, such that upon engagement of two adjacent carts together, a hitch pin220of a bearing hub assembly (not shown herein) of an adjacent cart112passes through a bearing slot towards a center of the coupling disc214. In this regard, for adjusting a distance between two carts, such as the cart112and an adjacent cart, the cart coupling disc126, includes a control slot (not shown herein) for receiving a position register screw (not shown herein) at different positions of the control slot and one or more mounting slots for receiving respective mounting pins218. To this extent, on rotating the coupling disc, a sliding movement of control slot cavity of a control slot and one or more mounting slot cavities of respective one or more mounting slots defined on the coupling disc214, relative to the position register screw and the mounting pins218respectively happens, thereby causing conversion of rotational motion of the coupling disc into a linear motion. Further, details of the cart coupling assembly126, including the coupling disc214, the mounting pins218, the hitch pin220, bearing slot, position register screw and the control slot, for engaging adjacent carts together are described with respect toFIGS. 4 and 5.

FIG. 3illustrates a fragmentary cutaway perspective view of a back of a sortation system200. The illustrated view representing an example embodiment corresponds to a first cart from amongst the multiple carts of the sortation system200which may be located at a first end of a sorter cart train. In some examples and in accordance with a back view of the sortation system200, which provides the cutaway perspective view of the sortation conveyor, cart112would move in a direction inwards of a viewing screen away from a user viewing theFIGS. 2 and 3upon movement of the sortation conveyor.

In this regard, cart coupling assembly126in this view, a bearing hub assembly302is illustrated, which passes through a central slot, i.e. the bearing slot of the coupling disc214for engaging two adjacent carts together in the sortation conveyor102. In an example embodiment, a sorter control card (SCC) (not shown herein) of the sortation conveyor102is illustrated which may be positioned near conveyor bed frame204and may be communicatively connected to the dual-linear induction motor. In this aspect, the SCC provides power and control commands to the CCC for controlling a movement of the sortation conveyor102. The SCC in this aspect is communicatively coupled to a dual induction linear motor (not shown herein) and controls a distribution of power generated by the dual linear induction motor. In this regard, the power generated by the dual induction linear motor is daisy chained out by means of conductor rails (CR) available at each of the conveyor bed frame204, into different carts positioned one after another in the sorter cart train. As illustrated, a motor timing gear306is connected via a timing belt308to a timing gear310of a driving roller of the sortation conveyor102. The motor timing gear306controls a speed of motion of each of the cart112in the sortation conveyor102, depending upon a power generated by the dual linear induction motor. The back of the sortation system200, as illustrated, also provides a view of Dlim inlet transition slots (not shown herein) which are present on the conveyor bed frame204and provides channeling and a protection fin of the cart main profile206, to protect the system in case the fin gets damaged or twisted, due to induction generated by the dual linear induction motor.

FIGS. 2 and 3as described herein illustrate an example perspective view of a cross section (e.g., a fragmented cut away view of the sortation conveyor) in an instance in which the cart coupling assembly126is installed for engaging two adjacent carts together in the sortation system. The structure and operations of the cart coupling assembly126are described in more detail with respect toFIGS. 4-8.

FIG. 4illustrates an exploded partially disassembled perspective view of the cart coupling assembly126of a sortation conveyor system400, according to one or more exemplary embodiments. It may be understood that the coupling arrangement mechanism, according to various embodiments described herein, may be implemented in a material handling environment, such as the environment illustrated inFIG. 1. In accordance with various embodiments described herein, the cart coupling assembly126, is adapted for engaging two adjacently positioned conveyor carts, such a cart402-1and a cart402-2of the sortation conveyor102. In this regard, as illustrated, two adjacently placed carts402-1and402-2may move in any direction, such as a first direction404representing a direction of movement of the cart from a source location to a destination. Alternatively, or additionally, the carts402-1and402-2may move in a second direction against the first direction404, such as from destination towards source location.

In one or more aspects, according to one or more exemplary embodiments, each of the carts402-1and402-2includes a main cart profile such as a cart frame406, left and right wheel assemblies408-1and408-2, and components of the cart coupling assembly126. In this aspect, the cart frame406includes a carrier support structure having a longitudinal portion and a transverse portion. The longitudinal portion terminates at horizontally-extending front hitch plate410-1and rear hitch plate410-2and the transverse portion terminates in left and right ends. The left and right wheel assemblies408-1and408-2are attached, respectively, to the left and right ends of the transverse portion that are received for longitudinal movement, in left and right tracks of a loop sorter track412of a loop sortation conveyor frame bed414. As illustrated, the cart coupling assembly126may include: (i) a vertically-extending bearing hub assembly416including a pivot pin419attached to one of the front and rear hitch plates410-1and410-2; and (ii) the cart coupling assembly126. The cart coupling assembly126further includes: (a) a coupling disc418attached to another of the front and rear hitch plates410-1and410-2, the coupling disc418having a central hub opening in form of a bearing slot420, that is adapted to receive the bearing hub assembly416with the pivot pin of an adjacent loop sorter cart, for instance, third cart402-3(not shown herein); and (b) an adjustment mechanism, including a position register screw421and one or more mounting pins422that attaches the coupling disc418to the other of the front and rear hitch plates410-1and410-2. To this extent, each of the position register screw412and the one or more mounting pins422engages the coupling disc418one of the front and rear hitch plates410-1and410-2and are fixed about its engaging positions once the coupling disc418is engaged to any of the plates. In this regard, the bearing hub assembly416, includes the pivot pin419, on top of which a castle nut424may be mounted over a spacer ring428, and locked by means of a carter pin426, so that in operation, the bearing hub assembly416never pops out from the bearing slot420of the coupling disc418. The adjustment mechanism, as illustrated herein, is responsive to a rotational adjustment of the coupling disc418, in a selected direction, to longitudinally move the bearing slot420or the central hub opening of the coupling disc418relative to the other of the front and rear hitch plate410-1and410-2. Further details of the cart coupling assembly126and its operation for engaging adjacent carts402-1and402-2are described in reference toFIG. 5.

FIG. 5illustrates an enlarged perspective view of a sortation conveyor system500including the cart coupling assembly126engaging two adjacent conveyor carts according to one or more exemplary embodiments. Illustratively, each of the carts402-1,402-2comprise two ends such as a front or primal end and a rear or distal end. In this regard, the cart402-1on its front end comprises a front hitch plate410-1which is engaged by the cart coupling assembly126to the cart402-2having a rear hitch plate502-2on its rear end. Also, carts402-1,402-2comprise rear hitch plates410-1,410-2engaged to its back or rear end. Similar, to the front hitch plate410-1, the cart402-2at its front end includes a front hitch plate502-1. In this aspect, the front hitch plates410-1and502-1and/or the rear hitch plates410-2(not shown herein) and502-2may be engaged to the first cart402-1and the second cart402-2by means of various pins, such as by engagement bolts504.

It may be understood, that along the sortation conveyor system500, there may be multiple carts402-1,402-2, . . .402-nand one or more of the multiple carts may comprise on its front ends, front hitch plates410-1,502-1, and on its rear ends, rear hitch plates410-2,502-2, where the front hitch plates of a cart engages with the rear hitch plates of an adjacent cart for enabling a movement of the sortation conveyor system500in a sorter cart train fashion. In accordance with various embodiments illustrated herein, the adjacent carts402-1and402-2may be engaged mechanically or by any other means to each other by engaging a front end of a first cart, such as the cart402-1, to a rear end of a second cart, such as the cart402-2. In this regard, the front plate410-1of the first cart402-1engages with the rear hitch plate502-2of the second cart402-2respectively, via the cart coupling assembly126including a coupling arrangement and the bearing hub assembly416. In this aspect, the cart coupling assembly126comprising the circular coupling disc418, is mounted via mounting plates (not shown herein) on the front hitch plates410-1,502-1and the bearing hub assembly416is mounted on the rear hitch plates410-2,502-2of respective carts402-1,402-2and/or the like.

In accordance with various embodiments illustrated herein for engaging the first cart402-1with the second cart402-2, the cart coupling assembly126that is mounted on the front hitch plate410-1of the first cart402-1is configured to engage with the bearing hub assembly416-1that is present on the rear hitch plate502-2of the second cart402-2. The cart coupling assembly126, according to various embodiments described herein, includes a coupling disc418-1which is adapted to be engaged on a mounting plate of complimentary size over the front hitch plate410-1of the first cart402-1. Similarly, for engaging the cart402-2with a next cart (not shown) of the sortation conveyor102, a coupling disc418-2on the front hitch plate502-1of the cart402-2is provided which is adapted to be engaged with a rear hitch plate (not shown) of a subsequently next cart.

In accordance with various embodiments described herein, the coupling discs418-1or418-2are rotatable around its center. Each of the coupling discs418-1or418-2, comprises bearing slots420-2and420-1(not visible in figure as a hitch pin of the bearing hub assembly416passes through the bearing slot) to engage the bearing hub assemblies416-1,416-2and so on of respective adjacent carts. In this aspect, as illustrated, the coupling disc418-2of the cart402-2, comprises the bearing slot420-2for engaging the bearing hub assembly416that may be mounted at the rear end or rear hitch plate of the next cart402-3. Alternatively, or additionally, two adjacent carts402-1and402-2may be engaged to each other based on engagement of the bearing hub assembly416-1on the rear-hitch plate502-2of the cart402-2into the bearing slot420-1of the coupling disc418-1on the front hitch plate410-1of the cart402-1. Further details pertaining to structure, components, and operations of the cart coupling assembly including the coupling discs418-1,418-2and the bearing hub assembly416-1are provided at least with respect toFIGS. 6 and 7respectively.

The coupling arrangement mechanism described herein and as illustrated inFIG. 5, provides for engagement of two adjacent carts, such as the first cart402-1and402-2while the multiple carts of the sortation conveyor system, such as a sorter train, moves over the conveyor frame bed414. Illustratively, in accordance with some exemplary embodiments, one or more of the carts, for instance, the first cart402-1or the second cart402-2, may comprise two support arms506-1and506-2that may be clamped on a main profile, such as the cart main profile206, as illustrated inFIG. 2. The support arms506-1and506-2may extend outwardly opposite to each other towards the conveyor frame bed414such as, a conveyor frame or a sorter frame. In this regard, in an example embodiment, the support arms506-1and506-2may be foldable about the cart main profile206, such as in a vertical direction for picking out the cart402-1or402-2out from the sortation conveyor system500and disengaging the carts402-1or402-2from the conveyor frame bed414. Illustratively, each of the support arms506-1and506-2may be engageable to cart wheel assemblies408-1and408-2, respectively, that enables movement of the carts402-1and402-2along the conveyor frame bed414.

FIG. 6illustrates a perspective view of a coupling arrangement mechanism, according to various embodiments of the present subject matter. In an aspect, a cart coupling assembly600facilitates engagement of adjacent carts in a sortation conveyor system such as, a loop sorter or a tilt-tray sorter. For purpose of understanding and clarity, various structural portions of coupling disc assembly600and its operational aspects in a material handling environment, are described based on referring toFIGS. 4 and 5respectively. However, this does not limit the operational aspects to which the cart coupling assembly600is capable of, i.e. the cart coupling assembly600, may be used in other application areas, as well, for various purposes. In accordance with various embodiments described herein, along with engaging two carts together, the cart coupling assembly also facilitates for adjustment of a length of a cart, such as carts402-1,402-2as illustrated inFIGS. 4 and 5, thereby adjusting a distance between the two adjacent carts, for instance, the carts402-1and402-2.

As illustrated, the cart coupling assembly600includes: a coupling disc602, a bearing unit604, and a bearing hub arrangement (not shown herein). As illustrated, a structure of the coupling disc includes, a bearing slot612adapted to hold the bearing unit604. In this regard, the bearing slot612is located circumferentially at a center of the coupling disc602. To this extent, the bearing unit604may be engaged into the bearing slot612by means of one or more markings604-1on the bearing unit, which on positioning the bearing unit604within the bearing slot, mechanically fits the bearing unit604into the bearing slot612by means of complimentary markings612-1that may be present inside on a lateral surface of the bearing slot612. A cavity, for instance, but not limited to, a circular shaped cavity as defined by the bearing slot612and the bearing unit604is such that, on engaging the two adjacent carts together, the pivot pin419of the bearing hub assembly416on a first cart passes through a cavity of the bearing unit604and thereby, through the bearing slot612of the coupling disc602, thereby engaging the two adjacent carts together. Illustratively, the bearing unit604may be a spherical bearing that may be configured to be seated in the recess of the bearing slot612.

The structure of the coupling disc602further includes various slots, illustratively, one or more mounting slots606-1,606-2, and606-3, and a control slot608, as illustrated inFIG. 6. In this regard, each one of respective mounting slots606-1,606-2, and606-3and the control slot608, are adapted to receive, the one or more mounting pins422and the position register screw421respectively, when the coupling disc600is mounted on an end of a cart, for instance, on the front hitch plate410-1of a cart as illustrated inFIGS. 4 and 5respectively. Thus, as the coupling disc602is positioned on the front hitch plate410-1of the cart402-1, the set of mounting pins422received into respective mounting slots606-1,606-2, and606-3, thereby temporarily engaging the coupling disc602on the front hitch plate410-1. Further, as the coupling disc602is positioned on the front hitch plate410-1, the position register screw421, which is of a size different than each of the one or more mounting pins422, is received in the control slot608.

In accordance with various embodiments described herein, each of the mounting slots606-1,606-2, and606-3defines a mounting slot cavity and the control slot608defines a control slot cavity along which the mounting pins422and the position register screw421slides, upon the rotation of the coupling disc602. The coupling602disc further includes, multiple spanner holes614-1,614-2,614-3,614-4that may be used for rotating the coupling disc602about its center by means of any conventionally known spanner tool. In this aspect, a spanner wrench may be used to engaged into the one or more spanner holes, such as614-1,614-2,614-3, so as to adjust a position of the coupling disc602when the coupling disc is engaged on a hitch plate of a cart. According to some embodiments, to rotate the coupling disc602, the mounting pins422may be manually or mechanically loosened, unmounted, unscrewed or unfastened, from its engagement with the front hitch plates410-1or502-1, so as to allow the coupling disc602to be rotated about its center. To this extent, upon engagement of the coupling disc602on the front hitch plate410-1, as the coupling disc602rotates, the control slot608and each of the mounting slots606-1,606-2, and606-3slide on each respective one of the position register screw421and the set of mounting pins422. In this regard, the structure defining cavity of the mounting slots606-1,606-2, and606-3and the control slot608, is such that, as the mounting slot cavities and the control slot cavity of the coupling disc602slid ably moves with respect to respective mounting pins422and the position register screw421moves inside the respective slots, a translational movement of the coupling disc602about the bearing unit604occurs. In some embodiments, when two adjacent carts are engaged together by means of the coupling disc602, this translational movement of the coupling disc602about the bearing unit604causes a change in gap between the two engaged carts. To this extent, a structure of the control slot608and each of the mounting slots606-1,606-2, and606-3respectively, facilitates, a continual linear translation of a center of rotation about the bearing unit604of the coupling disc602, as the coupling disc602is rotated continually. In this regard, cavities (i.e. the control slot cavity and the mounting slot cavity) defined by each of the control slot608and the one or more mounting slots606-1,606-2, and606-3respectively, represents circular arcs shaped structure that controls a movement of an instantaneous center of the coupling disc600as the coupling disc600is rotated about the mounting pins422. In this regard, the circular arc shaped structure of these cavities is such that, a radius of these control arcs with respect to a center of the bearing unit604remains constant, in an instance, when the coupling disc602is rotated about the mounting pins422and the circular arcs only allow linear translation of a center of the bearing unit604, as the mounting pins422slides within the mounting slot cavities defined by the one or more mounting slots606-1,606-2, and606-3respectively.

Accordingly, as the coupling disc602rotates, rotational motion of the coupling disc602is continually translated into the linear motion of the coupling disc602over the front hitch plate410-1about a slot (not shown herein) of the front hitch plate410-1, over which the bearing slot612of the coupling disc602is co-axially positioned while engaging the coupling disc602on the cart402-1(refer toFIG. 4). The coupling disc602, in accordance with various embodiments described herein, may be rotated in a first direction or a second direction, for instance, a clockwise or counterclockwise direction, about its continually translating center of rotation about the bearing unit604.

Illustratively, in accordance with various embodiments as described herein, the control slot608includes one or more position registers610, defined along the control slot cavity that is defined by the control slot608. To this extent, structure of the one or more position registers610is such that, in an instance, when the position register screw421is received in the control slot cavity of the control slot608and the coupling disc602is rotated, the one or more position registers610: (a) engages and lock, the position register screw421to restrict a sliding e movement of the control slot cavity defined by the control slot relative to the position register screw412, along the control slot cavity in one direction (a first direction), and (b) allows sliding movement of the control slot cavity relative to the position register screw421in another direction (a second direction) opposite to the one direction.

Accordingly, on rotating the coupling disc602, as the control slot608and mounting slots606-1,606-2, and606-3slides on each respective one of the position register screw421and the set of mounting pins422, the one or more position registers610restricts a sliding movement of the control slot cavity relative to the position register screw421in a direction, for instance, against the direction of rotation (clockwise or counter-clockwise) of the coupling disc602. For example, if the coupling disc602is rotated in a clockwise direction, one or more the position registers610restricts the movement of the control slot cavity relative to the position register screw421in a counter-clockwise direction, thereby allowing sliding of the position register screw421along the control slot cavity of the control slot608in one direction only, at an instance of time. Further, one or more the position registers610on the coupling disc602are also adapted to lock the position register screw421, as in, when, upon sliding movement of the control slot cavity as the coupling disc rotates, the position register screw421is completely recessed into a portion representative of a position register of the control slot cavity of the control slot608.

In accordance with an embodiment, as the coupling disc602is rotated, the one or more position registers610are configured to: (a) restrict a sliding movement of the control slot cavity relative to the position register screw421in the first direction, along the control slot cavity, as in when the rotation is in the second direction and allow the sliding movement of the control slot cavity of the control slot cavity relative to the position register screw421in the second direction. In this regard, in an embodiment, the first direction may correspond to a counterclockwise direction and the second direction may correspond to a clockwise direction. Alternatively, in some embodiments, the first direction may correspond to a clockwise direction and the second direction may correspond to a counterclockwise direction. Further, the one or more position registers610are configured to lock the position register screw421in one of the one or more position registers610, upon the movement of the control slot cavity relative to the position register screw421along the control slot cavity of the control slot608.

According to some embodiments, in an instance, when the coupling disc602is rotated in the clockwise direction, the control slot608and each of the mounting slots606-1,606-2, and606-3slides on each respective one of the position register screw421and the set of mounting pins422respectively, to produce translational movement of the bearing to change the gap between the first and second carts in a downstream direction, (for instance, a direction opposite to the direction115as illustrated inFIG. 1) of the sortation conveyor102. In alternate embodiments, in an instance, when the coupling disc is rotated in the counter-clockwise direction, the control slot and each of the mounting slots slide on each respective one of the position register screw421and the set of mounting pins respectively to produce translational movement of the bearing to change the gap between the first and second carts in an upstream direction, (for instance the direction115as illustrated inFIG. 1), of the sortation conveyor system.

In this regard, in accordance with said embodiments, as rotation of the coupling disc602is translated into a linear motion, the coupling disc602starts displacing over a front hitch plate of a cart, such as front hitch plate410-1of the cart402-1. As the coupling disc602couples the two adjacent carts together, any displacement in the coupling disc602over an edge of the cart causes variation in a distance between the two adjacent carts, thereby providing adjustments for any gaps formed between adjacent carts. Further, details related to rotation of the coupling disc602and its translation into linear motion to facilitate adjustments in distances between the front hitch plate410-1and the rear hitch plate502-2are provided in description ofFIGS. 7 and 8respectively.

FIG. 7illustrates, a sectional view of operations of a cart coupling assembly700for adjusting distance between two adjacent carts on a sortation conveyor, according to one or more embodiments described herein. As illustrated, the cart coupling assembly700includes a coupling disc701that may be configured to be rotated in a clockwise or counterclockwise direction about its center701a. In an aspect, the coupling disc701includes three shaped mounting slots such as, mounting slots704-1,704-2, and704-3respectively, for mounting the coupling disc701on a hitch plate (like the front hitch plate410-1of a cart). Further, the coupling disc701includes an control slot706, defining one or more position registers708(similar to the one or more position registers610illustrated inFIG. 6) that are adapted to hold a position register screw710, in three different positions respectively. As illustrated,702a,702b,702crepresent different positions of the position register screw710in the control slot706of the coupling disc701that may be achieved upon rotation of the coupling disc701about its central axis. In this regard,702brepresents a no-rotation or nominal position of the coupling disc701;702arepresents a first state or position of the coupling disc701upon rotation in a clockwise direction about its center; and702crepresents a third state or position of the coupling disc701upon rotation in the counterclockwise direction about its center. In accordance with various embodiments described herein, rotation of the coupling disc701causes: (a) a sliding movement of the mounting slot cavities of respective mounting slots704-1,704-2, and704-3relative to mounting pins712along the mounting slots704-1,704-2, and704-3respectively and (b) sliding movement of a control slot cavity relative to the position register screw710along the control slot cavity of the control slot706having the one or more position registers708.

As illustrated inFIG. 7, the coupling disc701comprises three such mounting slots704-1,704-2, and704-3which receives respective mounting pins712and one control slot706which receives the respective position register screw710. Alternatively, according to another embodiment, the coupling disc701may have any number of mounting slots and corresponding mounting pins and one or more control slots with corresponding position register screws.

According to various example embodiments described herein, the mounting slots704-1,704-2, and704-3may be similar in design to the mounting slots606-1,606-2, and606-3as illustrated and described in reference toFIG. 6. Similarly, the control slot706may be similar in design to the control slot608illustrated and described with reference toFIG. 6.

Referring to the first state702aof the coupling disc701, as illustrated, the position register screw710is engaged to an extreme end or a last position register in the control slot cavity of the control slot706. This represents a maximum adjustment or increase in a length of a cart that is possible by means of rotating the coupling disc701mounted on a front end of a cart. Illustratively, “+” as illustrated on the first state702aof the coupling disc701represents an increase in a length of the cart in a first direction, i.e. towards a forward direction of movement of the sortation conveyor102. In this regard, for increasing a length of a cart or for adjusting gaps between two adjacent carriers in the first direction of movement of the sortation conveyor, the coupling disc701may be rotated in a clockwise direction until the coupling disc701reaches the first state702a.

Referring to the third state702cof the coupling disc701, as illustrated, the position register screw710is engaged to an end or a first position register, in the control slot cavity of the control slot706. This represents a maximum adjustment or decrease in a length of a cart that is possible by means of rotating the coupling disc701mounted on a front end of a cart. Alternatively, or additionally, the third state702calso represents a maximum adjustment in length of a cart in a second direction, i.e. against the first direction of movement of the sortation conveyor102. Illustratively, in the first state702aof the coupling disc701a decrease (represented as “−”) in a length of the cart in the first direction (e.g., towards direction of movement of the sortation conveyor) or an increase (represented as “+”) in length of the cart in the second direction (e.g., against the first direction of movement of the sortation conveyor). In this regard, decreasing a length of a cart or for adjusting gaps between two adjacent carriers in the second direction of movement of the sortation conveyor, the coupling disc701may be rotated in the counterclockwise direction until the coupling disc701reaches the third state702c.

Similarly, the second state702brepresents a state or position of the coupling disc701achieved without any rotation of the coupling disc701(e.g., a nominal state). For instance, upon installation of the coupling disc on a cart in the sortation conveyor system, the coupling disc701may be in the second state702b. As illustrated in the state702b, the position register screw710is engaged on a position register at a middle of the control slot706. Illustratively, from a nominal state, i.e. the second state702bof the coupling disc701, the coupling disc701may be rotated in a clockwise direction to reach the first state702aor may be rotated in a counterclockwise direction to reach the third state702cof the coupling disc701. Operations related to adjustment of gaps between two adjacent carts by increasing or decreasing a length of the cart are described in more details with respect to description ofFIG. 8.

FIG. 8illustrates a method800for adjusting length of a cart assembly (to adjust gaps between adjacent carts), in a sortation conveyor system. It may be understood that various steps of the method800are described herein with respect to the cart coupling assembly and its operations illustrated inFIGS. 3-7. In one or more embodiments, method800includes engaging a first cart, such as the first cart402-1, with a second cart, such as the second cart402-2, via a cart coupling assembly126(block802). The cart coupling assembly126, as described before, herein, includes the coupling disc602having the control slot608, a bearing slot612, and one or more mounting slots606-1,606-2, and606-3. In this regard, during installation of carts on a sortation conveyor, the first cart402-1may be placed adjacent to the second cart402-2. Engaging the first carts to the second cart may further include engaging, a bearing hub assembly, like bearing hub assembly416, on a rear end of the second cart402-2into a bearing slot, such as bearing slot612, of a coupling disc, such as the coupling disc418, on a front end of the first cart402-1. Illustratively, in some embodiments, engaging the first cart402-1with the second cart402-2may further include fixing or fastening a screw or a nut bolt unit with a safety pin over a top of the bearing hub assembly engaged with the coupling disc, which locks the bearing hub assembly416with the coupling disc418.

Upon engaging the first cart with the second cart, method800includes, rotating the coupling disc, such as the coupling disc418in any of a clock-wise direction or counterclockwise direction relative to center axis of the coupling disc418, for instance, about a bearing slot, such as the bearing slot610or420(block804). Rotation of the coupling disc418causes, movement in a sliding fashion of the control slot cavity of the control slot608relative to: (a) a position register screw, such as the position register screw421or710, along the control slot cavity of the control slot608and movement in a sliding fashion of the mounting slot cavity of the one or more mounting slots606-1,606-2, and606-3respectively, relative to (b) a mounting pin, for instance, the mounting pins422along mounting slot cavity of one or more mounting slots606-1,606-2, and606-3respectively, in a second direction. Illustratively, rotating of the coupling disc418may be performed upon loosening or un-fastening of mounting pins on the coupling disc, such as mounting pins422. As described previously, mounting pins422maintain a tight engagement of the coupling disc over the front plate of a cart. In this regard, loosening the mounting pins422, allows rotation of the coupling disc about its center. Accordingly, in some examples, when any gaps are formed between carts in the sortation conveyor system, an operator may manually un-fasten the mounting pins and thereafter rotates the coupling disc using a spanner tool via one or more spanner holes, such as614-1,614-2,614-3provided on the coupling disc. In this aspect, a spanner wrench may be used to engaged with the one or more spanner holes, such as614-1,614-2,614-3, so as to adjust a position of the coupling disc602when the coupling disc is engaged on a hitch plate such as, the front hitch plate410-1of a cart. As described earlier, rotation of the coupling disc causes displacement of the coupling disc over a front plate of a cart, thereby adjusting a length of the cart to overcome any such gaps.

Upon rotating the coupling disc, method800includes, pausing the rotation of the coupling disc418, based on a locking of the position register screw421or710by the position register708(block806). In this regard, as described regarding block804, the rotation is continued in the clockwise or counterclockwise direction which causes the position register screw421or710to slide inside the control slot cavity of the control slot608, until, the position register708restricts any further sliding movement of the control slot cavity relative to the position register screw710in the control slot cavity, thereby causing the position register screw710to lock in the position register708. As described earlier in reference to states, for instance, a first state702a, a second state702b, and a third state702cof the coupling disc701inFIG. 7, locking the position register screw710by the position register708, also restricts sliding movement of the control slot cavity relative to the position register screw710in a first direction opposite to the second direction. Thus, to overcome any gaps formed between the carts, the operator may continue rotating the coupling disc, such that the rotational motion of the coupling disc is translated into linear displacement of the coupling disc over a cart and thereby providing an infinitely variable (+/−) adjustment for increasing or decreasing length of the cart. Accordingly depending on a determined adjustment in length of cart and a position of the position register screw710relative to the position register along the control slot cavity of the control slot608, the operator can pause the rotation of the coupling disc as soon as the position register screw710locks in the position register708. In this regard, based on sliding of the control slot cavity and the mounting slot cavity relative to: (a) the position register screw421or710in the control slot608and (b) the one or more mounting pins422in the mounting slots606-1,606-2, and606-3respectively, a continually translation of a center of rotation of the bearing unit604of the coupling disc418or602, occurs, thereby sliding the coupling disc602over an end of the cart and resulting in the adjustment of distance or gaps formed between the cart and an adjacent cart in one direction at an instance of time.

According to an embodiment, the method800includes mounting the cart coupling assembly126on the first cart, for instance the cart402-1via the one or more mounting pins422configured to be received in the one or more mounting slots606-1,606-2, and606-3respectively, of the coupling disc606. In this aspect, the method also includes, engaging the bearing hub assembly416-1on a rear end of the second cart402-2in the bearing slot418-1of the coupling disc602that is mounted on a front end of the first cart402-1.