Patent Publication Number: US-9422115-B1

Title: Conveyor system

Description:
CROSS REFERENCE TO RELATED APPLICATION 
     This application is a continuation of and claims priority to U.S. patent application Ser. No. 13/899,865, titled “Conveyor System,” and filed on May 22, 2013, which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND 
     An item can be loaded into a truck and shipped to a fulfillment center. Upon arrival of the item at a receiving area of the fulfillment center, the item is unloaded from the truck and entered into the fulfillment center for storage. A conveyor system can be used to move the item from the truck and into the fulfillment center. Additionally, one or more conveyor systems can be used to move the item within the fulfillment center. Upon the item being sold, for example, workers at the fulfillment center may prepare the item to be shipped to a recipient. For example, the item can be placed into a suitable shipping container, such as a cardboard box, and then loaded onto another truck that delivers the item to the recipient of the sale. A conveyor system can also be used to load the outgoing item into the truck. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Many aspects of the present disclosure can be better understood with reference to the following drawings. The components in the drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views. 
         FIGS. 1-2  are drawings of examples of a conveyor system according to various embodiments of the present disclosure. 
         FIGS. 3-4  are drawings of an example of a roller cover for the conveyor system of  FIGS. 1-2  according to various embodiments of the present disclosure. 
         FIG. 5  is another drawing of the conveyor system of  FIGS. 1-2  according to various embodiments of the present disclosure. 
         FIG. 6  is a flowchart illustrating an example of functionality implemented by the conveyor system of  FIGS. 1-2  according to various embodiments of the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The present disclosure relates to a conveyor system that facilitates the movement of items carried by the conveyor system. As a non-limiting example, a conveyor system may be used in the loading dock of a fulfillment center to transport items from the loading dock to a truck. For example, an item can be placed on a conveyor that moves the item towards the destination end of the conveyor system. At the destination end of the conveyor system, there may be passive rollers, where the item can rest prior to the item being manually loaded into the truck. 
     However, an item riding on the conveyor can gain sufficient speed and momentum to travel from the conveyor to the passive rollers without coming to a stop on the rollers. For example, after traveling along the conveyor to the passive rollers, the item may travel over the passive rollers and fall off the destination end of the conveyor system that is adjacent to the passive rollers. Workers may be injured by an item falling from the destination end of the conveyor system. Additionally, by falling off the conveyor system, the item or equipment may be damaged. 
     In accordance with various embodiments of the present disclosure, a roller cover is positioned over and/or adjacent to one or more of the passive rollers. An item on the conveyor system travels along the conveyor, to one or more passive rollers, and then to the roller cover that is positioned over one or more other passive rollers. Due to friction between the item and the roller cover, the travel of the item is restricted along the roller cover. As such, the roller cover may stop the item before it would otherwise fall off the conveyor system. Thus, the roller cover can reduce injury to workers and damage to items and equipment. 
     In the following discussion, a general description of the system and its components is provided, followed by a discussion of the operation of the same. 
     With reference to  FIG. 1 , shown is a non-limiting example of a conveyor system  100  according to various embodiments of the present disclosure. The conveyor system  100  can move items (not shown), such as packaged or unpackaged products, goods, or any other type of object that is suitable for transport by the conveyor system  100 . The conveyor system  100  is used to transport items into, within, and/or out of an environment. The conveyor system  100  in the embodiment shown in  FIG. 1  can be used, for example, at a loading or unloading dock in a fulfillment center. For instance, the conveyor system  100  in the embodiment shown in  FIG. 1  can be used to load and/or unload items in a truck or a trailer. 
     In alternative embodiments, a conveyor system  100  can be located at a manufacturing facility, a warehouse, an airport, a shopping center, or in any other type of environment where it is desirable to transport items from one location to another location. For example, a conveyor system  100  may be located at a retail environment where it is used to move items, such as groceries, at a point of sale station. As another example, a conveyor system  100  may be used to transport luggage into and/or out of inspection systems, airplanes, and/or buildings at the airport. As another non-limiting example, a conveyor system  100  can be used in a manufacturing environment to transport an item being manufactured from one manufacturing station to another manufacturing station. In further embodiments, a conveyor system  100  may be located in a warehouse for transporting items between various storage locations and/or processing stations, for example. 
     In the embodiment shown in  FIG. 1 , the conveyor system  100  includes a driven conveyor section  103  and a passive conveyor section  106 . The driven conveyor section  103  is representative of multiple driven conveyor sections  103  that can be used in a conveyor system  100  according to various embodiments. The driven conveyor section  103  is a portion of the conveyor system  100  that uses supplied drive power to transport an item. For example, the driven conveyor section  103  shown in  FIG. 1  includes a conveyor belt  109 . The conveyor system  100  uses power supplied by an external source, such as a drive motor, to move the conveyor belt  109  and thus an item that can be located on the conveyor belt  109 . In alternative embodiments, the driven conveyor section  103  may include a track, a powered roller, a vibrating table, or any other type of conveyor that uses a power drive. 
     The passive conveyor section  106  is representative of multiple passive conveyor sections  106  that may be used in the conveyor system  100  according to various embodiments. The passive conveyor section  106  is a portion of the conveyor system  100  that facilitates the movement of an item without the use of a power drive. Such a passive conveyor section  106  may use gravity to facilitate the transportation of an item. For example, according to various embodiments, the passive conveyor section  106  can include, for example but not limited to, a roller, a table, a chute, or any other type of conveyor element that transports items without the use of a power drive. An item can be moved onto the passive conveyor section  106  to, for example, await a worker manually moving the item. 
     The passive conveyor section  106  in the embodiment shown in  FIG. 1  includes multiple rollers. In particular, the passive conveyor section  106  includes a first roller  113 , a second roller  116 , a third roller  119 , and a fourth roller  123 . The first roller  113  is located proximate to the end of the driven conveyor section  103 , and the fourth roller  123  is located proximate to a ledge  126  of the conveyor system  100 . The second roller  116  and the third roller  119  are located between the first roller  113  and the fourth roller  123 , as shown in  FIG. 1 . 
     The first roller  113 , the second roller  116 , the third roller  119 , and the fourth roller  123  facilitate the movement of items along the passive conveyor section  106 . In this regard, the first roller  113 , the second roller  116 , the third roller  119 , and the fourth roller  123  can rotate freely about their respective axes as an item moves along the passive conveyor section  106 . In alternative embodiments, the first roller  113 , the second roller  116 , the third roller  119 , and/or the fourth roller  123  may comprise, for example, a respective row of multiple wheels that can rotate about their respective axes. 
     The conveyor system  100  in the embodiment shown in  FIG. 1  is a telescopic conveyor system. In this regard, one or more portions of the conveyor system  100  can extend and retract in order to adjust the distance that the conveyor system  100  can transport items. For example, the conveyor system  100  shown in  FIG. 1  includes a base  129 , a first extension  133 , a second extension  136 , and/or a third extension  139 . The base  129  can be fastened to, for example, the floor, a cart used to move the conveyor system  100 , or any other suitable support structure. 
     The base  129 , the first extension  133 , the second extension  136 , and/or the third extension  139  may provide support for the conveyor belt  109  and items that ride on the conveyor belt  109 . The first extension  133 , the second extension  136 , and the third extension  139  can also extend and retract with respect to the base  129  and/or with respect to each other. As such, the distance that the conveyor belt  109  can transport items may be adjusted by extending and/or retracting one or more of the first extension  133 , the second extension  136 , and/or the third extension  139 . 
     The conveyor system  100  shown in  FIG. 1  also includes one or more user controls  143 , one or more sensors  146 , one or more lights  149 , and/or other components that are not discussed in detail herein, as they are not necessary for an understanding of embodiments of the disclosure. The user controls  143  facilitate a worker controlling the conveyor system  100 . For example, the user controls  143  may be used to adjust the speed of the conveyor belt  109 , the incline of the conveyor belt  109 , the positions of the first extension  133 , the second extension  136 , and the third extension  139 , and/or other aspects of the conveyor system  100 . 
     The sensor  146  may detect whether an item is located on the passive conveyor section  106 . In response to detecting that an item is on the passive conveyor section  106 , the sensor  146  may cause the conveyor belt  109  to stop in order to prevent additional items accumulating on the passive conveyor section  106  and pushing the item off of the ledge  126  of the conveyor system  100 . 
     The light  149  can provide illumination for workers that are in proximity to the conveyor system  100 . For example, if the third extension  139  has been extended into a trailer of a truck, the light  149  may illuminate the interior of the trailer to facilitate the loading and/or unloading of items from the trailer by workers. 
     Next, a general description of the operation of the various components of the conveyor system  100  is provided. To begin, is it assumed that the first extension  133 , the second extension  136 , and the third extension  139  are set to their desired positions. Additionally, it is assumed that the conveyor system  100  is powered up and that the conveyor belt  109  of the driven conveyor section  103  is moving. 
     An item can be positioned on the conveyor belt  109 . To this end, a person or a robotic arm, for example, can place the item on the conveyor belt  109 . Once the item has been positioned on the conveyor belt  109 , the item rides on the conveyor belt  109  towards the passive conveyor section  106 . 
     Upon the item reaching the end of the conveyor belt  109 , the item transitions from the conveyor belt  109  to the first roller  113 . Due to the item making contact with the first roller  113 , the first roller  113  rotates about its axis, thereby facilitating movement of the item across the passive conveyor section  106 . Additionally, a portion of the item may still be on the conveyor belt  109 . As such, the conveyor belt  109  may push the item further onto the passive conveyor section  106 . The item then makes contact with the second roller  116 , the third roller  119 , and/or the fourth roller  123  as it continues moving along the passive conveyor section  106  towards the ledge  126  of the conveyor system  100 . In alternative embodiments, the item may travel across more or fewer rollers. 
     The sensor  146  may detect that the item is located on or near the passive conveyor section  106  and cause the conveyor belt  109  to stop. In some situations, the item stops while on the first roller  113 , the second roller  116 , the third roller  119 , the fourth roller  123 , and/or the ledge  126 . 
     However, in some cases, the momentum of the item causes the item to continue moving along the passive conveyor section  106 , over the ledge  126 , and off the conveyor system  100 . Additionally or alternatively, the momentum of another item that is on the conveyor belt  109  and/or the passive conveyor section  106  may cause the other item to bump into the item, thereby causing the item to travel over the ledge  126  and fall off the conveyor system  100 . The item may become damaged as a result of the fall off of the conveyor system  100 . Additionally, the falling item may injure a worker and/or cause damage to equipment near the conveyor system  100 . 
     With reference to  FIG. 2 , shown is the conveyor system  100  equipped with a roller cover  200  according to various embodiments of the present disclosure. As will be described in more detail below, the roller cover  200  can be installed over and/or adjacent to the first roller  113 , the second roller  116 , the third roller  119 , and/or the fourth roller  123  to restrict an item from making contact with at least a portion of the first roller  113 , the second roller  116 , the third roller  119 , and/or the fourth roller  123 . When the roller cover  200  is installed, the item makes contact with the roller cover  200  as it moves across the passive conveyor section  106 . As a result, friction between the item and the roller cover  200  restricts the movement of the item along the passive conveyor section  106 . Thus, the item may stop on the roller cover  200  prior to the item otherwise traveling over the ledge  126  and falling off of the conveyor system  100 . 
     With reference to  FIG. 3 , shown is the roller cover  200  according to various embodiments of the present disclosure. The roller cover  200  may comprise, for example, aluminum, steel, plastic, and/or any other suitable type of material that increases the friction between an item and the passive conveyor section  106 . In the embodiment shown in  FIG. 3 , the roller cover  200  comprises a plate  300 , a first fin  303  that extends from a first side of the plate  300 , and second fin  306  that extends from a second side of the plate  300 . The plate  300  is configured to be positioned over one or more rollers, such as the first roller  113  ( FIG. 1 ), the second roller  116  ( FIG. 1 ), the third roller  119  ( FIG. 1 ), and/or the fourth roller  123  ( FIG. 1 ). Additionally, the outer surface of the plate  300  is configured to make contact with an item transported using the conveyor system  100  ( FIG. 1 ). 
     According to various embodiments, the surface of the plate  300  that contacts an item may comprise various features that increase the friction between the plate  300  and the item. For example, the surface of the plate  300  may comprise protrusions, such as studs, ribs, or other types of members that are configured to increase the amount of friction between the plate  300  and an item transported by the conveyor system  100 . Additionally or alternatively, the plate  300  may comprise a coating configured to increase the amount of friction between the plate  300  and an item. For instance, a rubber coating, a sandpaper coating, and/or any other type of coating may be disposed on the exterior surface of the plate  300 . Additionally, the concentration of the friction coating or feature that is disposed on the plate  300  may vary along various points of the plate  300 . For example, the concentration of protrusions may increase as the distance from the first fin  303  increases. Thus, the plate  300  can comprise a friction gradient for which the friction between the plate  300  and an item increases as the distance to the ledge  126  of the conveyor system  100  decreases. 
     The first fin  303  is configured to insert between a roller and another element in the conveyor system  100 . For example, the first fin  303  according to various embodiments may insert between the first roller  113  and the end of the conveyor belt  109  ( FIG. 1 ), between the first roller  113  and the second roller  116 , between the second roller  116  and the third roller  119 , or the third roller  119  and the fourth roller  123 . By inserting between a roller and another element in the conveyor system  100 , the first fin  303  may restrict the roller cover  200  such that the plate  300  is retained in positioned over one or more of the rollers. 
     The first fin  303  in the embodiment shown in  FIG. 3  includes a first section  309 , a second section  313 , and a third section  316 . The first section  309 , the second section  313 , and the third section  316  are respectively oriented so that the first fin  303  forms a shape that can receive a roller, such as the first roller  113 , the second roller  116 , the third roller  119 , or the fourth roller  123 . As such, a roller can be nested within the space between the first fin  303  and the plate  300  when the roller cover  200  is installed in the conveyor system  100 . 
     Additionally, the first section  309  of the first fin  303  forms a ramp that may facilitate an item moving onto the plate  300 . In this regard, the first section  309  is exposed to and may contact an item that travels from the second roller  116  onto the roller cover  200 . Because of the orientation of the first section  309  with respect to the second roller  116  and the plate  300 , the first section  309  can guide the item onto the plate  300  of the roller cover  200 . 
     The second fin  306  in the embodiment shown in  FIG. 3  is also configured to insert between a roller and another element in the conveyor system  100 . For example, the second fin  306  may insert between the first roller  113  and the second roller  116 , between the second roller  116  and the third roller  119 , between the third roller  119  and the fourth roller  123 , or between the fourth roller  123  and the ledge  126  ( FIG. 1 ) of the conveyor system  100 . By inserting between a roller and another element in the conveyor system  100 , the second fin  306  may restrict the roller cover  200  such that the plate  300  is retained in position over one or more of the rollers. 
     The second fin  306  in the embodiment shown in  FIG. 3  is angled towards the first fin  303 . With the second fin  306  oriented towards the first fin  303 , the area between the second fin  306  and the plate  300  forms a space that can receive a roller, such as the first roller  113 , the second roller  116 , the third roller  119 , or the fourth roller  123 . As such, a roller can be nested within the space between the second fin  306  and the plate  300  when the roller cover  200  is installed in the conveyor system  100 . 
     With reference to  FIG. 4 , shown is a cross-sectional view of an example of the roller cover  200  installed in the conveyor system  100  ( FIG. 1 ) according to various embodiments of the present disclosure. In the embodiment shown in  FIG. 4 , the first fin  303  has been inserted between the second roller  116 , and the second fin  306  has been inserted between the fourth roller  123  and the ledge  126 . 
     As shown, the third roller  119  is nested within the space between the first fin  303  and the plate  300 , and the fourth roller  123  is nested within the space between the second fin  306  and the plate  300 . In this position, the first fin  303  in conjunction with the plate  300  clamp onto the third roller  119 . Similarly, the second fin  306  in conjunction with the plate  300  clamp onto the fourth roller  123 . Accordingly, the roller cover  200  is retained in position over the third roller  119  and the fourth roller  123 . 
     To remove the roller cover  200  from the conveyor system  100 , the roller cover  200  can be pulled away from the third roller  119  and the fourth roller  123 . As the plate  300  moves away from the second roller  116  and the third roller  119 , the first fin  303  and the second fin  306  flex away from the plate  300 . As the plate  300  is moved further away from the third roller  119  and the fourth roller  123 , the first fin  303  and the second fin  306  become separated from the third roller  119  and the fourth roller  123 . 
     Thus, the roller cover  200  can be installed on a pre-existing conveyor system  100  without the use of bolts, adhesives, or any other type of fastener. Additionally, the roller cover  200  can be removed merely by pulling the roller cover  200  away from the conveyor system  100 . Thus, the roller cover  200  can be installed and removed without making a permanent modification to the conveyor system  100 . 
     With reference to  FIG. 5 , shown is an example of the conveyor system  100  with the roller cover  200  installed. A general description of the operation of the conveyor system  100  with the roller cover  200  installed follows. In the following discussion, is it assumed that the conveyor system  100  is powered up and that the conveyor belt  109  is moving. Additionally, it is assumed that an item has been placed on the conveyor belt  109  and is moving towards the passive conveyor section  106 . 
     Upon the item reaching the end of the conveyor belt  109 , the item transitions from the conveyor belt  109  to the first roller  113 . Due to the item making contact with the first roller  113 , the first roller  113  rotates about its axis, thereby facilitating movement of the item across the passive conveyor section  106 . Additionally, a portion of the item may still be on the conveyor belt  109 . Thus, the conveyor belt  109  may push the item further onto the passive conveyor section  106 . Thereafter, item makes contact with the second roller  116 , which rolls to facilitate movement of the item across the passive conveyor section  106 . 
     The item then makes contact with the roller cover  200 . In particular, the item contacts the first section  309  of the first fin  303 . Because of the slope of the first section  309 , the first section  309  acts as a ramp to facilitate the item moving onto the plate  300  of the roller cover  200 . Additionally, because the slope of the first section  309  of the first fin  303  acts as a ramp for the item, the item may not tumble or tip over upon contacting the roller cover  200 . 
     The item may continue to move onto the plate  300  of the roller cover  200  and to progress towards the ledge  126  of the conveyor system  100 . Due to the friction between the item and the plate  300  of the roller cover  200 , the speed at which the item is traveling may be reduced. Eventually, the friction between the plate  300  and the item may be sufficient to cause the item to come to a stop on the plate  300  and/or the ledge  126 . Thus, the roller cover  200  restricts the movement of the item on the passive conveyor section  106  of the conveyor system  100 . Additionally, the roller cover  200  may restrict the item from traveling over the ledge  126  and thus off of the conveyor system  100 . 
     With reference to  FIG. 6 , shown is a flowchart that represents an example of the operation of the conveyor system  100  according to various embodiments of the present disclosure. It is understood that the flowchart of  FIG. 6  provides merely an example among others of the operation of the conveyor system  100  as described herein. As an alternative, the flowchart of  FIG. 6  may be viewed as depicting an example of steps of a method performed by the conveyor system  100  according to one or more embodiments. 
     Beginning at box  603 , the conveyor system  100  accepts an item on the conveyor belt  109  ( FIG. 2 ). The item may be positioned on the conveyor belt  109  by a worker or a robotic arm, for example. As shown in box  606 , the conveyor belt  109  is used to transport the item to the first roller  113  ( FIG. 2 ). When the item arrives at the first roller  113 , the first roller  113  may rotate about its axis to facilitate moving the item across the passive conveyor section  106 . As indicated in box  609 , the item is then transported from the first roller  113  to the second roller  116 . The second roller  116  may also rotate about its axis to facilitate the movement of the item along the passive conveyor section  106 . 
     Moving to box  613 , the conveyor system  100  then transports the item from the second roller  116  to the roller cover  200  ( FIG. 2 ). The first section  309  ( FIG. 4 ) of the first fin  303  ( FIG. 4 ) of the roller cover  200  may act as a ramp and guide the item onto the plate  300  ( FIG. 4 ) of the roller cover  200 . As shown at box  616 , the conveyor system  100  uses the roller cover  200  to reduce the speed of the item. In particular, the friction between the roller cover  200  and the item causes the speed of the item to reduce. Thereafter, the process ends. 
     Although the flowchart of  FIG. 6  shows a specific order of execution, it is understood that the order of execution may differ from that which is depicted. For example, the order of execution of two or more boxes in  FIG. 6  may be scrambled relative to the order shown. Also, two or more boxes shown in succession in  FIG. 6  may be executed concurrently or with partial concurrence. Further, in some embodiments, one or more of the blocks shown in  FIG. 6  may be skipped or omitted. It is understood that all such variations are within the scope of the present disclosure. 
     It is emphasized that the above-described embodiments of the present disclosure are merely possible examples of implementations set forth for a clear understanding of the principles of the disclosure. Many variations and modifications may be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.