Patent Abstract:
A rotary diverter can be operated at high speed to divert selected products from one conveyor to a vertically displaced second conveyor. The rotary diverter can have at least one rotary member with a plurality of radial arms. Each radial arm can have an end effector with a lifting platform. A timing belt may be coupled to each end effector to the rotary member in order to keep the lifting platform substantially horizontal. A control system is provided to control a drive mechanism for rotating the rotary member. As the rotary member rotates, the lifting platform of the end effector rises through the first conveyor to lift a selected product over the second conveyor. As the rotary member continues to rotate the lifting platform can then descend through the second conveyor to deliver the selected product upon the second conveyor. During operation, the control system can ensure that the lifting platform of the end effectors: (i) substantially matches the horizontal velocity of the first conveyor when they lift a selected product from the first conveyor; and (ii) substantially matches the horizontal velocity of the second conveyor when they deliver a selected product upon the second conveyor. This arrangement diminishes the amount of acceleration, deceleration and knocking that the selected products are subjected to during the diverting process, which reduces the risk of product misalignment.

Full Description:
FIELD OF THE INVENTION 
     The present invention relates to conveyor systems, including conveyor systems that divert items/products from one conveyor to another conveyor. 
     BACKGROUND OF THE INVENTION 
     The use of conveyors is well known in many industries. In manufacturing, conveyors are commonly used, for example, to move partially assembled products or parts between workstations. In product packaging environments, conveyors commonly move finished products and packages through packaging stations. 
     Whatever the application, it is sometimes necessary to selectively divert items/products from one conveyor to another conveyor. For example, when a downstream packaging station is incapable of handling the volume of products arriving from an upstream conveyor, it may be necessary to employ two or more downstream conveyors and packaging machines to avoid a bottleneck in the process. In such cases, some of the products must be diverted from the upstream conveyor to the additional downstream conveyor(s) in order to apportion product between them. In another example, pre-arranged lightweight products, such as a stack of tissue paper or fabric softener sheets, may become misaligned if they are knocked or subjected to rapid acceleration or deceleration during the packaging process. In these cases, product misalignment may be diminished by reducing the speed at which the product is moved during the packaging process. This may be achieved by diverting some upstream products to one or more downstream conveyors to reduce the load of product that each packaging station must handle. 
     A problem with known diverters is that they too often knock or subject the diverted products to rapid acceleration or deceleration during the diverting process. This may have a number of undesirable effects. For example, in a manufacturing environment, diversion of sensitive or delicate products by a conventional diverter may dislodge components or otherwise damage the products. In a packaging environment, pre-arranged lightweight products may easily become misaligned during the diverting process by these conventional diverters and thereby compromise the proper operation of packaging machines. 
     Known diverters utilise apparatus which selectively divert items or products in a generally horizontal plane. Items are taken out of the incoming conveyor stream and moved sideways or at an angle, but in a generally horizontal plane. These types of diverters are not particularly good at providing a low level of acceleration or deceleration during the diversion process. 
     Accordingly, there is a need for diverters that can diminish the amount of acceleration, deceleration and knocking that products are subjected to during the diverting process. 
     Another problem with some conveyor systems exists at the end of a conveyor where product has to be transferred from the conveyor into a bucket that will take the product to a further station. If the product is flexible about its transverse axes, then if there is any misalignment or any force applied to the front of the product, such as from movement through air as the product leaves the conveyor for the bucket, then the product can fold about a transverse axis, possibly resulting in mis-feed into the bucket. Accordingly, it is desirable to provide a bucket in-feed station that reduces the risk of mis-feeding. 
     SUMMARY OF THE INVENTION 
     It is desirable to provide a conveyor system that has a diverter for selectively diverting products from one conveyor to another conveyor. It is also desirable to provide a conveyor system that can easily transfer flexible products into a bucket. The diverter will be particularly useful in high-speed conveyor systems. 
     Advantageously, the present invention may diminish product acceleration, deceleration and knocking during the diverting process so as to reduce product misalignment; may reduce the volume of product on the conveyors after selected products are diverted; and may reduce the incidence of product misfeeds. 
     In accordance with an aspect of the present invention there is provided an apparatus for transferring a selected product of a plurality of products carried on a first conveyor, from a pickup position on said first conveyor to a delivery position on a second conveyor, said second conveyor being vertically displaced relative to said first conveyor, said apparatus comprising: (a) a member having a transfer effector, said member mounted to a frame for movement to move said transfer effector between said pick-up position and said delivery position; (b) a drive mechanism for moving said member; and (c) a control system operable to control the speed and position of said transfer effector; said transfer effector being adapted for retrieving said selected product at said pick-up position and depositing said selected article at said delivery position, wherein said control system controls the speed and position of said transfer effector from retrieval of said selected product at said pickup position to delivery of said selected product at said delivery position. 
     In accordance with another aspect of the present invention there is provided an apparatus for transferring a selected product from a pick-up position on a first conveyor to a delivery position on a vertically displaced second conveyor, comprising: (a) a plurality of rotary members rotatable in a substantially vertical plane of rotation about a sun axis; (b) a plurality of radial arms extending outward from each of said rotary members, said radial arms spaced equally apart along said plane of rotation; (c) a drive mechanism for rotating each of said rotary members about said sun axis; (d) a lifting effector extending from each of said radial arms; and (e) a control system for controlling the speed and position of each said lifting effector by controlling the rotation of said rotary members; wherein said control system controls the rotation of each of said rotary members so that said lifting effector obtains said selected product at said pickup position and delivers said selected product to said delivery position. 
     In accordance with another aspect of the present invention there is provided a system for diverting selected product from non-selected product comprising: (a) a first conveyor; (b) a second conveyor vertically displaced from said first conveyor; (c) a rotary diverter for acquiring said selected product from said first conveyor at substantially the same horizontal velocity as said first conveyor, and for delivering said selected product onto said second conveyor at substantially the same horizontal velocity as said second conveyor; and (d) a pair of in-feed conveyor stations, one of said in-feed conveyor stations positioned at the terminal end of said first conveyor for receiving said non-selected product, and the other one of said in-feed conveyor stations positioned at the terminal end of said second conveyor for receiving said selected product. 
     In accordance with another aspect of the present invention there is provided a conveyor system comprising: (a) a diverter station having a diverter; (b) a first conveyor diverter portion, said first conveyor being configured to deliver items in succession, to and through said diverter station; (c) a second conveyor having a receiving portion vertically displaced in relation to said first conveyor, said second conveyor operable to move selected items transferred from said first conveyor to said receiving portion of said second conveyor by said diverter, away from said diverter station; said diverter, having a pick-up member, said diverter operable to move said pick-up member to pick up selected items positioned at said diverter portion from said first conveyor in succession and move said selected items from said first conveyor to said receiving portion and release said selected items in succession at said receiving portion of said second conveyor; whereby at least some of said items arriving at said diverter station on said first conveyor are diverted by said diverter onto said second conveyor. 
     In accordance with another aspect of the invention there is provide a conveyor system comprising: (a) a diverter station having a diverter; (b) a first conveyor diverter portion, said first conveyor being configured to deliver items in succession, to and through said diverter station, said first conveyor having a receiving portion; (c) a second conveyor that is vertically displaced in relation to said first conveyor, said second conveyor operable to move selected items to said unloading portion for transfer to said first conveyor by said diverter; said diverter, having a pick-up member, said diverter operable to move said pick-up member to pick up selected items positioned at said unloading portion in succession from said second conveyor and move said selected items from said unloading portion of said second conveyor to said receiving portion of said first conveyor and release said selected items in succession at said receiving portion of said second conveyor; whereby at least some of said items arriving at said diverter station on said first conveyor are diverted by said diverter onto said second conveyor. 
     In accordance with another aspect of the invention there is provide a conveyor system comprising: (a) a first conveyor having a moving conveyor carrier; (b) a second conveyor having a moving conveyor carrier; (c) a driving system to drive both said carriers at substantially the same speed; said first conveyor carrier being mounted in spaced, opposed relation to said second conveyor carrier to permit a deflectable product to be received between said first conveyor carrier and said second conveyor carrier and be carried between said carriers when said driving system is operated; at least one of said first conveyor carrier and said second conveyor carrier having a contoured inward facing surface configured and adapted to press against a surface of said deflectable product received between said first conveyor carrier and said second conveyor carrier, to deflect a side portion of said product relative to a medial portion of said product; whereby said deflectable product is bent along a longitudinal axis. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     In figures which illustrate embodiments of the invention, by way of example only: 
     FIG. 1 is a schematic plan view of a conveyor system employing a rotary diverter positioned between a single upstream conveyor and two downstream conveyors terminating with separate bucket in-feed conveyor stations; 
     FIG. 2 illustrates an enlarged side elevation view of the rotary diverter taken in the direction of arrows  2 — 2  of FIG. 1; 
     FIG. 3 is an enlarged side view of part of the diverter of FIG. 1, in the direction of arrow  3  of FIG. 1; 
     FIG. 4 is a perspective view of another part of the diverter of FIG. 1, taken in the direction of arrows  4 — 4  of FIG. 2; 
     FIG. 5 is a cross-sectional view of part of the diverter of FIG. 1, in the direction of arrows  5 — 5  of FIG. 1; 
     FIG. 6 is a perspective view of an in-feed conveyor station in the general direction of arrow  6  of FIG. 1; 
     FIG. 7 is a cross-sectional side view of a bucket in-feed station in the system of FIG. 1, in the direction of arrows  7 — 7  of FIG. 1; 
     FIG. 7A is a cross-sectional view of a convex transverse member and top conveyor belt of the in-feed station in FIG. 7; 
     FIG. 7B is a cross-sectional view of a product bent between a convex transverse member of FIG. 7A and a concave transverse member of FIG. 7B; 
     FIG. 7C is a cross-sectional view of a concave transverse member and bottom conveyor belt of the in-feed station in FIG. 7; 
     FIG. 8 is a perspective view of part of the diverter of FIG. 1, in the direction of arrow  8  of FIG. 1; 
     FIG. 9 is a perspective view of a part of the diverter of FIG. 2, in the direction of arrow  9  of FIG. 2; 
     FIG. 10 is a chart illustrating how rotational speed of part of the diverter is varied during rotation; and 
     FIG. 11 is a schematic side elevation view, similar to FIG.  2 . 
    
    
     Similar references are used in different figures to denote similar components. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     With reference to FIGS. 1 and 2, a conveyor system generally designated  140 , includes a rotary diverter station  111  having a diverter  10  positioned between a single conveyor  80  moving products from a product feed station  13  to diverter  10 , and downstream conveyors  90 ,  92 . Conveyors  80 ,  90  and  92  may be operate continuously or intermittently and at constant or variable speed. Conveyors  90 , 92 , move product to conveyors  91 ,  93  respectively, which in turn each move product to separate bucket in-feed conveyor stations  100 . As an item or product  101 , such as a pre-arranged stack of fabric softener sheets, as shown in FIGS. 2,  3 ,  6 , and  7 C travels down conveyor  80 , rotary diverter  10  selectively diverts product  101  from upstream conveyor  80  to downstream conveyor  92 . Products  101  that are not diverted from upstream conveyor  80 , continue along downstream conveyor  90 . In this embodiment, every other product  101  on upstream conveyor  80  can be diverted to downstream conveyor  92  at diverter station  13 , so that the resulting delivery rate of products  101  on each of downstream conveyors  90  and  92  is half of the delivery rate of products  101  on upstream conveyor  80 . In this specification the term “delivery rate” means the number of products that pass a point on the conveyor path in any given period of time (eg. 5 units every second passing a point on the path). It is possible however, to vary the distribution of products diverted as between conveyor  90  and conveyor  92 , as will be evident hereinafter. 
     The specific configuration of high-speed rotary diverter  10  is shown in FIGS. 2 to  5  and  8  to  9 . With particular reference to FIG.  2  and FIG. 8, rotary diverter  10  has a left hand section  18  and a right hand section  19 , which are constructed of the same parts and mounted substantially in the same way as each other, but in a way so that the operation of one section does not interfere with the operation of the other section during the transfer of products between conveyors. Sections  18  and  19  can be driven independently of each other, in that one can be driven at a rotational speed different than the other, but co-operate in that they work together to transfer products from one conveyor to another. 
     Unless otherwise indicated, for ease of reference, complementary left hand and right hand sections of rotary diverter  10  are denoted by similar reference numbers. In overview, each section  18 ,  19  has an arm each having a pair of opposed, integrally connected arm portion  62  which rotate about the centre of the arm at a central sun axis  15 . Each arm portion has an end effector such as for example, an end effector  20 , at its outer end. As arm portions  62  are rotated, they each are able to pick up a product  101  arriving on conveyor  80 . In this embodiment, the pick-up of a product  101  by an end effector  20  is possible because of the co-operating configuration of the end effectors and the end portion of conveyor  80 . Once product  101  is picked-up, the arm portions  62  then rotate and end effectors  20  lift the product  101  upwards in a vertical direction, following a curved path about axis of a sun shaft  15 . As each arm portions  62  reaches conveyor  92 , the end effector  20  and conveyor  92  are also co-operatively configured such that the end effector can deposit the product  101  onto conveyor  92 . In the preferred embodiment, the arm portions  62  of section  18  co-operate with the arm sections of section  19 , so that each section in turn will rotate an arm portion so that an end effector will transfer a product  101  from conveyor  80  to conveyor  92 . 
     Referring to FIGS. 2,  3 ,  4  and  5 , illustrating section  19  in detail, illustrate a rotary member  60  mounted for rotation in a vertical plane about the central axis X—X of sun shaft  15 . Shaft  15  is fixedly mounted in stationary shaft block  14 , which is secured to a frame. Thus, shaft  15  is held in a stationary position relative to the frame. 
     As shown in FIG. 5, shaft  15  has a variable, stepped diameter, upon which various components are mounted. Main pulley  35  is rotatably mounted about sun shaft  15  on main bearings  11  and  12  (FIG.  5 ), which are retained by main bearing housing  16 . Sun pulley  32  is concentrically mounted about shaft  15  using a key-way  23  (so sun pulley  32  is fixed relative to shaft  15 ). Main pulley  35  is mounted by bolts on bearing housing  16  and on rotary hub  70 , so that all these parts ( 35 ,  16 ,  60 ) rotate together about shaft  15  as one unit. Accordingly, when main pulley  35  is rotated by a drive belt  17 , rotary member  60  and bearing housing  16  wall also rotate together with main pulley  35 , about shaft  15 . 
     Rotary member  60  has two radial arm portions  62  that extend radially outward in a vertical plane, in opposite directions, from a round central portion  61 . In other embodiments, each section&#39;s rotary member  60  could have only one radial arm or more than two radial arms may extend from said round central portion  61 , although it will be appreciated that particularly in high speed applications it is desirable to ensure that during the rotation there is proper balancing of the loads resulting from rotation from the arms. Thus, there should be a relatively balanced placement of the arms around central portion  61 , such as for example, three arm portions  62  spaced at 120 degrees from each other or four arm portions  62  spaced at 90 degrees to each other. Alternatively, counter-weights could be used if the placement of the end effectors  20  alone does not provide for proper balancing. 
     Planetary shaft bearings  102  are retained by a bushing  63  in the outward end of each radial arm portions  62 . A planetary shaft  34  is rotatably mounted through each bushing  63  on bearings  102 . Planetary shafts  34  extend through either side of radial arm portions  62  along an axis parallel to sun shaft  15 . 
     On the same side of radial arm portions  62  that main pulley  35  is mounted to rotary member  60 , planetary pulleys  103  are fixedly mounted on planetary shafts  34  and thus will rotate with shafts  34 . Planetary pulleys  103  are retained in place by flat washers  104  bolted to planetary shaft  34 . A planetary pulley spacer  106  prevents frictional contact between planetary pulleys  103  and radial arms  62 . 
     Terminating each planetary shaft  34 , on the end opposite from which planetary pulley  103  is a flange  23  (FIGS. 3 to  5 ). An end effector  20  extends vertically from each flange  23 . Each end effector  20  comprises a centre lifter segment  22  (FIGS. 4 and 5) bolted with bolts  27  to flange  23  and two side lifter segments  24  bolted through lifter segment separators  25 , on either side of centre lifter segment  22 . Side lifter segments  24  are separated in parallel relation from centre lifter segment  22  by lifter segment separators  25  (FIG.  5 ). Above horizontal plane Y—Y which is aligned with the top surface of lifter segments  25 , it is possible for conveyor belt  80 ,  90 ,  92  to pass between a side lifter segment  24  and centre lifter segment  22  (FIG.  9 ). 
     In this embodiment, centre lifter segment  22  and side lifter segments  24  are generally triangularly shaped wherein one side of said triangular lifting segments of each end effector  20  define a flat lifting plane that is in parallel orientation to the centre axis of planetary shaft  34 . The bases of side lifter segments  24  are fitted with product guide rails  26  in opposing parallel relation, which define the outer side edges of said lifting plane (FIG.  5 ). 
     End effector  20  could be comprised of a variety of shapes, structures or mechanisms capable of transferring a selected product  101  from a pickup point P to a delivery point D. For example, depending on the nature and configuration of product  101 , the rotary path of radial arm  62 , and the configuration of the conveyors from which the product is to be transferred from and to, end effector  20  could be for example any of a platform, hook, pair of rails, magnet, suction cup, pincer or clamp. 
     Rotary member  60  is driven by a drive mechanism  50  (FIGS. 2,  3  and  5 ), which is clamped to a stationary portion of work frame  127  by clamping plate  38 . Drive mechanism  50  drives a drive pulley  21 , which transfers power to main pulley  35  through drive belt  17  to turn main pulley  35 . Thus, the rotation of drive pulley  21  causes main pulley  35  to rotate. As pulley  35  rotates, so does rotary member  60 , along with its arm portions  62 . As arm portions  62  rotate, the position of planetary shafts  34  and planetary pulleys  103  move relative to sun pulley  32  is altered. As sun pulley  32  is fixed on main shaft  15 , the interconnection of sun pulley  32  to planetary pulley  103  through timing belt  105  will cause pulley  103 , shaft  34  and effector  20  to rotate in the opposite direction to the rotation of arm portions  62 . So long as the turning belt  105  and sun pulley  32  counteract precisely the rotation of arm portions  62 , then the orientation of effector  20  will not be changed during rotation of arm portions  62  (eg. in the preferred embodiment the orientation of the top surface of end effector  20  will remain horizontal). This will be the case if the outer diameter of sun pulley  32  is the same as the outer diameter of planetary pulley  103 , with each typically having the same number, and same spacing of teeth. 
     By way of further explanation, timing belt  105  causes the rotation of each planetary pulley  103  as it is driven around stationery sun pulley  32  in order to maintain the lifting plane of each end effector  20  in a constant (eg. horizontal) position during the rotation of rotary member  60 . The timing belt  105 , planetary pulleys  103  and sun pulley  32  are arranged so that the ratio of end effector  20  rotation to rotary member  60  rotation is set to 1:−1, wherein each end effector  20  will rotate one revolution in the opposite direction for every revolution of rotary member  60 . It may of course be desirable in some applications to vary the orientation of position of the plane or one or more of the effectors during its change in position from pick-up to drop-off of the product. This could be accomplished in another set-up by providing gearing to effect the rotation of the end effectors and by varying the gear ratios of the sun pulley  32  to the planetary pulley  103 . 
     A way of simply varying the orientation of the end effector relative to the arm portions  62  is to make an adjustment to shaft  15  by rotating it (while the drive is disengaged), such a rotation will cause sun pulley  32  to rotate, thus then turning belt  105  rotating end effector  20 . Thus, as shown in outline in FIG. 3, both end effectors  20  orientation can be altered by angle alpha, by a corresponding rotation of shaft  15  relative to rotary member  60 . 
     Two idler pulleys  107  are rotatably mounted by idler bearings  108  on shoulder screws  109 , which are attached to the circular portion of rotary member  60 . Idler pulley spacers  36  prevent frictional contact between idler pulleys  107  and rotary member  60 . Idler pulleys  107  are arranged on opposite sides of sun pulley  32  and are situated inside timing belt  105 . During high speed rotation, idler pulleys  107  assist in maintaining the shape and proper positioning of, and provide an efficient path for, timing belt  105 , which, in turn, better maintains the orientation of end effectors  20 . Two tension rollers  33  are rotatably mounted to the circular portion of rotary member  60 . As best seen in FIG. 3, tension rollers  33  are arranged on opposite sides of sun pulley  32  and outside of timing belt  105  so as to urge timing belt  105  into better contact with sun pulley  32 . 
     Sensor bracket  40  (FIG. 5) is mounted to shaft block  14  by sensor mounting bracket  39 . A flag  41  associated with each of arm portions  62  is attached to bearing housing  16  so that flag  41  rotates with bearing housing  16 . An optical sensor, or any other conventional, suitable sensor (“sensor 1”), not shown, is mounted to sensor bracket  40  to monitor the position of flag  41 . A conventional programmable logic controller (“PLC1”), not shown, or any other conventional electronic control mechanism, communicates with drive mechanism  50  and sensor  1 . The angular position of each radial arm portions  62  and the corresponding position of the lifting plane of end effectors  20  is ascertained by sensor  1  sensing the position of flag  41  and sending a signal to PLC 1 . Accordingly, once sensor  1  detects the flag  41 , PLC 1  know the position of the lifting plane of end effectors  20  is at the “homing” or “ready” position for the end effector  20 . Once identified to be in the homing position (angular position H in FIG.  11 ), an end effector  20  can be held there until it is ready to be rotated to pick up a product  101 . 
     A second conventional optical or other suitable sensor  31  (FIG. 2 ), also in communication with PLC 1  is mounted to work frame  127  or a stationary portion of upstream of a pick-up point P, on or adjacent conveyor  90  or conveyor  80 . Sensor  31  is appropriately configured to monitor the position of products  101  on upstream conveyor  80  and sends a signal to PLC 1  when a product  101  approaches designated pickup point P on upstream conveyor  80 . A third conventional optical or other suitable sensor  30 , also in communication with PLC 1  could optionally be utilized to confirm the synchronization of movement of product  101  and end effector  20  pick-up point , as is hereinafter described. Sensor  30  can be mounted to work frame  27  or a stationary portion of upstream conveyor  80 . Sensor  30  sends a signal to PLC 1  when a product  101  is exactly at a designated pick-up point P on upstream conveyor  80 . 
     The position of the pickup point P is programmed into PLC 1  and from this reference point, the rotary members  60  are appropriately rotated in accordance with the angular displacement from this reference point. Also, PLC 1  is programmed such that only certain selected products of the group of products  101  are diverted by diverter  10  from conveyor  80  onto conveyor  92 , whereas other products are allowed to proceed on to conveyor  92 . Thus, PLC 1  will upon the identification of a product  101  approaching pickup point P, determine if this is a product which should be diverted to conveyor  92 , and then either give or not give an instruction to drive mechanism to rotate an arm portion  62  of one of sections  18  or  19 . 
     Upon receipt of an appropriate signal from sensor  31 , PLC 1  will if designated for diversion, instruct drive mechanism  50  to rotate drive pulley  21  to move a lifting plane of an end effector  20  from its homing position H, to underneath the pickup point P on upstream conveyor  80  in order to position end effector  20  for pick up of a selected product  101 . Under the control of PLC 1 , the drive mechanism  50  will rotate drive pulley  21  to move a lifting plane of an end effector  20  through the pickup point P on upstream conveyor  80  to obtain the selected product  101  (FIG.  9 ). After a selected product  101  is obtained by an end effector  20 , PLC 1  controls drive mechanism  50  in continuing to rotate drive pulley  21  until the lifting plane of end effector  20  crosses the plane of downstream conveyor  92  and deposits product  101  at the delivery point D (FIG.  9 ). 
     PLC 1  controls the speed of rotation of drive pulley  21 . The rotational speed of the pulley  21  can be selected such that the horizontal component of velocity of an end effector  20  is substantially equal to the horizontal velocity of the upstream conveyor  80  when the lifting plane of end effector  20  obtains a selected product  101  at the pickup point P. Similarly, PLC 1  can control the rotation of drive pulley  21  so that the horizontal component of velocity of an end effector  20  is substantially equal to the horizontal velocity of the downstream conveyor  92  when the lifting plane of end effector  20  delivers a selected product  101  at the delivery point D. By substantially matching the horizontal velocity of the end effector  20  with the horizontal velocity of the upstream conveyor  80  and downstream conveyor  92  at the pickup and delivery points P and D, sudden acceleration and deceleration of product  101  is reduced during the diverting process and the risk of misalignment is accordingly diminished. The speeds at which the conveyors will operate are input into the PLC 1 , which can then determine an appropriate velocity profile for the end effector  20  (for example see FIG.  10 ). 
     With reference to FIGS. 10 and 11, the rotational speed of an arm portion  62  is shown as the arm moves from the homing position H (−10 degrees in FIG. 11) to the pickup position P (0 degrees in FIG. 11) through the drop-off position D to approximately 100 degrees as shown in FIG.  11 . The curve marked “TL” is the speed curve if the linear speed of the end effector is to remain constant as it rotates from position P through position D to 100 degrees rotation. In one practical embodiment, the rotational speed is controlled by PLC 1  to follow line PL 1  between 0 degrees (position P) and just past 50 degrees at drop off position D. In a preferred embodiment, the speed can actually be increased once product  101  is deposited on conveyor  92 , so that it quickly moves away from the product. Thus, the rotational speed after release of product, may be programmed to follow line PL 2  between drop-off to 100 degrees. This increase in speed, particularly the linear component, will ensure that any following product  101  moving along conveyor  90  and not being diverted will not have its movement interfered with by end effector  20  as it passes back through conveyor  90  during its further rotation. 
     The drive mechanism  50  is a servo drive, so that the speed of rotation or radial arms  62  can be varied during the rotation, as discussed above. With respect to the two sections  18  and  19 , each of their rotary members  60  are driven separately, so that their speeds at any particular time, can be different. This provides for much greater flexibility in the operation of the diverter  10 . For example, the effector  20  of one section  18  can be stationary at position H, while an effector  20  of the other section  19  can be moving while dropping a product at position D. 
     As illustrated in FIG.  2  and FIG. 9, diverter  10  is generally positioned between upstream conveyor  80  and downstream conveyors  90  and  92 . In the present embodiment, upstream conveyor  80  and downstream conveyors  90  and  92  each comprise two parallel carrying belts (not shown) in the area between the pickup point P and delivery point D. The belts are separated to provide enough space for centre lifter segment  22  to pass in between the belts and for side lifter segments  24  to pass outside the belts when an end effector  20  crosses the plane of upstream and downstream conveyors  80  and  92 . It will be understood that the number of belts comprising conveyors  80  and  92 , both inside and outside the above noted area, may be greater or less than two. 
     Downstream conveyor  92  is vertically displaced and from and vertically aligned with, upstream conveyor  80  and they are aligned in a parallel plane to the plane of rotation of rotary member  60 . The vertical displacement between downstream conveyor  92  and upstream conveyor  80  is sufficient to permit non-diverted product  101  to continue along upstream conveyor  80  to downstream conveyor  90  without contacting the underside of downstream conveyor  92 , but less that the distance between plane Y—Y of each end effector  20  and the lifting plane of end effector  20 , so that lifter segment separators  25  do not contact the underside of upstream conveyor  80  during diversion of product  101 . 
     As rotary member  60  rotates in a clockwise direction, the top surfaces of side segments  24  and centre segment  22  of end effectors  20  define a circular path. In the upper left quadrant of the lifting plane path, the lifting plane has a lifting (upward) and translating (forward) component of motion. In the upper right quadrant of the circular path the lifting plane has a lowering (downward) and translating (forward) component of motion. In the particular arrangement of the preferred embodiment shown in FIG.  2 . and FIG. 9, downstream conveyor  92  is positioned above upstream conveyor  80 , pickup point P is positioned in the upper left quadrant of the circular path and delivery point D is positioned in the upper right quadrant of the lifting plane path. With this arrangement selected product  101  is raised by the lifting plane of end effector  20  at pickup point P as it crosses upstream conveyor  80  and is lowered onto delivery point D as it crosses downstream conveyor  92 . As explained above, PLC 1  controls the rotation of drive pulley  21  to substantially match the translating component of the lifting plane&#39;s motion with the translating component of the upstream conveyor  80  at the pickup point P and of the downstream conveyor  92  at the delivery point D. It will also be noted from FIG. 2, that throughout the rotation from pick-up and particularly at drop-off, the vertical component of velocity will be relatively small compared to the horizontal component, and provides for relatively small accelerations in the vertical direction. Furthermore, with respect to certain flimsy products such as a stack of fabric softeners, any vertical acceleration during pick-up will actually serve to stabilize the product as it is pushed against the under supporting segments of end effectors  20 . 
     As referenced above, in this embodiment, there are two sections  18  and  19 . It will be observed in FIG. 8 that left hand section  18  and right hand section  19  are arranged in opposing relation to one another so that the lifting plane paths of their respective end effectors  20  are concentric and travel in the same vertical plane. This arrangement may be achieved by orienting the sun shafts  15  (as shown in FIG. 5 for right hand section  19 ) of both left hand section  18  and right hand section  19  along the same axis of rotation and by aligning both sets of centre lifter segments  22  on the same plane of rotation. 
     Left hand section  18  and right hand section  19  may be controlled by a single programmable logic controller, by separate programmable logic controllers in communication with one another, or some other combination of conventional controller devices. The radial arms  72  of left hand section  18  and of right hand section  19  maintain a minimum angular separation so as to prevent the lifting plane of an end effector  20  of one radial arm  60  from contacting the planetary shaft  34  of the next radial arm  60 . 
     With reference to FIG. 2, the employment of both a left hand section  18  and a right hand section  19 , described above, increases the capacity of products  101  that may be diverted from upstream conveyor  80 . Moreover, if left hand section  18  and right hand section  19  are controlled and are driven independently of each other, the end effector  20  of the one section may be positioned under pickup point P in preparation to obtain a selected product  101 , while the end effector  20  of the other section is still in the process of diverting a previously selected product  101 . 
     It will be appreciated many different variations to the preferred embodiment described above are possible. For example, multiple radial arms may be provided in a single section rotary diverter instead of or in addition to positioning a left hand section  18  and a right hand section  19  in opposite arrangement. The path of the end effectors does not necessarily have to be circular. 
     Other variations of the diverter station are possible. For example, it would be possible to arrange diverter  10  to consolidate two streams of product arriving on two separate conveyors, into a single stream of products leaving on a single conveyor. This would be accomplished by the diverter picking up product from one of the incoming conveyors, and depositing the product on an outgoing conveyor, that also receives product from an second incoming conveyor. 
     Once product  101  reaches the end of downstream conveyors  90  it can be transferred to a conveyor  91  (FIG. 2) which could be operated at a lower speed, with the result that the products can again have their spacing decreased, now some product has been diverted to conveyor  92 . Likewise product carried on conveyor  92  can be transferred to a slower conveyor  93  (FIG. 2) with the same effect. 
     At the end of conveyors  91 ,  93  are in-feed conveyor stations  100 , load products  101  into buckets  112 , shown in FIG. 6, carried on auto-loader  110 . When bucket  112  is filled with a predetermined amount of product  101 , auto-loader  110  advances said filled bucket  112  and positions an empty bucket  112  in its place. Product  101  in filled buckets  112  is eventually transferred to a packaging conveyor (not shown) for transport to a packaging machine (not shown) for packaging. The use of auto-loaders  110 , packaging conveyors and packaging machines to load and package various products positioned in buckets is well known to those skilled in the art. 
     With reference to FIGS. 6 and 7, in-feed conveyor station  100  has a top conveyor portion  130  in fixed vertical displacement from a bottom conveyor portion  120 . Bottom portion  120  comprises of a conveyor  122  having a bottom conveyor carrier such as belt  124  that is driven in a conventional manner through in-feed conveyor station  100 . As illustrated in FIG. 6, bottom conveyor carrier such as belt  124  has mounted to it a series of concave up (or generally V-shaped) transverse members  125  (one of which is separately shown in FIG. 7C) mounted along its length. Bottom conveyor  120  is positioned at the terminal end of downstream conveyor  90  or  92  so that any product  101  transported by downstream conveyors  90  or  92  is received by a bottom conveyor  120  and can be transported at substantially the same velocity by bottom conveyor belt  124 . 
     Top portion  130  includes a conveyor  132  on which a top conveyor carrier such as belt  134  can be driven in a conventional manner. As illustrated in FIG. 6, top conveyor belt  134  has mounted along its length a series of convex down (also generally V-shaped) transverse members  135  (one of which is separately shown in FIG.  7 A). In operation, top conveyor belt  134  revolves in an opposite direction to bottom conveyor belt  124  so that the velocity of the bottom surface of top conveyor belt  134  is substantially equal to the velocity of the top surface of bottom conveyor belt  124 . 
     Product  101  is a product or item that can be deformed when a load is applied to it by being pinched between members  125  and  135  of the bottom and top conveyors respectively. As illustrated in FIG. 7, the vertical separation between the bottom surface of top conveyor belt  134  and the top surface of bottom conveyor belt  124  diminishes from upstream to downstream. The upstream separation diminishes from a separation greater than the height of product  101  to a separation less than the height of product  101 , to compress the product  101 . As product  101  is moved along by bottom belt  124  under top portion  130  it is gradually pinched between bottom conveyor belt  124  and top conveyor belt  134 . As product  101  is pinched by belts  124  and  134  (shown in FIG.  7 B), convex transverse members  135  and concave transverse members  125  gently bend product  101  along its longitudinal centre line of motion. It will be appreciated that flexible products, like paper or fabric softener sheets, are more resistant to bending in one direction when a bend is introduced in the transverse direction. Accordingly, by bending product  101  along a central longitudinal axis, in-feed conveyor station  100  makes product  101  more resistant to bending in the transverse direction (ie. about a transverse axis) and, therefore, less likely to fold or become misaligned as it is loaded into bucket  112 . 
     The conveyor system referred above can be operated at relatively high speeds, including the diverter  10 . For example, in the preferred embodiment, the conveyors  80 ,  90  and  92  can be operated with a linear speed of in the order of 250 feet per minute. 
     Numerous other modifications, variations and adaptations may be made to the particular embodiments of the invention described above without departing from the scope of the invention, which is defined in the claims.

Technology Classification (CPC): 1