Patent Description:
In a high-volume distribution and fulfillment center, material handling systems, such as conveyors, vertical conveyors, and the like, are generally used to convey articles, such as, totes, containers, cartons, and the like, for further handling and/or processing. Thus, in a distribution and fulfillment center, articles are regularly transferred from one material handling system to another throughout the processing cycle of the article. Applicant has identified several technical challenges associated with loading of the articles from one material handling system to a downstream system. Through applied effort, ingenuity, and innovation, many of these identified challenges have been overcome by developing solutions that are included in embodiments of the present invention, many examples of which are described in detail herein. <CIT> discloses a baggage passes over the horizontal rod of a pushing arm, the pushing arm is raised by an elevating device, and then, when a running body is moved from a retraction limit to an advancing limit by means of a running device, the pushing arm advances being left raised owing to the movement of the lower end of a vertical rod along a second guide rail and can push the baggage on a roller conveyor until it passes the front end of the roller conveyor. When the operation mentioned above is reversed, the pushing arm is retracted and lowered, retreating to a position where the carrying of the baggage on the roller conveyor is not obstructed. <CIT> discloses a load assist module according to the preamble of claim <NUM>. <CIT> discloses when the container on the main carrying passage reaches a branch point to the sub carrying passage, a gate part is closed, the container is moved to a starting end of a stand by part, an engagement pin is abutted on and engaged with an inner circumference of a skirt part, and the container is pulled to a terminating end of the stand by part while correcting the position thereof. At the terminating end of the stand by part, a pressing pin pushes the container, and transfers it to the starting end of the sub carrying passage onto a carrying base, a sliding mechanism is moved parallel to the loading position of the sub carrying passage, the container is left at the loading position by an unloading mechanism, and only the carrying base is returned to the starting end of the sub carrying passage.

The illustrative embodiments of the present disclosure relate to systems and methods for loading articles in a material handling environment.

According to the invention, a load assist module for transferring an article onto a downstream conveyor is provided. The load assist module includes a roller conveyor having one or more rollers that together define a conveyor plane, such that the one or more rollers are actuatable to convey the article along the conveyor plane in a direction of a downstream conveyor. The load assist module further includes a pusher assembly that is positioned adjacent to the conveyor plane. The pusher assembly includes a track-guided vertical popup with a base and a pop-up, the pop-up may be actuatable such that the pop-up extends through the conveyor plane to contact the article. Further, the pusher assembly drives the track-guided vertical popup toward the direction of the downstream conveyor such that the track-guided vertical popup may push the article.

According to the invention, the pusher assembly includes a drive assembly operatively coupled to the track-guided vertical popup. The drive assembly drives the track-guided vertical popup in a first direction, towards the downstream conveyor, to transfer the article onto the downstream conveyor, and drives the track-guided vertical popup in a second direction, away from the downstream conveyor, once the article is transferred onto the downstream conveyor. According to the invention, the drive assembly includes a timing belt driven by a pair of roller mounted timing pulleys. The timing belt is coupled to the track-guided vertical popup for driving the track-guided vertical popup in the first direction and the second direction. According to the invention, the drive assembly further includes a flag coupled to the timing belt such that the flag moves in a direction opposite to a direction of movement of the track-guided vertical popup. In a preferred embodiment according to the invention, the drive assembly may include a pneumatic cylinder coupled to the track-guided vertical popup, such that the pneumatic cylinder may extend to drive the track-guided vertical popup in the first direction and may retract to drive the track-guided vertical popup in the second direction.

According to a preferred embodiment according to the invention, the popup may be vertically movable to extend above the conveyor plane for pushing the article onto the downstream conveyor and retract below the conveyor plane for receiving a next article onto the load assist module.

According to the invention, the load assist module further includes one or more pneumatic pop-out stops positioned adjacent to the downstream conveyor, such that the one or more pneumatic pop-out stops may extend to stop the article against the one or more pneumatic pop-out stops until the downstream conveyor may be ready to receive the article.

According to a preferred embodiment according to the invention, the load assist module may further include a controller operatively coupled to the roller conveyor and the pusher assembly. The controller may receive a notification of a presence of the article on the roller conveyor. In response to the notification, the controller may drive the roller conveyor to convey the article along the conveyor plane towards the downstream conveyor, actuate the pusher assembly to extend the track-guided vertical popup above the conveyor plane such that the track-guided vertical popup may contact the rear end of the article, and actuate the pusher assembly to drive the track-guided vertical popup against the rear end of the article to push the article onto the downstream conveyor.

According to a preferred embodiment according to the invention, the load assist module may further include one or more guide rails positioned parallel to the conveyor plane for aligning and guiding the article while the article may be conveyed by the roller conveyor.

According to the invention, a material handling system is provided. The material handling system includes a conveyor for conveying an article in a conveyance direction, and a load assist module positioned adjacent the conveyor for receiving the article from the conveyor. The load assist module includes a roller conveyor having one or more rollers that together define a conveyor plane, such that the one or more rollers are actuatable to convey the article along the conveyor plane in a direction of a downstream conveyor. The load assist module further includes a pusher assembly that is positioned adjacent to the conveyor plane. The pusher assembly includes a track-guided vertical popup with a base and a pop-up, the pop-up is actuatable such that the pop-up extends through the conveyor plane to contact the article. Further, the pusher assembly drives the track-guided vertical popup toward the direction of the downstream conveyor such that the track-guided vertical popup may push the article.

According to one or more embodiments of the present disclosure not part of the invention, the downstream conveyor may include a vertical conveyor for moving the article vertically across one or more levels.

According to the invention, the pusher assembly includes a drive assembly operatively coupled to the track-guided vertical popup. The drive assembly drives the track-guided vertical popup in a first direction, towards the downstream conveyor, to transfer the article onto the downstream conveyor, and drives the track-guided vertical popup in a second direction, away from the downstream conveyor, once the article is transferred onto the downstream conveyor. According to the invention, the drive assembly includes a timing belt driven by a pair of roller mounted timing pulleys. The timing belt is coupled to the track-guided vertical popup for driving the track-guided vertical popup in the first direction and the second direction. According to the invention, the drive assembly further includes a flag coupled to the timing belt such that the flag moves in a direction opposite to a direction of movement of the track-guided vertical popup. According to a preferred embodiment according to the invention, the drive assembly includes a pneumatic cylinder coupled to the track-guided vertical popup, such that the pneumatic cylinder extends to drive the track-guided vertical popup in the first direction and retracts to drive the track-guided vertical popup in the second direction.

According a preferred embodiment according to the invention, the popup is vertically movable to extend above the conveyor plane for pushing the article onto the downstream conveyor and retract below the conveyor plane for receiving a next article onto the load assist module.

According to a preferred embodiment according to the invention, the material handling system further includes a controller operatively coupled to the load assist module. The controller receives a notification of a presence of the article on the roller conveyor. In response to the notification, the controller drives the roller conveyor to convey the article along the conveyor plane towards the downstream conveyor, actuates the pusher assembly to extend the track-guided vertical popup above the conveyor plane such that the track-guided vertical popup contacts the rear end of the article, and actuates the pusher assembly to drive the track-guided vertical popup against the rear end of the article to push the article onto the downstream conveyor.

According to another aspect of the present disclosure not part of the invention, a method of operating a load assist module for transferring an article onto a downstream conveyor is provided. The method may include receiving a notification of a presence of the article on a roller conveyor of the load assist module, in response to the notification, driving the roller conveyor to convey the article along a conveyor plane towards the downstream conveyor, actuating a pusher assembly, positioned adjacent the conveyor plane, having a track-guided vertical popup to extend the track-guided vertical popup above the conveyor plane such that the track-guided vertical popup contacts a rear end of the article, and actuating the pusher assembly to drive the track-guided vertical popup against the rear end of the article to push the article onto the downstream conveyor.

According to one or more embodiments of the present disclosure not part of the invention, the method may include receiving a notification of transfer of the article onto the downstream conveyor, in response to the notification, actuating the pusher assembly to retract the track-guided vertical popup adjacent the conveyor plane, and actuating the pusher assembly to drive the track-guided vertical popup away from the downstream conveyor and into the load assist module to an initial position.

According to one or more embodiments of the present disclosure not part of the invention, the method may include receiving a notification of conveyance of the article on the roller conveyor towards the downstream conveyor, actuating one or more pneumatic pop-out stops positioned adjacent to the downstream conveyor, such that the one or more pneumatic pop-out stops may extend to stop the article against the one or more pneumatic pop-out stops, detecting that the downstream conveyor may be ready to receive the article, and actuating the one or more pneumatic pop-out stops to retract to allow the article to be transferred onto the downstream conveyor.

The above summary is provided merely for purposes of summarizing some example embodiments to provide a basic understanding of some aspects of the disclosure.

Some embodiments of the present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the inventions are shown. Indeed, the disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. The terms "or" and "optionally" are used herein in both the alternative and conjunctive sense, unless otherwise indicated. The terms "illustrative" and "exemplary" are used to be examples with no indication of quality level.

The components illustrated in the figures represent components that may or may not be present in various embodiments of the invention described herein such that embodiments may include fewer or more components than those shown in the figures while not departing from the scope of the invention as defined in the appended claims.

Turning now to the drawings, the detailed description set forth below in connection with the appended drawings is intended as a description of various configurations and is not intended to represent the only configurations in which the concepts described herein may be practiced. The detailed description includes specific details for the purpose of providing a thorough understanding of various concepts with like numerals denoting like components throughout the several views. However, it will be apparent to those skilled in the art of the present disclosure that these concepts may be practiced without these specific details.

Example distribution and order fulfillment centers may include material handling systems for conveying, diverting, sorting, and/or organizing articles, such as, but not limited to, totes, containers, cartons, and the like. In some examples, material handling systems may transfer and/or load the articles from one material handling system to another material handling system, such as a material handling system that is adjacently positioned in the direction of travel of the material being handled (e.g., a downstream direction), for further handling and/or processing.

In some examples, the transfer and/or loading of the articles from one material handling system to a downstream material handling system may result in a loading error. For example, a conveyor may load a tote onto a downstream conveyor, however, the tote may be partially loaded, may bounce back and/or be reoriented during the loading operation, resulting in a jam on the downstream conveyor.

Further, in some examples, the downstream conveyor may also include a vertical conveyor. In such examples, loading errors may introduce down time for the system and may require that an operator clears jams at high elevations which requires additional safety measures to resolve, further increasing down time of the system.

One or more example embodiments of the present disclosure described herein include an efficient, cost-effective, and low-maintenance means, in some examples, for assisting in loading articles onto a downstream system. The load assist module described herein, in some examples, includes a pusher assembly having a track-guided vertical popup for pushing the articles fully and in a desired orientation, speed, etc. onto a downstream conveyor and/or machine.

<FIG> illustrates a perspective view of a material handling system <NUM>, in accordance with one or more embodiments of the present disclosure. As shown in <FIG>, the material handling system <NUM> includes a load assist module <NUM> for transferring an article <NUM>, such as, a tote, onto a downstream conveyor <NUM>. Further, in an embodiment, the downstream conveyor <NUM> may include a vertical conveyor <NUM>, as shown in <FIG>. The vertical conveyor <NUM> may be configured to convey articles vertically between one or more levels. In an example embodiment, the vertical conveyor <NUM> may include vertical uprights <NUM> for supporting a support structure <NUM>. The support structure <NUM> may receive and/or support the article <NUM> received from the load assist module <NUM>. Further, as shown in <FIG>, the load assist module <NUM> may be installed as a stand-alone unit that is attached to an in line with existing conveyors, such as, conveyor <NUM>. Alternatively or additionally, the load assist module <NUM> may be integral with or otherwise a part of one or more conveying systems.

In accordance with one or more example embodiments of the present disclosure, the load assist module <NUM> includes a roller conveyor <NUM> for receiving the article <NUM> from the conveyor <NUM>. In an example embodiment, the roller conveyor <NUM> may be coplanar with the conveyor <NUM> to receive the article <NUM>. The roller conveyor <NUM> may convey the article <NUM> along a conveyor plane <NUM> in the direction of the downstream conveyor <NUM>, as shown in <FIG>. The term conveyor plane <NUM>, as used herein, may be defined as a conveyance surface defined by a surface of the rollers and is bounded by one or more edges of the rollers of the roller conveyor <NUM>. In an example embodiment, when the downstream conveyor <NUM> includes the vertical conveyor <NUM>, the support structure <NUM> may be coplanar with the roller conveyor <NUM> to support the article <NUM>. It should be noted that the present disclosure is not limited to roller-based conveyors, and the term roller conveyor <NUM> may include or may otherwise take the form of any other means for conveying an article, such as, belted conveyor, strip belts, and the like.

In some examples, the load assist module <NUM> includes a pusher assembly <NUM> positioned adjacent the conveyor plane <NUM> and along the roller conveyor <NUM> in the downstream direction, as shown in <FIG>. In some examples, the pusher assembly <NUM> may be place in the center or substantially the center of the roller conveyer <NUM>. The pusher assembly <NUM> includes a track-guided vertical popup <NUM> that extends vertically in the downstream direction and that may be extendable above the conveyor plane <NUM> and may be retractable below and/or in line with the conveyor plane <NUM>. Further, the pusher assembly drives the track-guided vertical popup <NUM> horizontally towards the downstream conveyor <NUM>.

In an embodiment, the track-guided vertical popup <NUM> is extendable above the conveyor plane <NUM> to contact the article <NUM>, as shown in <FIG>. As shown in <FIG>, the track-guided vertical popup <NUM> is configured such that the track-guided vertical popup <NUM> pushes the article <NUM> onto the downstream conveyor <NUM> and loads the article <NUM> all the way into the vertical conveyor <NUM>, thus, minimizing loading errors.

<FIG> illustrates a perspective view of load assist module <NUM>, in accordance with one or more example embodiments of the present disclosure. As shown in <FIG>, the roller conveyor <NUM> includes the article <NUM>, having a frond end <NUM> and a rear end <NUM>, and is shown resting on the surface of the one or more rollers (e.g., the conveyor plane <NUM>). Further, the load assist module <NUM> includes the pusher assembly <NUM> having the track-guided vertical popup <NUM> positioned adjacent the conveyor plane <NUM>. As shown in <FIG>, the track-guided vertical popup <NUM> may be positioned in an initial position <NUM>, that is, the track-guided vertical popup <NUM> may be fully retracted into the load assist module <NUM> such that the track-guided vertical popup <NUM> may be positioned adjacent the rear end <NUM> of the article <NUM>. Further, as shown in <FIG>, the track-guided vertical popup <NUM> may extend vertically above the conveyor plane <NUM>, by means of a pneumatic cylinder, for example, to contact the rear end <NUM> of the article <NUM> when the article <NUM> may be detected to be present on the roller conveyor <NUM> by one or more sensors of the load assist module <NUM>. In an example embodiment, the pusher assembly <NUM> may drive the track-guided vertical popup <NUM> in a first direction <NUM> towards a downstream conveyor (not shown) for transferring the article <NUM> from the load assist module <NUM> onto the downstream conveyor. Further, in an example embodiment, the pusher assembly <NUM> drives the track-guided vertical popup <NUM> in a second direction <NUM> away from a downstream conveyor (not shown) to retract the track-guided vertical popup <NUM> into the load assist module <NUM>, for example, after transferring the article <NUM> onto the downstream conveyor. In an example embodiment, the track-guided vertical popup <NUM> may be retracted vertically to be adjacent the conveyor plane <NUM> before, while, and/or after being retracted into the load assist module <NUM> to allow a next article to be conveyed on the roller conveyor <NUM> without impeding conveyance of the next article.

<FIG> illustrates a perspective view of the load assist module <NUM>, in accordance with one or more example embodiments of the present disclosure. As shown in <FIG>, the load assist module <NUM> includes the roller conveyor <NUM> for conveying an article (not shown) along the conveyor plane <NUM> towards a downstream conveyor (not shown). In this embodiment there are a first set of full length rollers <NUM> that extend from a first wall <NUM> to a second wall <NUM> of the load assist module <NUM>. Adjacent to the first set of full length rollers <NUM> are two sets of short rollers <NUM> and <NUM>'. The first set of short rollers <NUM> are bounded on a first side by the first wall <NUM> and a second side by wall <NUM> of the pusher assembly <NUM>. The second set of short rollers <NUM>' are bounded on a first side by the second wall <NUM> and a second side by wall <NUM> of the pusher assembly <NUM>. In some examples, one or more rollers in the first set of short rollers <NUM> may be aligned in parallel with one or more rollers in the second set of short rollers <NUM>'. The first set of full length rollers <NUM> and the two sets of short rollers <NUM> and <NUM>' may be arranged in series so as to form a conveying surface defining the conveyor plane <NUM> that is configured to convey an article.

The load assist module <NUM> further includes the pusher assembly <NUM> having the track-guided vertical popup <NUM>. The pusher assembly <NUM> is defined by opposing walls <NUM> and <NUM> that extend in a downstream direction from the first set of full length rollers <NUM> to a downstream end of the roller conveyor <NUM>. In some examples, each wall <NUM> and <NUM> comprises a track <NUM>. In some examples the track <NUM> is defined by the walls <NUM> and <NUM> whereas in other examples the track <NUM> extends from or is attached to the walls <NUM> and <NUM>. In an example embodiment, track <NUM> on each wall <NUM> and <NUM> may be arranged such that they extend in the same plane and oppose one another. In some examples, track <NUM> may be sized to receive protrusions <NUM> and <NUM>', as shown in <FIG>, that extends from track-guided vertical popup <NUM>.

Referring now to <FIG>, that illustrate perspective views of the track-guided vertical popup <NUM> in an extended position and a retracted position, in accordance with one or more example embodiments of the present disclosure. In this example embodiment, the track-guided vertical popup <NUM> comprises an elongate base <NUM>. The base <NUM> may include protrusions <NUM> and <NUM>' extending from both sides of the base <NUM>. The protrusions <NUM> and <NUM>' may be sized to fit in the channel and/or tracks defined by the walls of the pusher assembly, as described above. Base <NUM> may further comprise a vertical pop-up <NUM> having a pop-up head <NUM> coupled to a pop-up base <NUM>. In some examples, the pop-up head <NUM> may be operatively coupled to a pneumatic cylinder such that the pop-up head <NUM> may be vertically movable relative to the base <NUM> and relative to a conveyor plane. Specifically, the pop-up head <NUM> may be coupled to the pop-up base <NUM> through pistons <NUM> movable pneumatically in and out of openings <NUM> formed in the pop-up base <NUM>. Thus, enabling the pop-head <NUM> to extend from and/or retract into the pop-up base <NUM>. <FIG> illustrates the track-guided vertical popup <NUM> with the pop-head <NUM> extending from the pop-up base <NUM>. <FIG> illustrates the track-guided vertical popup <NUM> with the pop-head <NUM> retracting into the pop-up base <NUM>.

Referring back to <FIG>, the track-guided vertical popup <NUM> may be extendable to be positioned above the conveyor plane <NUM> and may be retractable relative to the to be positioned in line with and/or below the conveyor plane <NUM> for receiving a next article onto the load assist module <NUM>.

In an example embodiment, the load assist module <NUM> further includes opposing pneumatic pop-out stops <NUM> positioned at the downstream end of the load assist module <NUM> such that they are adjacent to a downstream conveyor, as shown in <FIG>. In an example embodiment, the pneumatic pop-out stops <NUM> may be coupled to one or more pneumatic cylinders, such that the pneumatic pop-out stops <NUM> may be extendable inwardly toward one another and, thus, may be configured to stop an article, until the downstream conveyor may be ready to receive the article. Further, the pneumatic pop-out stops <NUM> may be retractable to allow the article at a front of the load assist module <NUM> to be transferred onto the downstream conveyor, when the downstream conveyor may be ready to receive the article.

In an example embodiment, the load assist module <NUM> may further include guide rails <NUM> positioned parallel to the conveyor plane <NUM>. Guide rails <NUM> may be attached to one or more supports that may extend in a perpendicular direction from the conveyor plane <NUM>. In some examples, the guide rails <NUM> may be positioned such that they extend along the length of the conveyor plane <NUM> and are parallel to the roller conveyor <NUM>. Further, in some examples, the guide rails <NUM> may be parallel to one another for a portion of their length and may curve outwardly away from one another for another portion of their length. The guide rails <NUM> may align and guide an article being conveyed on the roller conveyor <NUM> to a desired position and/or orientation. For example, the guide rails <NUM> may guide the article such that the article may be positioned above the pusher assembly <NUM>.

In an example embodiment, the load assist module <NUM> may further include one or more sensors <NUM> mounted at different locations on the load assist module <NUM> to track the movement of the article on the load assist module <NUM>. In an example embodiment, the sensors <NUM> may include, but are not limited to, photoeyes, encoders, proximity sensors, and the like.

In accordance with one or more example embodiments of the present disclosure, one or more sensors <NUM> positioned at a rear end of the load assist module <NUM> may detect that the roller conveyor <NUM> may be clear and ready to receive an article from an upstream conveyor. In response, the roller conveyor <NUM> may receive the article and convey the article along the conveyor plane <NUM> towards a downstream conveyor. While the article may be conveyed by the roller conveyor <NUM>, the guide rails <NUM> may guide and align the article, such that the article may pass over the track-guided vertical popup <NUM> that may be in a retracted position. Further, in an example embodiment, the one or more sensors <NUM> may detect a presence of the article on the roller conveyor <NUM>, and may actuate the pneumatic pop-out stops <NUM>, such that the article may stop against the pneumatic pop-out stops <NUM>. Further, once the downstream conveyor may be ready to receive the article, the pneumatic pop-out stops <NUM> may retract, and the roller conveyor <NUM> may start conveying the article towards the downstream conveyor. Further, the track-guided vertical popup <NUM> may extend above the conveyor plane <NUM> and may contact a rear end of the article. The pusher assembly <NUM> may drive the track-guided vertical popup <NUM> along the track <NUM> and against the rear end of the article, thus, pushing the article onto the downstream conveyor. In an example embodiment, once the article may be transferred onto the downstream conveyor, the track-guided vertical popup <NUM> may be retracted and be driven back into the load assist module <NUM> by the pusher assembly <NUM>.

<FIG> illustrates a front view of the load assist module <NUM>, in accordance with one or more example embodiments of the present disclosure. As shown in <FIG>, the track-guided vertical popup <NUM> may be retracted vertically, such that, the pop-up head <NUM> may be retracted into the pop-up base <NUM> and be in line with and/or below a top surface of the roller conveyor <NUM>. That is, the pop-up head <NUM> may be adjacent the conveyor plane <NUM>, so as to allow an article to be conveyed on the roller conveyor <NUM> without being impeded by the track-guided vertical popup <NUM>.

<FIG> illustrates a bottom view of the load assist module <NUM>, in accordance with one or more example embodiments of the present disclosure. As shown in <FIG>, the pusher assembly <NUM> of the load assist module <NUM> includes a drive assembly <NUM> operatively coupled to the track-guided vertical popup (not shown) for driving the track-guided vertical popup, as described above. In an example embodiment, the drive assembly <NUM> includes a first roller mounted timing pulley <NUM> and a second roller mounted timing pulley <NUM>, as shown in <FIG>. In an example embodiment, the first roller mounted timing pulley <NUM> may be mounted on a motorized roller and the second roller mounted timing pulley <NUM> may be mounted on an idler roller. The drive assembly <NUM> further includes a timing belt <NUM> reeved around and driven by the first roller mounted timing pulley <NUM> and the second roller mounted timing pulley <NUM>.

The timing belt <NUM> is coupled to the base <NUM> of the track-guided vertical popup <NUM> (not shown) of the pusher assembly <NUM>, such that, as the timing belt <NUM> is driven by the first roller mounted timing pulley <NUM> and the second roller mounted timing pulley <NUM>, the track-guided vertical popup <NUM> is driven along with the timing belt <NUM>. For example, the first roller mounted timing pulley <NUM> may be rotated in a first direction to drive the timing belt <NUM> forward, towards the downstream conveyor. The timing belt <NUM> may, in turn, drive the track-guided vertical popup <NUM> (not shown) that is coupled to the timing belt <NUM> towards the downstream conveyor. Further, the first roller mounted timing pulley <NUM> may be rotated in a second direction, opposite to the first direction, to drive the timing belt <NUM> backwards, away from the downstream conveyor, thus, moving the track-guided vertical popup <NUM> back into the load assist module <NUM>.

Further, in an example embodiment, the drive assembly <NUM> includes a flag <NUM> coupled to the timing belt <NUM>, as shown in <FIG>. The flag <NUM> is coupled to an underside of the timing belt <NUM>, such that the flag <NUM> moves in a direction opposite to a direction of motion of the timing belt <NUM>. Further, in an example embodiment, the load assist module <NUM> includes one or more sensors, such as, but not limited to, proximity sensors, photoeyes, encoders, etc., that detect the flag <NUM> to determine a position of the timing belt <NUM>. For example, the flag <NUM> may move between sensors mounted on each end of the load assist module <NUM>, such that, the sensors may detect a position of the flag <NUM>. In an example embodiment, based on the sensor data, the load assist module <NUM> determines a position of the timing belt <NUM>, and subsequently, a position of the track-guided vertical popup that are coupled to the timing belt <NUM>.

<FIG> illustrates a bottom view of the load assist module <NUM>, in accordance with another example embodiment of the present disclosure. In an alternate embodiment, as shown in <FIG>, the drive assembly <NUM> may include a pneumatic cylinder <NUM> coupled to the track-guided vertical popup (not shown) of the pusher assembly <NUM>. In an example embodiment, the pneumatic cylinder <NUM> may extend to drive the track-guided vertical popup towards the downstream conveyor and may retract to drive the track-guided vertical popup away from the downstream conveyor and back into the load assist module <NUM>.

<FIG> illustrates a schematic block diagram of a controller <NUM> for controlling the operation of the load assist module <NUM>, in accordance with one or more embodiments of the present disclosure. As shown, the controller <NUM> may include at least one processor <NUM>, memory <NUM>, communication module <NUM>, and input/output module <NUM>. The processor <NUM> may be configured with processor executable instructions to perform operations described herein. Processor <NUM> may, for example, be embodied as various means including one or more microprocessors with accompanying digital signal processor(s), one or more processor(s) without an accompanying digital signal processor, one or more coprocessors, one or more multi-core processors, one or more controllers, processing circuitry, one or more computers, various other processing elements including integrated circuits such as, for example, an ASIC (application specific integrated circuit) or FPGA (field programmable gate array), or some combination thereof. Accordingly, although illustrated in <FIG> as a single processor, in some embodiments processor <NUM> may comprise a plurality of processors. The plurality of processors may be embodied on a single device or may be distributed across a plurality of devices. The plurality of processors may be in operative communication with each other and may be collectively configured to perform one or more functionalities of the controller <NUM> as described herein. In an example embodiment, processor <NUM> is configured to execute instructions stored in memory <NUM> or otherwise accessible to processor <NUM>. These instructions, when executed by processor <NUM>, may cause controller <NUM> to perform one or more of the functionalities of controller <NUM>, as will be described with reference to <FIG>.

Memory <NUM> may comprise, for example, volatile memory, non-volatile memory, or some combination thereof. Although illustrated in <FIG> as a single memory, memory <NUM> may comprise a plurality of memory components. The plurality of memory components may be embodied on a single device or distributed across a plurality of devices. In various embodiments, memory <NUM> may comprise, for example, a hard disk, random access memory, cache memory, read only memory (ROM), erasable programmable read-only memory (EPROM) & electrically erasable programmable read-only memory (EEPROM), flash memory, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, a compact disc read only memory (CD-ROM), digital versatile disc read only memory (DVD-ROM), an optical disc, circuitry configured to store information, or some combination thereof. Memory <NUM> may be configured to store information, data (including item data and/or profile data), applications, instructions, or the like for enabling controller <NUM> to carry out various functions in accordance with example embodiments of the present disclosure. For example, in at least some embodiments, memory <NUM> may buffer input data for processing by processor <NUM>. Additionally or alternatively, in at least some embodiments, memory <NUM> may store program instructions for execution by processor <NUM>. Memory <NUM> may store information in the form of static and/or dynamic information. This stored information may be stored and/or used by the controller <NUM> during the course of performing its functionalities.

Communications module <NUM> may be embodied as any device or means embodied in circuitry, hardware, a computer program product comprising computer readable program instructions stored on a computer readable medium (e.g., memory <NUM>) and executed by a processing device (e.g., processor <NUM>), or a combination thereof that is configured to receive and/or transmit data from/to another device and/or network, such as, for example, sensors, roller conveyor <NUM>, pusher assembly <NUM>, drive assembly <NUM>, and the like. In some embodiments, communications module <NUM> (like other components discussed herein) may be at least partially embodied as or otherwise controlled by processor <NUM>. In this regard, communications module <NUM> may be in communication with processor <NUM>, such as via a bus. Communications module <NUM> may include, for example, an antenna, a transmitter, a receiver, a transceiver, network interface card and/or supporting hardware and/or firmware/software for enabling communications with another device. Communications module <NUM> may be configured to receive and/or transmit any data that may be stored by memory <NUM> using any protocol that may be used for communications between devices. Communications module <NUM> may additionally or alternatively be in communication with the memory <NUM>, input/output module <NUM> and/or any other component of the controller <NUM>, such as via a bus.

Input/output module <NUM> may be in communication with processor <NUM> to receive an indication of a user input and/or to provide an audible, visual, mechanical, or other output to a user. As such, input/output module <NUM> may include support, for example, for a keyboard, a mouse, a joystick, a display, a touch screen display, a microphone, a speaker, a RFID reader, barcode reader, biometric scanner, and/or other input/output mechanisms. In embodiments wherein the controller <NUM> is embodied as a server or database, aspects of input/output module <NUM> may be reduced as compared to embodiments where the controller <NUM> is implemented as an end-user machine (e.g., remote worker device and/or employee device) or other type of device designed for complex user interactions. In some embodiments (like other components discussed herein), input/output module <NUM> may even be eliminated from the controller <NUM>. Alternatively, such as in embodiments wherein the controller <NUM> is embodied as a server or database, at least some aspects of input/output module <NUM> may be embodied on an apparatus used by a user that is in communication with the controller <NUM>. Input/output module <NUM> may be in communication with the memory <NUM>, communications module <NUM>, and/or any other component(s), such as via a bus. One or more than one input/output module and/or other component can be included in the controller <NUM>.

As described above and as will be appreciated based on this disclosure, embodiments of the present disclosure not part of the invention may be configured as methods, conveyors, material handling systems, warehouse management servers, personal computers, servers, mobile devices, backend network devices, and the like. Accordingly, embodiments may comprise various means formed entirely of hardware or any combination of software and hardware. Furthermore, embodiments may take the form of a computer program product on at least one non-transitory computer-readable storage medium having computer-readable program instructions (e.g., computer software) embodied in the storage medium. Any suitable computer-readable storage medium may be utilized including non-transitory hard disks, CD-ROMs, flash memory, optical storage devices, or magnetic storage devices.

Embodiments of the present disclosure not part of the invention have been described below with reference to block diagrams and flowchart illustrations of methods, apparatuses, systems and computer program goods. It will be understood that each block of the circuit diagrams and process flowcharts, and combinations of blocks in the circuit diagrams and process flowcharts, respectively, can be implemented by various means including computer program instructions. These computer program instructions may be loaded onto a general purpose computer, special purpose computer, or other programmable data processing apparatus, such as processor <NUM>, as discussed above with reference to <FIG>, to produce a machine, such that the computer program product includes the instructions which execute on the computer or other programmable data processing apparatus create a means for implementing the functions specified in the flowchart block or blocks.

These computer program instructions may also be stored in a computer-readable storage device (e.g., memory <NUM>) that can direct a computer or other programmable data processing apparatus to function in a particular manner, such that the instructions stored in the computer-readable storage device produce an article of manufacture including computer-readable instructions for implementing the function discussed herein. The computer program instructions may also be loaded onto a computer or other programmable data processing apparatus to cause a series of operational steps to be performed on the computer or other programmable apparatus to produce a computer-implemented process such that the instructions that execute on the computer or other programmable apparatus provide steps for implementing the functions discussed herein.

Accordingly, blocks of the block diagrams and flowchart illustrations support combinations of means for performing the specified functions, combinations of steps for performing the specified functions and program instruction means for performing the specified functions. It will also be understood that each block of the circuit diagrams and process flowcharts, and combinations of blocks in the circuit diagrams and process flowcharts, can be implemented by special purpose hardware-based computer systems that perform the specified functions or steps, or combinations of special purpose hardware and computer instructions.

<FIG> illustrates an example method <NUM> for operating the load assist module <NUM>, in accordance with one or more embodiments of the present disclosure not part of the invention. The method <NUM> may include, at block <NUM>, receiving, by the material handling system <NUM>, the load assist module <NUM>, and/or the controller <NUM>, a notification of a presence of the article <NUM> on a roller conveyor <NUM> of the load assist module <NUM>. In an exemplary embodiment, as described above with reference to <FIG> and <FIG>, the roller conveyor <NUM> may receive the article <NUM> from an upstream conveyor. Further, one or more sensors <NUM> may detect a presence of the article <NUM> on the roller conveyor <NUM> and may provide a notification of the presence of the article <NUM> on the roller conveyor <NUM> to the material handling system <NUM>, the load assist module <NUM>, and/or the controller <NUM>. As described above, the one or more sensors <NUM> may include photoeyes, proximity sensors, encoders, etc. for detecting a presence of the article <NUM> on the roller conveyor <NUM>.

In response to the notification, the method <NUM> may further include driving, by the material handling system <NUM>, the load assist module <NUM>, and/or the controller <NUM>, the roller conveyor <NUM> to convey the article <NUM> along a conveyor plane <NUM> towards the downstream conveyor, at block <NUM>. The method <NUM> further includes actuating, by the material handling system <NUM>, the load assist module <NUM>, and/or the controller <NUM>, a pusher assembly <NUM>, positioned adjacent the conveyor plane <NUM>, having a track-guided vertical popup <NUM> to extend the track-guided vertical popup <NUM> above the conveyor plane <NUM> such that the track-guided vertical popup <NUM> contacts a rear end of the article <NUM>, at block <NUM>, as described above with reference to <FIG>.

The method <NUM> may further include actuating, by the material handling system <NUM>, the load assist module <NUM>, and/or the controller <NUM>, the pusher assembly <NUM> to drive the track-guided vertical popup <NUM> against the rear end of the article <NUM> to push the article <NUM> onto the downstream conveyor, at block <NUM>, as described above with reference to <FIG> and <FIG>.

Thus, the material handling system <NUM> including the load assist module <NUM> may transfer and/or load articles onto the downstream conveyors efficiently, thereby reducing, in some examples, loading errors, such as, bounce back, incomplete loading, etc..

It must be noted that, as used in this specification and the appended claims, the singular forms "a," "an," and "the" include plural referents unless the content clearly dictates otherwise.

References within the specification to "one embodiment," "an embodiment," "embodiments", or "one or more embodiments" are intended to indicate that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. The appearance of such phrases in various places within the specification are not necessarily all referring to the same embodiment, nor are separate or alternative embodiments mutually exclusive of other embodiments. Further, various features are described which may be exhibited by some embodiments and not by others. Similarly, various requirements are described which may be requirements for some embodiments but not other embodiments.

It should be noted that, when employed in the present disclosure, the terms "comprises," "comprising," and other derivatives from the root term "comprise" are intended to be open-ended terms that specify the presence of any stated features, elements, integers, steps, or components, and are not intended to preclude the presence or addition of one or more other features, elements, integers, steps, components, or groups thereof.

Claim 1:
A load assist module (<NUM>) for transferring an article (<NUM>) onto a downstream conveyor (<NUM>), the load assist module comprising:
a roller conveyor (<NUM>) comprising one or more rollers that define a conveyor plane (<NUM>), wherein the one or more rollers are actuatable to convey the article along the conveyor plane in a direction of a downstream conveyor;
a pusher assembly (<NUM>) positioned adjacent to the conveyor plane, wherein the pusher assembly comprises a track-guided vertical popup (<NUM>) defining a base and a pop-up,
wherein the pop-up is actuatable to extend through the conveyor plane to contact the article,
wherein the pusher assembly is configured to drive the track-guided vertical popup in the direction of the downstream conveyor such that the track-guided vertical popup pushes the article;
a drive assembly (<NUM>) comprising a timing belt (<NUM>) driven by a pair of roller mounted timing pulleys, wherein the timing belt is coupled to the track-guided vertical popup to:
drive the track-guided vertical popup in a first direction (<NUM>), towards the downstream conveyor, to transfer the article onto the downstream conveyor; and
drive the track-guided vertical popup in a second direction (<NUM>), away from the downstream conveyor, once the article is transferred onto the downstream conveyor;
characterized in that the drive assembly further comprises a flag (<NUM>) coupled to the timing belt and configured to move in a direction opposite to a direction of movement of the track-guided vertical popup;
and in that the load assist module further comprises:
one or more sensors configured to detect the flag, based on which detection the load assist module being configured to determine: a position of the timing belt and a position of the track-guided vertical popup;
one or more pneumatic pop-out stops (<NUM>) positioned adjacent to the downstream conveyor, such that the one or more pneumatic pop-out stops extend to stop the article against the one or more pneumatic pop-out stops until the downstream conveyor is ready to receive the article.