Patent Description:
When first introduced into the system of conveyors and equipment, the parcels are randomly positioned on a conveyor in a "bulk flow. " Thus, within the sorting facility, the first step is often to transform the bulk flow into a singulated flow of parcels in which the parcels are positioned at substantially equal intervals and aligned (i.e., in a single file line) along a conveyor for subsequent processing. A wide variety of singulators exist in the art, many of which employ various combinations of belt conveyors and/or roller conveyors to achieve the desired singulation of the parcels. However, there are certain deficiencies in such prior art systems. For example, a surge in the volume of parcels may overwhelm the mechanical systems, and parcels may not be fully singulated. Non-singulated parcels may then interfere with subsequent processing, including downstream sorting.

<CIT> thus describes a system and method for identifying and transferring parcels from a bulk flow on the first conveyor (or "pick conveyor") to a singulated stream of parcels on the second conveyor (or "place conveyor"). Specifically, a robot singulator (or robot) receives parcels via the first conveyor, engages each parcel, and then places it onto the second conveyor. The robot singulator thus includes an end effector with a means for engaging the selected parcel. For example, the end effector may include one or more vacuum cups for engaging the selected parcel. The end effector is mounted on a framework, which is controlled to move and position the end effector. To position the framework and the end effector to engage the selected parcel, the system also includes a vision and control subsystem associated with the robot. The vison and control subsystem includes one or more cameras that are operably connected to a computer for receiving and processing image data. Specifically, the one or more cameras are used to generate a three- dimensional representation of the parcels. Parcels are identified in the three-dimensional representation, and the computer then communicates instructions to position the robot such that the end effector can engage and manipulate each parcel.

<CIT> discloses a case manipulator receives cases from an infeed conveyer and manipulates individual cases or groups of cases and transfers the manipulated cases to a row accumulator platform in a desired and pre-determined orientation and positioned on the accumulator platform to a desired and pre-determined location. The manipulation of individual cases, or groups of cases, is continued in a sequential operation until a complete row is formed on the accumulator platform according to a pre-determined build menu. The case manipulator includes a swing plate pivotal on a first axis and a paddle arm that is attached to the swing plate and pivotal on a second axis that is transverse to the first axis. This allows the palletizer to have the next case in a row transferred from the infeed conveyer to the row-build staging area while the case manipulator is operating on an already-delivered case. <CIT> discloses a rejection mechanism according to the preamble of claim <NUM>.

However, in some cases, certain parcels may exceed size and/or weight limitations or otherwise may be characterized as "unconveyable. " In other cases, the vision and control subsystem may not be able to accurately identify a parcel because of a "hidden" edge or other anomaly that makes it difficult to identify the parcel. Thus, there is a need for a rejection mechanism to handle those parcels that cannot be readily transferred from the first conveyor to the second conveyor. Furthermore, in handling those parcels, it is important that the rejection mechanism not inadvertently "trap" parcels.

According to the invention there is provided a rejection mechanism for a conveyor system in accordance with the features of Claim <NUM>.

A rejection mechanism for a conveyor system generally includes a linear actuator and a paddle mounted to the linear actuator for movement between a first position and a second position. The paddle includes a lower bracket portion for mounting the paddle to the linear actuator, an upright portion that extends upward from the bracket portion, and a lateral wall portion that extends from the upright portion. In use, the lateral wall portion of the paddle maintains a substantially horizontal orientation relative to the upright portion of the paddle as the paddle is moved from the first position to the second position. The rejection mechanism can thus be mounted relative to a target surface (or"rejection zone") of a conveyor, such that, as the linear actuator is actuated to move the paddle from the first position to the second position, the lateral wall portion of the paddle moves across the rejection zone. Parcels located in the rejection zone are thus pushed across the rejection zone and off of the conveyor by the lateral wall portion as the paddle is moved from the first position to the second position.

The rejection mechanism further includes a way cover having a first end fixed in position and a second end that is mounted to the lateral wall portion of the paddle. The way cover expands and contracts with movement of the paddle, such that the way cover provides a trailing wall that fills in the space behind the lateral wall portion as the paddle moves from the first position to the second position. The way cover thus prevents parcels from falling behind the lateral wall portion of the paddle as the paddle is moved between the first position and the second position. In some embodiments, the paddle further includes a brush mounted to the lateral wall portion of the paddle, which fills in any gap existing between the lateral wall portion of the paddle and an underlying surface, such as an upper surface of a conveyor, thereby ensuring smaller or flatter parcels are engaged by the paddle as it is moved from the first position to the second position.

In some embodiments, the lateral wall portion of the paddle is configured to transition between an engaged position and a disengaged position. In the engaged position, the lateral wall portion of the paddle is in a substantially horizontal orientation for engaging parcels in the rejection zone as the paddle is moved from the first position to the second position. In the disengaged position, the lateral wall portion is in a substantially vertical orientation, such that the paddle is able to move from the second position to the first position without moving over the rejection zone and engaging any parcels positioned thereon, thereby ensuring no parcels become trapped behind the lateral wall portion of the paddle.

In some examples, the upright portion of the paddle includes an upper section and a lower section connected by a hinge. The hinge defines an axis of rotation about which the lateral wall portion of the paddle can rotate to move between the engaged position and the disengaged position. To rotate the lateral wall portion from the disengaged position, the rejection mechanism further includes a first pushing mechanism, such as a linear actuator. Similarly, to rotate the lateral wall portion from the engaged position the disengaged position, the rejection mechanism further includes a second pushing mechanism, such as a linear actuator.

In some examples, the lateral wall portion of the paddle is operably connected to the upright portion of the paddle by a hinge. The hinge defines an axis of rotation about which the lateral wall portion of the paddle can rotate between the engaged position and the disengaged position. In such examples, the first rejection mechanism further includes a first linkage that is operably connected the lateral wall portion of the paddle and mounted for sliding movement in a channel defined by a guide that is mounted to a surface of the upright portion of the paddle. A cam follower is mounted to and extends from the first linkage and is received within a track along which the cam follower moves as the linear actuator moves the paddle between the first position and the second position. In some examples, the track may be defined by, and thus be characterized as including: an upper track portion; a lower track portion; a first inclined ramp interconnecting the upper track portion and the lower track portion; and a second inclined ramp that also interconnects the upper track portion and the lower track portion. In some embodiments, the track is designed such that as the cam follower moves along the first inclined ramp, the lateral portion of the paddle is transitioned from the engaged position to the disengaged position, and, as the cam follower moves along the second inclined ramp, the lateral wall portion of the paddle is transitioned from the disengaged position to the engaged position.

The rejection mechanism of the present invention can be combined with a conveyor for conveying a flow of parcels to provide an improved conveyor system for processing and sorting parcels. In some embodiments, the conveyor system can further include a rejection chute, a robot singulator, an additional conveyor, and/or a control subsystem which regulates certain operations of one or more components of the conveyor system.

The present invention is a rejection mechanism for a conveyor system, which pushes parcels across a surface, such as an upper surface of a conveyor.

<FIG> and IB are perspective views of a conveyor system <NUM> for conveying and transferring parcels 12a, 12b, 12c, which includes an exemplary rejection mechanism <NUM> made in accordance with the present invention. As shown in <FIG> and IB, the conveyor system <NUM> further includes a first conveyor (or "pick conveyor") <NUM>, a second conveyor (or "place conveyor') <NUM> downstream of the first conveyor <NUM>, and a robot singulator (or robot) <NUM> for transferring parcels from the first conveyor <NUM> to the second conveyor <NUM>. (For sake of clarity, only a portion of the robot is shown in <FIG>, and it is not shown at all in <FIG>). Parcels 12b, 12c which cannot be readily transferred by the robot singulator <NUM> end up in a rejection zone 20a (indicated in dashed lines in <FIG>) near a leading edge 20b of the first conveyor <NUM>. The rejection zone 20a corresponds with a portion of an upper surface of the first conveyor <NUM>, which is in the path of a paddle <NUM> of the rejection mechanism <NUM>, as further described below. Of course, parcels can also be accessed and engaged by the robot singulator <NUM> in the rejection zone 20a; in other words, parcels are not exclusively engaged by the rejection mechanism <NUM> in this area, as should become clear in the discussion that follows.

As evidenced by viewing <FIG> and <FIG> in sequence, and as further described below, the rejection mechanism <NUM> is selectively activated to push parcels 12b, 12c located in the rejection zone 20a off of the first conveyor <NUM> and onto a rejection chute <NUM> positioned to the side of the first conveyor <NUM> for subsequent sorting or recirculation back to the first conveyor <NUM>. Following discharge of the parcels 12b, 12c onto the rejection chute <NUM>, the rejection mechanism <NUM> is returned to its home position, and the first conveyor <NUM> is indexed forward to facilitate subsequent sorting of any remaining parcels located on the first conveyor <NUM>. As further described below with reference to <FIG>, operation of the first conveyor <NUM>, second conveyor <NUM>, and/or the robot singulator <NUM> are, in at least some embodiments, regulated by a control subsystem <NUM>.

<FIG> is a perspective view of the exemplary rejection mechanism <NUM>, in isolation from the other components of the conveyor system <NUM> shown in <FIG> and <FIG>.

<FIG> is a sectional view of the paddle of the exemplary rejection mechanism of <FIG> taken along line <NUM>-<NUM> of <FIG>.

Referring now to <FIG>, <FIG>, and <FIG>, the rejection mechanism <NUM> includes a paddle <NUM> that is mounted on a linear actuator <NUM>, such that the paddle <NUM> can be moved between a first (or home) position, as shown in <FIG>, and a second position, as shown in <FIG>, via the linear actuator <NUM>. In this exemplary embodiment, the linear actuator <NUM> is a motor-controlled actuator, with a carriage 54a that moves between the first position and the second position. Many suitable linear actuators are commercially available. For example, one suitable linear actuator for this purpose is manufactured and distributed by Schneider Electric USA of Andover, Massachusetts, Model. No. PAS42BB. Of course, this is only one example of a suitable actuator, and many other forms of pneumatic or motor-controlled actuators could be incorporated into the rejection mechanism <NUM> and still enable the rejection mechanism <NUM> to operate as intended and described herein. For example, in alternative embodiments, the linear actuator <NUM> may be a rod-less pneumatic actuator, such as that manufactured and distributed by Festo Corporation of Hauppauge, New York, Model No. DGC-<NUM>-<NUM>-KF-YSRW-A ZUB-F-M. As further described below with reference to <FIG>, in some embodiments, operation of the linear actuator <NUM> (i.e., movement of the carriage 54a) may be regulated, at least in part, by a control subsystem <NUM>.

Referring now specifically to <FIG>, in this exemplary embodiment, the paddle <NUM> has a unitary construction. According to the invention the paddle includes: a lower bracket portion 52a; an upright portion 52b that extends from the lower bracket portion 52a; and a lateral wall portion 52c that extends from the upright portion 52b. Specifically, in this exemplary embodiment, the lateral wall portion 52c extends horizontally from the upright portion 52b and is in a perpendicular orientation relative to the upright portion 52b of the paddle <NUM>. The lower bracket portion 52a is mounted to the carriage 54a of the linear actuator <NUM> by one or more fasteners <NUM>, such as bolts or similar conventional fasteners.

Referring now again to <FIG> and <FIG>, the rejection mechanism <NUM> is positioned relative to the first conveyor <NUM>, such that, as the paddle <NUM> moves from the first position to the second position, the paddle <NUM> moves across the rejection zone 20a toward the rejection chute <NUM>. The movement of the lateral wall portion 52c of the paddle <NUM> across the rejection zone 20a thus pushes any parcels 12b, 12c located in the rejection zone 20a off of the first conveyor <NUM> and onto the rejection chute <NUM>. The linear actuator <NUM> of the rejection mechanism <NUM> can thus be selectively activated to discharge parcels 12b, 12c from the first conveyor <NUM>.

Although only a portion of the linear actuator <NUM> is visible in <FIG> and <FIG>, as a result of the positioning of the second conveyor <NUM>, the linear actuator <NUM>, in this embodiment, is mounted below the leading edge 20b of the first conveyor <NUM>, such that the upright portion 52b of the paddle <NUM> extends upward and adjacent to the leading edge 20b of the first conveyor <NUM>, and the lateral wall portion 52c of the paddle <NUM> is thus positioned over the upper surface of the first conveyor <NUM>. In the conveyor system <NUM> shown in <FIG> and <FIG>, the second conveyor <NUM> is positioned downstream of and adjacent to the first conveyor <NUM>, such that the upright portion 52b of the paddle <NUM> extends upward through a gap between the first conveyor <NUM> and the second conveyor <NUM>. Of course, in other embodiments, the linear actuator <NUM> may alternatively be mounted to the second conveyor <NUM> and still enable the exemplary rejection mechanism <NUM> to function in the manner described herein.

Referring now to <FIG>, <FIG>, and <FIG>, to prevent parcels 12a, 12b, 12c from passing under the lateral wall portion 52c of the paddle <NUM> as the paddle <NUM> moves from the first position (<FIG>) and across the rejection zone 20a of the first conveyor <NUM> to the second position (<FIG>), it is generally preferred that there is a minimal vertical gap between the bottom edge of the lateral wall portion 52c of the paddle <NUM> and the upper surface of the first conveyor <NUM>. For example, in some embodiments, this vertical gap may be approximately <NUM>. Furthermore, in this exemplary embodiment, the paddle <NUM> includes a brush 52d mounted to the front face of the lateral wall portion 52c, such that the bristles of the brush 52d extend below the bottom edge of the lateral wall portion 52c to engage the upper surface of the first conveyor <NUM>. In this regard, the brush 52d thus substantially eliminates the gap existing between the lateral wall portion 52c and the upper surface of the first conveyor <NUM>. As such, when the paddle <NUM> is moved from the first position and across the rejection zone 20a to the second position, the brush 52d provides a sweeping force across the upper surface of the first conveyor <NUM>, which ensures that smaller parcels 12a, 12b, 12c, such as flat mailers, are engaged by the paddle <NUM> and do not pass under the lateral wall portion 52c of the paddle <NUM>. Preferably, the brush 52d is removably mounted to the lateral wall portion 52c by one or more fasteners <NUM>, such as bolts or similar conventional fasteners.

In at least some embodiments, the components of the paddle <NUM> are constructed of steel or another suitable metal to prevent or limit the extent to which the paddle <NUM> is deformed or broken down as a result of repeated trips across the rejection zone 20a and engagement with parcels 12a, 12b, 12c located thereon. To reduce the strain imposed on the upright portion 52b of the paddle <NUM> as a result of the forces acting on the lateral wall portion 52c, in this exemplary embodiment, a plurality of openings 52e are defined by, and thus can be characterized as being present within, the lateral wall portion 52c. Such openings 52e reduce the overall weight of the lateral wall portion 52c.

Referring still to <FIG>, <FIG>, and <FIG>, and according to the invention, the rejection mechanism <NUM> further includes a way cover <NUM>. The way cover <NUM> has a first end 60a fixed in position relative to the conveyor system <NUM> and a second end 60b mounted to the lateral wall portion 52c of the paddle <NUM>. Specifically, in this exemplary embodiment, the first end 60a of the way cover <NUM> is mounted to a bracket <NUM> mounted to the first conveyor <NUM> by one or more fasteners (not shown), such as bolts or similar conventional fasteners, and the second end 60b of the way cover <NUM> is mounted to a rear face of the lateral wall portion 52c of the paddle <NUM> by one or more fasteners <NUM>, such as bolts or similar conventional fasteners.

As evidenced again by viewing <FIG> and <FIG> in sequence, the way cover <NUM> is configured to expand and contract with movement of the paddle <NUM>. As the paddle <NUM> is moved by the linear actuator <NUM> from the first position and across the rejection zone 20a to the second position, the way cover <NUM> gradually expands from a contracted configuration (as shown in <FIG>) to an expanded configuration (as shown in <FIG>). In this exemplary embodiment, the way cover <NUM> is designed and configured such that, upon the paddle <NUM> reaching the second position (<FIG>), the way cover <NUM> is fully expanded, resulting in a substantially flat upper surface of the way cover <NUM>. The way cover <NUM> thus provides a trailing wall behind the lateral wall portion 52c of the paddle <NUM>, which fill in the space behind the lateral wall portion 52c of the paddle <NUM> as the paddle <NUM> moves from the first position to the second positon, thereby preventing any parcels located on the first conveyor <NUM> from falling behind the lateral wall portion 52c of the paddle <NUM> as the paddle <NUM> moves between the first position and the second position. In this way, the way cover <NUM> prevents parcels from becoming trapped behind the lateral wall portion 52c of the paddle <NUM> during operation of the rejection mechanism <NUM>. In the absence of the way cover <NUM>, a parcel could flip over the lateral wall portion 52c of the paddle <NUM> as the paddle <NUM> moves from the first position and the second position, which could hinder or prevent the paddle <NUM> from returning back to the first position.

Although not shown, as a further refinement, in some embodiments, the conveyor system <NUM> may include a wall surface positioned above the way cover <NUM>, which would push any parcels 12a, 12b, 12c having fallen on top of the way cover <NUM> off of the way cover <NUM> as the paddle <NUM> is returned by the linear actuator <NUM> to the first position. In other words, if any parcels flip over the lateral wall portion 52c of the paddle <NUM> and onto the upper surface of the way cover <NUM>, they would be pushed off the upper surface of the way cover <NUM> as the paddle <NUM> returns back to the first position.

<FIG> is an enlarged front view of the way cover <NUM> in isolation.

Referring now to <FIG> and <FIG>, in this exemplary embodiment, the way cover <NUM> is comprised of a first face plate <NUM>, a second face plate <NUM>, a cover <NUM>, and a plurality of stiffeners <NUM>. The first face plate <NUM>, which is at the second end 60b of the way cover <NUM>, is mounted to the lateral wall portion 52c of the paddle <NUM>. To this end, the first face plate <NUM> defines a plurality of openings <NUM> corresponding to a plurality of openings defined by the lateral wall portion 52c, so that the first face plate <NUM> can be mounted to the lateral wall portion 52c via one or more fasteners <NUM>, such as bolts or similar conventional fasteners. In this exemplary embodiment, the first face plate <NUM> can be characterized as including three sections: a first side section 62a; a second side section 62b; and a top section 62c extending between the first and second side sections 62a, 62b. Furthermore, in this exemplary embodiment, the width and the height of the first face plate <NUM> substantially corresponds to that of the lateral wall portion 52c of the paddle <NUM>.

Referring still to <FIG> and <FIG>, the second face plate <NUM> is mounted to a component of the conveyor system <NUM> to hold the first end 60a of the way cover <NUM> in a fixed position as the paddle <NUM> moves the first face plate <NUM>, and thus the second end 60b of the way cover <NUM>, across the rejection zone 20a. In this exemplary embodiment, and as mentioned above, the second face plate <NUM> is mounted to the bracket <NUM>, which is shown in <FIG> and <FIG>. The shape of the second face plate <NUM> preferably corresponds to that of the first face plate <NUM>, and thus, in this exemplary embodiment, the lateral wall portion 52c of the paddle <NUM>. Although not shown, the second face plate <NUM> thus also defines a plurality of openings corresponding to a plurality of openings defined by the bracket <NUM>, so that the second face plate <NUM> can be mounted to the bracket <NUM> via one or more fasteners (not shown), such as bolts or similar conventional fasteners.

Referring now to <FIG>, <FIG>, and <FIG>, to facilitate extension and contraction of the way cover <NUM>, the opposing ends 66a, 66b of the cover <NUM> are mounted to the first face plate <NUM> and the second face plate <NUM>, and the cover <NUM> is comprised of a flexible fabric or similar material that can readily expand or contract as the paddle <NUM> is moved between the first position and the second position. Multiple stiffeners <NUM> are positioned along the length of the cover <NUM> between the opposing ends 66a, 66b of the cover <NUM>, and these stiffeners <NUM> are mounted to and enclosed by the cover <NUM>. The stiffeners <NUM> maintain the shape of the trailing wall established by the way cover <NUM> as the paddle <NUM> moves between the first position and the second position. In this exemplary embodiment, the stiffeners <NUM> are at equally spaced intervals along the length of the way cover <NUM>. Furthermore, in this exemplary embodiment, each stiffener <NUM> is constructed of a metal plate having a shape corresponding to that of the first face plate <NUM> and the lateral wall portion 52c of the paddle <NUM>. Accordingly, like the first face plate <NUM>, each stiffener <NUM> can be characterized as including three sections: a first side section; a second side section; and a top section extending between the first and second side sections. The cover <NUM> extends along and fully covers the first side section, the second side section, and the top section of each stiffener <NUM>. Thus, the cover <NUM> establishes a three-sided wall (two side walls and a top wall), which expands and contracts with movement of the paddle <NUM>. As shown, the flexible material of the cover <NUM> is configured to fold in an accordion-like manner as the paddle <NUM> is moved from the second position to the first position and the way cover <NUM> contracts. In this regard, the way cover <NUM> may also be referred to as a "bellows.

As perhaps best shown in <FIG>, in this exemplary embodiment, each stiffener <NUM> includes a tip <NUM> on at least one of its sides. Specifically, in this exemplary embodiment, each side (only one of which is shown in <FIG>) of each stiffener <NUM> terminates at a tip <NUM>. Each tip <NUM> is configured to engage and move along an upper surface of the first conveyor <NUM> as the paddle <NUM> moves across the rejection zone 20a. In this exemplary embodiment, the lowermost portion of each tip <NUM> and the lowermost portion of the brush 52d reside in substantially the same plane. The tips <NUM> maintain the lateral wall portion 52c of the paddle <NUM> in a generally parallel orientation relative to the upper surface of the first conveyor <NUM> and reduce the strain imposed on the upright portion 52b caused by the weight of the lateral wall portion 52c. To ensure that each tip <NUM> effectively glides across the upper surface of the first conveyor <NUM> and will not damage the upper surface of the first conveyor <NUM>, each tip <NUM> is preferably constructed from a material with a low coefficient of friction and high durability, such as an ultra-high molecular weight polyethylene (UHMW).

Although not shown, as a further refinement, in some embodiments, the way cover <NUM> may further include a plurality of lamellas (or plates) provided along each wall of the cover <NUM>. In such embodiments, each lamella would be mounted to a respective wall of the cover <NUM>, such that the lamellas effectively stack upon each other as the way cover <NUM> contracts. In such embodiments, the lamellas effectively cover the"valleys" resulting from the cover <NUM> being folded into an accordion-like construction, thereby preventing parcels 12a, 12b, 12c from becoming caught or trapped in the way cover <NUM> as it is contracted.

In some alternative embodiments, rather than a"bellows" structure, the way cover may be constructed as to transition between a rolled-up configuration and an extended (or unrolled) configuration. Like the way cover <NUM> described above with reference to <FIG>, the way cover would have a first end fixed in position relative to the conveyor system and a second end mounted to the lateral wall portion of the paddle. However, it would not include any of the plates <NUM>, <NUM> or stiffeners <NUM> described above with reference to <FIG>. Rather, the way cover would include a single length of material that is rolled onto a rod, much like a roll-up window shade. When the paddle <NUM> is in the first position, the material would be stored on the rod in the rolled- up configuration. As the paddle <NUM> moves to the second position, the rod would rotate, and the material would unfurl from the rod until the way cover is in the extended (or unrolled) configuration. In that extended (or unrolled) configuration, the way cover would again provide a wall extending across the rejection zone 20a of the first conveyor <NUM>.

<FIG> are perspective views of another conveyor system <NUM> for conveying and transferring parcels 12a, 12b, 12c, which includes another exemplary rejection mechanism <NUM> falling outside the literal scope of Claim <NUM>. As shown in <FIG>, the conveyor system <NUM> includes each of the components (i.e., the first conveyor <NUM>, the second conveyor <NUM>, robot singulator <NUM>, and rejection chute <NUM>) of the conveyor system <NUM> illustrated and described above with reference to <FIG>, where each respective component includes the same features and provides the same functionality as described above.

As evidenced by viewing <FIG> and <FIG> in sequence, like the rejection mechanism <NUM> described above with reference to <FIG>, IB, and <NUM>, the rejection mechanism <NUM> is selectively activated to push parcels 12b, 12c located in the rejection zone 20a off of the first conveyor <NUM> and onto a rejection chute <NUM> positioned to the side of the first conveyor <NUM> for subsequent sorting or recirculation back to the first conveyor <NUM>. Following discharge of the parcels 12b, 12c onto the rejection chute <NUM>, the rejection mechanism <NUM> can be returned to its home position, and the first conveyor <NUM> is indexed forward to facilitate subsequent sorting of any remaining parcels located on the first conveyor <NUM>. As further described below with reference to <FIG>, movement of the first conveyor <NUM>, second conveyor <NUM>, and/or the robot singulator <NUM> are, in at least some embodiments, regulated by a control subsystem <NUM>.

Referring now to <FIG>, <FIG>, and <FIG>, the rejection mechanism <NUM> includes a paddle <NUM> that is mounted on a linear actuator <NUM>, such that the paddle <NUM> can be moved between a first (or home) position, as shown in <FIG>, and a second position, as shown in <FIG>, via the linear actuator <NUM>. In this exemplary embodiment, the linear actuator <NUM> is a motor-controlled actuator, with a carriage 154a that moves between the first position and the second position. Many suitable linear actuators are commercially available. For example, one suitable linear actuator for this purpose is manufactured and distributed by Schneider Electric USA of Andover, Massachusetts, Model. No. PAS42BB. Of course, this is only one example of a suitable actuator, and many other forms of pneumatic or motor-controlled actuators could be incorporated into the rejection mechanism <NUM> and still enable the rejection mechanism <NUM> to operate as intended and described herein. For example, in alternative embodiments, the linear actuator <NUM> may be a rod-less pneumatic actuator, such as that manufactured and distributed by Festo Corporation of Hauppauge, New York, Model No. DGC- <NUM>-<NUM>-KF-YSRW-A ZUB-F-M. As further described below with reference to <FIG>, in some embodiments, operation of the linear actuator <NUM> (i.e., movement of the carriage 154a) may be regulated, at least in part, by a control subsystem <NUM>.

As perhaps best shown in <FIG>, the paddle <NUM> includes: a lower bracket portion 152a; an upright portion 152b that extends from the lower bracket portion 152a; and a lateral wall portion 152c that extends from the upright portion 152b. The respective components of the paddle <NUM> may be constructed from the same materials as those of the paddle <NUM> of the rejection mechanism <NUM> described above with reference to <FIG>, IB, and <NUM>. Furthermore, the lateral wall portion 152c of the paddle <NUM> may also define a plurality of openings for weight reduction, like the rejection mechanism <NUM> described above with reference to <FIG>, IB, and <NUM>. The lower bracket portion 152a is mounted to the carriage 154a of the linear actuator by one or more fasteners <NUM>, such as bolts or similar conventional fasteners.

Referring still to <FIG>, the upright portion 152b of the paddle <NUM> includes an upper section 153a and a lower section 153b connected together by a hinge 153c. The lateral wall portion 152c is operably connected to and extends from the upper section 153a of the upright portion 152b, while the lower section 153b of the upright portion 152b is operably connected to the lower bracket portion 152a of the paddle <NUM>. In this exemplary embodiment, the lower section 153b of the upright portion 152b and the lower bracket portion 152a are formed from a single piece of material, i.e., have a unitary construction. As a result of the foregoing construction, the upper section 153a of the upright portion 152b can thus effectively rotate about an axis of rotation defined by the hinge 153c to transition the lateral wall portion 152c of the paddle <NUM> between: (i) an engaged position, in which the lateral wall portion 152c of the paddle is in a substantially horizontal orientation (i.e., extends perpendicular relative to the lower section 153b of the upright portion 152b); and (ii) a disengaged position, in which the lateral wall portion 152c of the paddle is in a substantially vertical orientation (i.e., extends vertically relative to the lower section 153b of the upright portion 152b). As a further refinement, the paddle <NUM> also includes a stop 153d mounted to the lower section 153b of the upright portion 152b, which prevents rotation of the upper section 153a of the upright portion 152b beyond a predefined limit when the lateral wall portion 152c of the paddle <NUM> is transitioned to a disengaged position.

Referring now again to <FIG> and <FIG>, the rejection mechanism <NUM> is positioned relative to the first conveyor <NUM>, such that, as the paddle <NUM> moves from the first position to the second position while the lateral wall portion 152c is in the engaged position, the paddle <NUM> moves across the rejection zone 20a toward the rejection chute <NUM>. The movement of the lateral wall portion 152c of the paddle <NUM> across the rejection zone 20a, while in the engaged position, thus pushes any parcels 12b, 12c located in the rejection zone 20a off of the first conveyor <NUM> and onto the rejection chute <NUM>. The linear actuator <NUM> of the rejection mechanism <NUM> can thus be selectively activated while the lateral wall portion 152c is in the engaged position to discharge parcels 12b, 12c from the first conveyor <NUM>.

Referring still to <FIG>, the linear actuator <NUM> (only a portion of which is shown in <FIG> and <FIG>) is mounted below the leading edge 20b of the first conveyor <NUM>, such that both the upper section 153a and the lower section 153b of the upright portion 152b of the paddle <NUM> extend upward and adjacent to the leading edge 20b of the first conveyor <NUM> when the lateral wall portion 152c is in the engaged position. In the conveyor system <NUM> shown in <FIG> and <FIG>, the second conveyor <NUM> is positioned downstream of and adjacent to the first conveyor <NUM>, such that the upright portion 152b of the paddle <NUM> extends upward through a gap between the first conveyor <NUM> and the second conveyor <NUM>. Of course, the linear actuator <NUM> may alternatively be mounted to the second conveyor <NUM> and still enable the exemplary rejection mechanism <NUM> to function in the manner described herein.

Referring still to <FIG> and <FIG>, to prevent parcels 12a, 12b, 12c from passing under the lateral wall portion 152c of the paddle <NUM> as the paddle <NUM> transitions from the first position across the rejection zone 20a of the first conveyor <NUM> to the second position while the lateral wall portion 152c is in the engaged position, it is generally preferred that there is a minimal vertical gap between the bottom edge of the lateral wall portion 152c of the paddle <NUM> and the upper surface of the first conveyor <NUM>. For example, in some embodiments, this vertical gap may be approximately <NUM>.

Referring now to <FIG>,, after the linear actuator <NUM> has moved the paddle <NUM> from the first position to the second position, and thus pushed the parcels 12b, 12c that are in the rejection zone 20a from the first conveyor <NUM> onto the rejection chute <NUM>, the lateral wall portion 152c of the paddle <NUM> can be rotated from the engaged position to the disengaged position about the hinge 153c. Accordingly, when the linear actuator <NUM> returns the paddle <NUM> from the second position to the first position, the lateral wall portion 152c of the paddle <NUM> does not pass back over the rejection zone 20a. Rather, the lateral wall portion 152c is in a substantially vertical orientation during its return to the first position. Accordingly, in the event that any parcels have entered the rejection zone 20a after the paddle <NUM> has reached the second position, such parcels will not impede the movement of the paddle <NUM> from the second position back to the first position, as the lateral wall portion 152c is no longer positioned over an upper surface of the first conveyor <NUM>. After the paddle <NUM> has returned to the first position, the lateral wall portion 152c of the paddle can be rotated from the disengaged position back to the engaged position (as shown in <FIG>).

Referring again to <FIG> and <FIG>, to facilitate rotation of the lateral wall portion 152c of the paddle <NUM> between the engaged position and the disengaged position, the conveyor system <NUM> further includes a first pushing mechanism <NUM> and a second pushing mechanism <NUM>. In this exemplary embodiment, and as best shown in <FIG>, the first pushing mechanism <NUM> is a motor-controlled linear actuator, which includes an arm 160a that can be extended to engage the lateral wall portion 152c of the paddle <NUM>, rotating it about the hinge 153c from the disengaged position to the engaged position. Similarly, and as best shown in <FIG>, the second pushing mechanism <NUM> is a motor-controlled linear actuator, which includes an arm 162a that can be extended to engage the lateral wall portion 152c of the paddle <NUM>, rotating it about the hinge 153c from the engaged position to the disengaged position. Of course, many different types of linear actuators or other similar mechanisms may provide the desired rotation (or flipping) of the lateral wall portion 152c of the paddle <NUM> between the engaged position and the disengaged position.

Referring now specifically to <FIG>, the first pushing mechanism <NUM> is mounted such that the arm 160a of the first pushing mechanism <NUM> can be extended in a substantially horizontal direction to engage the lateral wall portion 152c of the paddle <NUM> when the paddle <NUM> is in the first position. As the arm 160a of the first pushing mechanism <NUM> is extended, the lateral wall portion 152c rotates about the axis of rotation defined by the hinge 153c from the disengaged position to the engaged position. In other words, the first pushing mechanism <NUM> flips the lateral wall portion 152c from the disengaged position to the engaged position. Specifically, in this exemplary embodiment, the first pushing mechanism <NUM> is mounted to the second conveyor <NUM> by a bracket <NUM>. Of course, the first pushing mechanism <NUM> may be mounted in any suitable orientation which permits the arm 160a to extend and engage the lateral wall portion 152c of the paddle <NUM> in the manner described above.

Referring now specifically to <FIG>, the second pushing mechanism <NUM> is mounted such that the arm 162a of the second pushing mechanism <NUM> can be extended in a substantially vertical direction to engage the lateral wall portion 152c of the paddle <NUM> when the paddle <NUM> is in the second position. As the arm 162a of the second pushing mechanism <NUM> is extended, the lateral wall portion 152c rotates about the axis of rotation defined by the hinge 153c from the engaged position to the disengaged position. In other words, the second pushing mechanism <NUM> flips the lateral wall portion 152c from the engaged position to the disengaged position. Specifically, in this exemplary embodiment, the second pushing mechanism <NUM> is mounted to the first conveyor <NUM> below the rejection chute <NUM>. Thus, the rejection chute <NUM> defines an opening 40a through which the arm 162a of the second pushing mechanism <NUM> can extend to engage the lateral wall portion 152c of the paddle <NUM>. Of course, the second pushing mechanism <NUM> may be mounted in any suitable orientation which permits the arm 162a of the second pushing mechanism <NUM> to extend and engage the lateral wall portion 152c of the paddle <NUM> in the manner described above.

As further described below with reference to <FIG>, operation of the linear actuator <NUM>, the first pushing mechanism <NUM>, and/or the second pushing mechanism <NUM> are, in at least some embodiments, regulated by a control subsystem <NUM>.

<FIG> are perspective views of another conveyor system <NUM> for conveying and transferring parcels 12a, 12b, 12c, which includes another exemplary rejection mechanism <NUM> outside the literal scope of Claim <NUM>. As shown in <FIG> and <FIG>, the conveyor system <NUM> includes each of the components (i.e., the first conveyor <NUM>, the second conveyor <NUM>, robot singulator <NUM>, and rejection chute <NUM>) of the conveyor system <NUM> illustrated and described above with reference to <FIG>, where each respective component includes the same features and provides the same functionality as described above.

As evidenced by viewing <FIG> and <FIG> in sequence, like the rejection mechanisms <NUM>, <NUM> described above, the exemplary rejection mechanism <NUM> is selectively activated to push parcels 12b, 12c located in the rejection zone 20a off of the first conveyor <NUM> and onto a rejection chute <NUM> positioned to the side of the first conveyor <NUM> for subsequent sorting or recirculation back to the first conveyor <NUM>. Following discharge of the parcels 12b, 12c onto the rejection chute <NUM>, the rejection mechanism <NUM> can be returned to its home position, and the first conveyor <NUM> is indexed forward to facilitate subsequent sorting of any remaining parcels located on the first conveyor <NUM>. As further described below with reference to <FIG>, operation of the first conveyor <NUM>, second conveyor <NUM>, and/or the robot singulator <NUM> are, in at least some embodiments, regulated by a control subsystem <NUM>.

<FIG> is a perspective view of the exemplary rejection mechanism <NUM>, in isolation from the other components of the conveyor system <NUM> shown in <FIG>.

Referring now to <FIG>, <FIG>, and <FIG>, the rejection mechanism <NUM> includes a paddle <NUM> that is mounted on a linear actuator <NUM>, such that the paddle <NUM> can be moved between a first (or home) position, as shown in <FIG>, and a second position, as shown in <FIG>, via the linear actuator <NUM>. The linear actuator <NUM> is a motor-controlled actuator, with a carriage 254a that moves between the first position and the second position. Many suitable linear actuators are commercially available. For example, one suitable linear actuator for this purpose is manufactured and distributed by Schneider Electric USA of Andover, Massachusetts, Model. No. PAS42BB. Of course, this is only one example of a suitable actuator, and many other forms of pneumatic or motor-controlled actuators could be incorporated into the rejection mechanism <NUM> and still enable the rejection mechanism <NUM> to operate as intended and described herein. For example, in alternative embodiments, the linear actuator <NUM> may be a rod-less pneumatic actuator, such as that manufactured and distributed by Festo Corporation of Hauppauge, New York, Model No. DGC-<NUM>-<NUM>-KF-YSRW-A ZUB-F-M. As further described below with reference to <FIG>, in at least some embodiments, operation of the linear actuator <NUM> (i.e., movement of the carriage 254a) is regulated by a control subsystem <NUM>.

As perhaps best shown in <FIG>, in this exemplary embodiment, the paddle <NUM> includes: a lower bracket portion 252a; an upright portion 252b that extends from the lower bracket portion 252a; and a lateral wall portion 252c that extends from the upright portion 252b. The respective components of the paddle <NUM> may be constructed from the same materials as those of the paddles <NUM>, <NUM> of the rejection mechanisms <NUM>, <NUM> described above. Furthermore, the lateral wall portion 252c of the paddle <NUM> may also define a plurality of openings for weight reduction, like the rejection mechanisms <NUM>, <NUM> described above. The lower bracket portion 252a is mounted to the carriage 254a of the linear actuator by one or more fasteners <NUM>, such as bolts or similar conventional fasteners.

Referring still to <FIG>, in this exemplary embodiment, the lower bracket portion 252a and the upright portion 252b are formed from a single piece of material, i.e., have a unitary construction. The lateral wall portion 252c is connected to the upright portion 252b by a hinge 253a. As a result of the foregoing construction, the lateral wall portion 252c is able to rotate about an axis of rotation defined by the hinge 253a between: (i) an engaged position, in which the lateral wall portion 252c of the paddle <NUM> is in a substantially horizontal orientation (i.e., extends perpendicular relative to the upright portion 252b of the of the paddle <NUM>); and (ii) a disengaged position, in which the lateral wall portion 252c is in a substantially vertical orientation (i.e., extends vertically relative to the upright portion 252b of the paddle). To facilitate movement of the lateral wall portion 252c between the engaged position and the disengaged position, in this exemplary embodiment, the upright portion 252b defines a slit 252d in which the lateral wall portion 252c can travel through and rest within, as further described below.

Referring still to <FIG>, in this exemplary embodiment, to rotate the lateral wall portion 252c of the paddle <NUM> about the axis of rotation defined by the hinge 253a from the engaged position to the disengaged position, a first linkage 253b (or "linear slide") is mounted for sliding movement in a channel defined by a guide 253c, which, is mounted to a surface of the upright portion 252b of the paddle <NUM>. In this exemplary embodiment, a distal end of the first linkage 253b is operably connected to the lateral wall portion 252c of the paddle <NUM>, such that the first linkage 253b can be manipulated to slide the first linkage 253b within the guide 253c and move the lateral wall portion 252c between the engaged and disengaged position. Specifically, in this embodiment, a distal end of the first linkage 253b is pivotally connected to a proximal end of a second linkage 253d (or "connector linkage"), preferably via a pin connection. A distal end of the second linkage 253d is then pivotally connected to the lateral wall portion 252c of the paddle <NUM>. A cam follower 253e is mounted for rotation with respect to, and extends from, the first linkage 253b to control movement of the first linkage 253b within the guide 253c, as further described below.

Referring now to <FIG> and <FIG>, the linear actuator <NUM> (only a portion of which is shown in <FIG> and <FIG>) is mounted below the leading edge 20b of the first conveyor <NUM>, such that the upright portion 252b of the paddle <NUM> extends upward and adjacent to the leading edge 20b of the first conveyor <NUM>. In the conveyor system <NUM> shown in <FIG> and <FIG>, the second conveyor <NUM> is positioned downstream and adjacent to the first conveyor <NUM>, such that the upright portion 252b of the paddle <NUM> extends upward through a gap between the first conveyor <NUM> and the second conveyor <NUM>. Of course, in other embodiments, the linear actuator <NUM> may alternatively be mounted to the second conveyor <NUM> and still enable the exemplary rejection mechanism <NUM> to function in the manner described herein.

<FIG> and <FIG> are various side views of the paddle <NUM> at different positions along a track.

Referring now to <FIG>, <FIG>, <FIG>, and <FIG>, the cam follower 253e is positioned within a track <NUM> (or "linear cam"), such that, as the linear actuator <NUM> moves the paddle <NUM> between the first position (<FIG>) and the second position (<FIG>), the cam follower 253e is moved along the track <NUM> to transition the lateral wall portion 252c of the paddle between the engaged and disengaged position, as further described below. Although not shown in <FIG> and <FIG>, in this embodiment, the track <NUM> is mounted below the leading edge of the first conveyor <NUM>. Of course, in other embodiments, the track <NUM> may alternatively be mounted to the second conveyor <NUM> and still enable the exemplary rejection mechanism <NUM> to function in the manner described herein. As shown in <FIG> and <FIG>, the track <NUM> is defined by, and can be characterized as including: an upper track portion 260a; a lower track portion 260b; a first inclined ramp 260c, which interconnects the upper track portion 260a and the lower track portion 260b; and a second inclined ramp 260d, which also interconnects the upper track portion 260a and the lower track portion 260b. In this regard, the track <NUM> is a closed loop.

Referring now to <FIG>, <FIG>, <FIG>, <FIG>, and <FIG>, as the paddle <NUM> is moved from the first position (<FIG>) to the second position (<FIG>), the cam follower 253e is correspondingly moved from a first portion of the track <NUM> (<FIG>), which, in this embodiment, is an upper-right portion of the track <NUM>, to a second portion of the track <NUM>, which, in this embodiment, is lower-left portion of the track <NUM>. During movement from the first position to the second position, the lateral wall portion 252c of the paddle <NUM> is in the engaged position, and the weight of the lateral wall portion 252c of the paddle <NUM> causes it to remain in the engaged position. Thus, as the lateral wall portion 252c of the paddle moves over the rejection zone 20a of the first conveyor <NUM>, as the paddle <NUM> is moved from the first position to the second position by the linear actuator <NUM>, any parcels 12b, 12c located in the rejection zone 20a are pushed off of the first conveyor <NUM> and onto the rejection chute <NUM>.

Referring still to <FIG>, <FIG>, <FIG>, <FIG>, and <FIG>, during the movement of the paddle <NUM> from the first position to the second position, the cam follower 253e moves along the upper track portion 260a until reaching the first inclined ramp 260c, which, in this case, slopes downwardly to the lower track portion 260b. Upon reaching the first inclined ramp 260c, the cam follower 253e then moves from the upper track portion 260a to the lower track portion 260b. As the cam follower 253e transitions down the first inclined ramp 260c to the lower track portion 260b, the first linkage 253b slides to a lower position within the guide 253c. In turn, as the first linkage 253b slides downward in the channel defined by the guide 253c, a torque is effectively applied to the lateral wall portion 252c of the paddle <NUM> via the second linkage 253d, which causes the lateral wall portion 252c to rotate about the axis of rotation defined by the hinge 253a from the engaged position to the disengaged position. Once rotated into the disengaged position, the center of gravity of the paddle <NUM> has moved to the opposite side of the hinge 253a, such that the weight of the paddle <NUM> now biases it to remain in the disengaged position. The lateral wall portion 252c is now in a substantially vertical orientation during its return to the first position. As such, in the event any parcels have entered the rejection zone 20a after the paddle <NUM> has reached the second position, such parcels will not impede movement of the paddle <NUM> from the second position back to the first position, as the lateral wall portion 252c is no longer positioned over an upper surface of the first conveyor <NUM>.

Referring still to <FIG>, <FIG>, <FIG>, <FIG>, and <FIG>, as the linear actuator <NUM> moves the paddle <NUM> from the second position back to the first position, the cam follower 253e moves from the second (lower-left) portion of the track <NUM> across the lower track portion 260b until reaching the second inclined ramp 260d, which, in this case, slopes upwardly. Upon reaching the second inclined ramp 260d, the cam follower 253e then moves from the lower track portion 260b to the upper track portion 260a. As the cam follower 253e moves up the second inclined ramp 260d to the upper track portion 260a, the first linkage 253b slides to a higher position within the guide 253c. In turn, as the first linkage 253b slides upwardly in the channel defined by the guide 253c, a torque is effectively applied to the lateral wall portion 252c of the paddle <NUM> via the second linkage 253d, which causes the lateral wall portion 252c to rotate about the axis of rotation defined by the hinge 253a from the disengaged position to the engaged position, and the paddle <NUM> is again ready to push parcels located in the rejection zone 20a onto the rejection chute <NUM>.

In addition to changing the elevation and moving the cam follower 253e between the upper track portion 260a and the lower track portion 260b, the first inclined ramp 260c and the second inclined ramp 260d are also configured to prevent the cam follower 253e from receiving too much thrust, as excessive thrust can result in a whipping action and damaging impact to the cam follower 253e and/or the paddle <NUM> resulting from a sudden change in direction. In this regard, thrust is dependent on the incline angle at any given instant, from no thrust at <NUM>° to maximum thrust at <NUM>° to no thrust at <NUM>°. This potential for damaging impact is further exacerbated by the fact that the cam follower 253e is accelerating into the first and second inclined ramps 260c, 260d, assuming that a constant actuating force is being supplied to move the paddle <NUM> between the first position and the second position, or vice versa. Thus, the first and second inclined ramps 260c, 260d are designed to generate enough thrust to match the moment needed to rotate the paddle <NUM> about the axis of rotation defined by the hinge 253a, but prevent damaging impact of the cam follower 253e as it engages each of the first and second inclined ramps 260c, 260d.

<FIG> shows an enlarged partial view of the second inclined ramp 260d of the track <NUM>. As shown in <FIG>, in this exemplary embodiment, the second inclined ramp 260d is formed from three parabolic track sections S<NUM>, S<NUM>, S<NUM> spliced together at points of continuity C<NUM>, C<NUM>. In this embodiment, the shape of the respective track sections S<NUM>, S<NUM>, S<NUM> are define by the following equations: <MAT> Of course, the first inclined ramp 260c is formed in a similar manner, i.e., formed from three parabolic track sections spliced together, except the slope defined by the first inclined ramp 260c is inverted relative to the slope defined by the second inclined ramp 260d.

<FIG> is a schematic diagram of a control subsystem <NUM>, which can be utilized with the conveyor systems <NUM>, <NUM> described above with respect to <FIG>, <FIG>, <FIG>, and <FIG>. As shown in <FIG>, the control subsystem <NUM> includes one or more cameras <NUM>, where each camera <NUM> is configured to collect environmental image data regarding the positioning of parcels 12a, 12b, 12c within the conveyor system <NUM>, <NUM>. In some embodiments, the control subsystem <NUM> may include a first camera and a second camera. In such embodiments, the first camera is preferably positioned adjacent to the robot singulator <NUM> and is focused on the location where a selected parcel 12a, 12b, 12c is to be engaged by the robot singulator <NUM>, which, in this case is the first conveyor <NUM>. The first camera thus collects two-dimensional and/or three-dimensional image data, which assists the robot singulator <NUM> in identifying the location of a parcel 12a, 12b, 12c to be engaged and subsequently transported to the second conveyor <NUM>. The second camera is preferably positioned adjacent to the second conveyor <NUM> and focused on the area(s) where parcels 12a engaged by the robot singulator <NUM> are to be delivered. The second camera thus collects two-dimensional and/or three-dimensional image data that indicates whether a parcel has been successfully delivered to the second conveyor <NUM> by the robot singulator <NUM>. Suitable cameras for use in the present invention include three-dimensional image sensors manufactured and distributed by ifM Efector Inc. of Malvern, Pa.

Referring still to <FIG>, the control subsystem <NUM> further includes a computer <NUM> operably connected to the camera(s) <NUM>, such that the computer <NUM> can receive and process image data from the camera(s) <NUM>. In this regard, the computer <NUM> includes a processor <NUM> for executing instructions (routines) stored in a memory component <NUM> or other computer-readable medium.

Referring still to <FIG>, the control subsystem <NUM> further includes a motor control system <NUM>, which receives instructions from the computer <NUM> and controls operation of certain components of the conveyor system <NUM>, <NUM> operably connected to the motor control system <NUM>. For example, suitable motor control systems for use in the present invention include: ControlLogix® controllers, which are part of the Allen-Bradley product line manufactured and distributed by Rockwell Automation, Inc. of Milwaukee, Wis. ; and PacDrive™ controllers manufactured and distributed by Schneider Electric USA of Andover, Massachusetts. In this exemplary embodiment, the first conveyor <NUM>, the second conveyor <NUM>, the robot singulator <NUM>, and the linear actuator <NUM>, <NUM> of the rejection mechanism <NUM>, <NUM> are each operably connected to the motor control system <NUM>.

Referring now to <FIG>, <FIG>, <FIG>, <FIG>, and <FIG>, in some implementations, the conveyor system <NUM>, <NUM> may commence processing a bulk flow of parcels 12a, 12b, 12c positioned on the first conveyor <NUM> by having one or more cameras <NUM> acquire image data identifying the position of a parcel 12a located near the leading edge 20b of the first conveyor <NUM> intended for transport to the second conveyor <NUM>. Such image data is then transmitted to and processed by the computer <NUM>, which, in turn, communicates instructions to the motor control system <NUM>. Based on the instructions received from the computer <NUM>, the motor control system <NUM> then communicates instructions (or signals) to the robot singulator <NUM> (or the motors and/or linear actuators responsible for movement thereof), which cause the robot singulator <NUM> to move toward, engage, and transport the target parcel 12a to the second conveyor <NUM>, as shown, e.g., by viewing <FIG> and <FIG> in sequence. One or more cameras <NUM> may then capture image data which is processed by the computer <NUM> to verify delivery of the target parcel 12a to the second conveyor <NUM>. Upon such verification, the computer <NUM> can then communicate instructions to the motor control system <NUM>, which subsequently causes the second conveyor <NUM> to index forward and clear a path for subsequent parcels intended for delivery to the second conveyor <NUM>.

Following transport of the target parcel 12a off of the first conveyor <NUM>, the computer <NUM> can communicate instructions to the motor control system <NUM>, which causes the linear actuator <NUM>, <NUM> of the rejection mechanism <NUM>, <NUM> to first move the paddle <NUM>, <NUM> from the first position to the second position to push parcels 12b, 12c located in the rejection zone 20a onto the rejection chute <NUM>, and then return the paddle <NUM>, <NUM> from the second position to the first (or home) position. In some embodiments, the communication of instructions from the computer <NUM> to the motor control system <NUM> causing actuation of the linear actuator <NUM>, <NUM> of the rejection mechanism <NUM>, <NUM> may be conditioned upon the computer <NUM> receiving image data from one or more cameras <NUM> indicating that one or more parcels 12a, 12b, 12c in the rejection zone 20a exhibits a predefined characteristics (e.g., certain dimensions or shape) that signifies the parcel 12a, 12b, 12c is "unconveyable. " Accordingly, in some embodiments, the robot singulator <NUM> may transport multiple parcels to the second conveyor <NUM> before the linear actuator <NUM>, <NUM> of the rejection mechanism <NUM>, <NUM> is actuated in the manner described above. After the paddle <NUM>, <NUM> has been returned to the first position, the computer <NUM> communicates instructions to the motor control system <NUM> which causes the first conveyor <NUM> to index forward to move parcels remaining on the first conveyor <NUM> towards the leading edge 20b of the first conveyor <NUM>. The foregoing process can then be repeated to process the remainder of parcels 12a, 12b, 12c on the first conveyor <NUM>.

<FIG> is a schematic diagram of another control subsystem <NUM>, which can be utilized with the conveyor system <NUM> described above with respect to <FIG> and <FIG>. As shown in <FIG>, the control subsystem <NUM> includes each component and functions in the same manner as the control subsystem <NUM> described above with reference to <FIG>, except that the motor control system <NUM> is further operably connected to the first pushing mechanism <NUM> and the second pushing mechanism <NUM>. Accordingly, the control subsystem <NUM> can be utilized to process parcels 12a, 12b, 12c in substantially the same manner as the control subsystem <NUM> described above with reference to <FIG>. However, in addition to the steps identified in the exemplary implementation above, the computer <NUM> will also communicate instructions to the motor control system <NUM> which: (i) causes actuation of the second pushing mechanism <NUM>, after the paddle <NUM> has reached the second position, to engage the lateral wall portion 152c of the paddle <NUM> and rotate it from the engaged position to the disengaged position; and (ii) causes actuation of the first pushing mechanism <NUM>, after the paddle <NUM> has returned to the first position from the second position, to engage the lateral wall portion 152c of the paddle <NUM> and rotate it from the disengaged position to the engaged position.

Although the exemplary rejection mechanisms <NUM>, <NUM>, <NUM> are described above as being installed in relation to the first conveyor <NUM> and second conveyor <NUM> in the conveyor systems <NUM>, <NUM>, <NUM>, and as working in conjunction with the use of a robot singulator (or robot) <NUM> for transferring parcels 12a, 12b, 12c from the first conveyor <NUM> to the second conveyor <NUM>, it should be appreciated that the use of the exemplary rejection mechanisms <NUM>, <NUM>, <NUM> is not exclusively limited to this application. As noted above, within a sorting facility, there is often a complex system of conveyors and equipment that facilitates transport and sorting of the various parcels within the facility. The exemplary rejection mechanisms <NUM>, <NUM>, <NUM> described herein could thus be installed and used at other points within the sorting facility; indeed, the exemplary rejection mechanisms <NUM>, <NUM>, <NUM> could be installed at any location where it is desirable to push or sweep parcels or other objects from a surface.

Claim 1:
A rejection mechanism (<NUM>) for a conveyor system (<NUM>) including a conveyor for conveying parcels, comprising:
a linear actuator (<NUM>);
a paddle (<NUM>) mounted to the linear actuator (<NUM>) for movement between a first position and a second position, wherein the paddle (<NUM>) includes (i) a lower bracket portion (52a) for mounting the paddle (<NUM>) to the linear actuator (<NUM>), (ii) an upright portion (52b) extending upward and adjacent to an edge of the conveyor, and (iii) a lateral wall portion (52c) that extends from the upright portion (52b);
and wherein, in use, the lateral wall portion (52c) is positioned over a portion of an upper surface of the conveyor as the paddle (<NUM>) is moved from the first position to the second position, such that parcels positioned on the conveyor in a path of the lateral wall portion (52c) are pushed by the lateral wall portion (52c) as the paddle (<NUM>) is moved from the first position to the second position;
characterized in that
the rejection mechanism (<NUM>) further comprises a way cover (<NUM>) having a first end (60a) fixed in position and a second end (60b) mounted to the lateral wall portion (52c) of the paddle (<NUM>); and
wherein the way cover (<NUM>) expands and contracts with movement of the paddle (<NUM>).