Patent ID: 12214962

DETAILED DESCRIPTION OF THE INVENTION

Some embodiments of the present disclosure will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the disclosure are shown. Indeed, these disclosures 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. Like numbers refer to like elements throughout.

The components illustrated in the figures represent components that may or may not be present in various embodiments of the present disclosure 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 present disclosure. Some components may be omitted from one or more figures or shown in dashed line for visibility of the underlying components.

The phrases “in an example embodiment,” “some embodiments,” “various embodiments,” and the like generally mean that the particular feature, structure, or characteristic following the phrase may be included in at least one embodiment of the present disclosure, and may be included in more than one embodiment of the present disclosure (importantly, such phrases do not necessarily refer to the same embodiment).

The word “example” or “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any implementation described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other implementations.

If the specification states a component or feature “may,” “can,” “could,” “should,” “would,” “preferably,” “possibly,” “typically,” “optionally,” “for example,” “often,” or “might” (or other such language) be included or have a characteristic, that a specific component or feature is not required to be included or to have the characteristic. Such components or features may be optionally included in some embodiments, or may be excluded.

The term “electronically coupled” or “in electronic communication with” in the present disclosure may refer to two or more electrical elements (for example, but not limited to, an example processing circuitry, communication element, input/output module memory) and/or electric circuit(s) being connected through wired means (for example but not limited to, conductive wires, system bus, wired Ethernet connection or traces) and/or wireless means (for example but not limited to, wireless network, electromagnetic field, Wi-Fi, Bluetooth, Zigbee), such that data and/or information (for example, electronic indications, signals) may be transmitted to and/or received from the electrical elements and/or electric circuit(s) that are electronically coupled.

The terms “conveyor,” “conveyor section,” “conveyor bed,” “conveyor assembly” or “conveyor system,” and similar terms are used interchangeably herein to refer to an apparatus that is configured to convey objects or articles within a material handling system in accordance with embodiments of the present disclosure. A motorized conveyor roller according to some embodiments discussed herein may comprise a plurality of drive components including a motor assembly and a drive assembly which operate to drive a housing (e.g., roller tube). These assemblies may have one or more components that are arranged in various configurations within an inner portion of the motorized conveyor roller. In some embodiments, the drive assembly may be fixed relative to the housing (e.g., roller tube), while the motor assembly is fixed relative to a frame supporting the roller tube, such that the motor assembly may be configured to rotate the drive assembly and roller tube.

In some embodiments, motorized rollers for conveyors may utilize external control cards to facilitate various operations (e.g., to set control motor speed and direction). In some examples, these control cards are mounted directly to the conveyors (e.g., conveyor side rails) requiring additional space and complex wiring in order to interface with other devices or modules (e.g., sensors, power, input/output communications, or the like). For example, a motorized roller may be controlled by one or more motor controllers which communicate with a programmable controller. The programmable controller (PC) may be an industrial PC which communicates with the one or more motor controllers connected via a communication bus, for example, via a RS232 bus in order to set speed limit, set current limit, or set various modes of operation for the motorized rollers.

Additionally, many motorized rollers are not capable of detecting objects and rely on information obtained using separate imaging devices distributed within the environment. These imaging devices may also require additional hard wiring and complex configuration to interface properly with the motorized rollers.

In some examples, a motorized roller may be hard wired to one or more other motorized rollers (e.g., in a daisy chain fashion) in order to facilitate communication therebetween. Accordingly, an example motorized roller may comprise an extensive wired network (e.g., up to 34 individual wires to a given motorized roller) leading to and exacerbating installation and servicing complexities.

Moreover, in many examples, motorized rollers do not have any diagnostic or self check capabilities and rely on physical inspections and troubleshooting to identify offline or non-functional motorized rollers within a system. For example, such motorized rollers are not capable of generating an indication or alert relating to operating conditions (e.g., motor failure or suboptimal performance). In order to identify damaged or motorized rollers or motorized rollers in a faulted state, a person may have to visually inspect the system for non-functional components and halt operations until certain motorized rollers can be repaired or replaced. This may lead to reduced throughput and operational inefficiencies.

In accordance with various embodiments of the present disclosure, example methods, apparatuses, computer program products and systems are provided.

For example, the present disclosure may provide an integrated motorized conveyor roller comprising a housing, a motor assembly and a drive assembly at least partially disposed within the housing that are configured to cause rotation of at least a portion of the integrated motorized conveyor roller, at least one sensing element, and an integrated controller component in electronic communication with the at least one sensing element, the motor assembly and the drive assembly, wherein the controller component is configured to obtain operational data via the at least one sensing element. In some examples, the controller component is further configured to receive configuration data from a computing entity in electronic communication with the controller component, and perform operations based at least in part on the configuration data. In some examples, the controller component is further configured to transmit at least a portion of the operational data to a computing entity in electronic communication with the controller component. In some examples, the at least one sensing element comprises a load sensor that is configured to detect a presence or weight of an object disposed adjacent the integrated motorized conveyor roller. In some examples, the controller component is further configured to provide information regarding the presence or location of the object to at least one of another integrated motorized conveyer roller controller component or another computing entity in electronic communication therewith. In some examples, the at least one sensing element comprises one or more light detection and ranging (LiDAR) sensors, radio detection and ranging (RADAR) sensors, infrared (IR) cameras, 3D cameras, 360° Cameras or photoelectric sensors. In some examples, the at least one sensing element is configured to detect one or more parameters associated with the motor assembly. In some examples, the one or more parameters comprise at least one of a lifetime motor operational time, a number of rotations, loading conditions or vibrational information. In some examples, the controller component comprises at least one printed circuit board (PCB) stack. In some examples, the at least one PCB stack is integrated into an end cap of the integrated motorized conveyor roller. In some examples, the controller component is in electronic communication with one or more other motorized conveyor roller controller components such that they can exchange data with one another. In some examples, the controller component is in electronic communication with the one or more other motorized conveyor roller controller components or computing entities via a Bluetooth, Bluetooth Low Energy (BLE) or Long Range (LoRa) connection.

In another example, a method is provided. The method may comprise receiving, by a controller component of an integrated motorized conveyor roller, configuration data from a computing entity in electronic communication with the controller component, and causing, by the controller component and based at least in part on the configuration data, rotation of at least a portion of the integrated motorized conveyor roller via a motor assembly and a drive assembly at least partially disposed within a housing of the integrated motorized conveyor roller. In some examples, the method may comprise obtaining, by the controller component, operational data via at least one sensing element of the integrated motorized conveyor roller. In some examples, the method may comprise transmitting, by the controller component, at least a portion of the operational data to a computing entity in electronic communication with the controller component. In some examples, the at least one sensing element comprises a load sensor that is configured to detect a presence or weight of an object disposed adjacent the integrated motorized conveyor roller. In some examples, the method may comprise providing, by the controller component, information regarding the presence or location of the object to at least one of another integrated motorized conveyer roller controller component or another computing entity in electronic communication therewith. In some examples, the at least one sensing element comprises one or more LiDAR sensors, RADAR sensors, IR cameras, 3D cameras, 360° Cameras or photoelectric sensors. In some examples, the at least one sensing element is configured to detect one or more parameters associated with the motor assembly. In some examples, the one or more parameters comprise at least one of a lifetime motor operational time, a number of rotations, loading conditions or vibrational information.

As such, the present disclosure provides a integrated motorized conveyor roller that can be remotely configured with ease. Additionally, the integrated motorized conveyor roller is configured to obtain operational data (e.g., sensor data) relating to its functioning (e.g., for prognostic and/or diagnostic purposes) and/or objects in its environment. Moreover, the integrated motorized conveyor roller comprises a simplified networking interface requiring a reduced number of wires (e.g., 2 wires to provide power) thereby simplifying installation and maintenance of conveyor systems that include integrated motorized conveyor rollers.

Referring now toFIG.1, a schematic diagram depicting an example system100in accordance various embodiments of the present disclosure is provided. As depicted, the example system100comprises a conveyor102comprising one or more motorized conveyor rollers, one or more computing entities106(e.g., servers), one or more databases104, one or more networks105, one or more user computing entities108, and/or the like. In various examples, the system100may operate to convey objects within a particular location or environment.

In various embodiments, the conveyor102may be configured to transport objects within a particular location or environment utilizing one or more motorized conveyor rollers. In some embodiments, the conveyor102comprising one or more motorized conveyor rollers, the one or more computing entities106, the one or more databases104and/or the one or more user computing entities108are in electronic communication with each other over the one or more networks105such that they can exchange data (e.g., receive and transmit data) with one another (e.g., periodically and/or in response to requests). Each of the components of the system100, including the conveyor102comprising the one or more motorized conveyor rollers, the one or more computing entities106, the one or more databases104and/or the one or more user computing entities108may be in communication with one another over the same or different wireless or wired networks105including, for example, a wired or wireless Personal Area Network (PAN), Local Area Network (LAN), Metropolitan Area Network (MAN), Wide Area Network (WAN), cellular network, and/or the like. WhileFIG.1illustrates certain system components as separate, standalone devices, the various embodiments are not limited to this particular architecture.

As depicted inFIG.1, the example system100comprises one or more computing entities106. In general, the terms computing device, entity, device, system, and/or similar words used herein interchangeably may refer to, for example, one or more computers, computing devices, computing entities, desktop computers, mobile phones, tablets, phablets, notebooks, laptops, distributed systems, terminals, servers or server networks, blades, gateways, switches, processing devices, set-top boxes, relays, routers, network access points, base stations, the like, and/or any combination of devices adapted to perform the functions, operations, and/or processes described herein. Such functions, operations, and/or processes may include, for example, transmitting, receiving, operating on, processing, displaying, storing, determining, generating/creating, monitoring, evaluating, comparing, and/or similar terms used herein interchangeably. In one embodiment, these functions, operations, and/or processes can be performed on data, content, information, and/or similar terms used herein interchangeably.

In some examples, the computing entity106may also include one or more network and/or communications interfaces for communicating with various computing entities, such as by communicating data, content, information, and/or similar terms used herein interchangeably that can be transmitted, received, operated on, processed, displayed, stored, and/or the like.

In one embodiment, the computing entity106may further include or be in communication with non-volatile media (also referred to as non-volatile storage, memory, memory storage, memory circuitry and/or similar terms used herein interchangeably). In one embodiment, the non-volatile storage or memory may include one or more non-volatile storage or memory media as described above, such as hard disks, ROM, PROM, EPROM, EEPROM, flash memory, MMCs, SD memory cards, Memory Sticks, CBRAM, PRAM, FORAM, RRAM, SONOS, racetrack memory, and/or the like. As will be recognized, the non-volatile storage or memory media may store databases, database instances, database management system entities, data, applications, programs, program modules, scripts, source code, object code, byte code, compiled code, interpreted code, machine code, executable instructions, and/or the like. The term database, database instance, database management system entity, and/or similar terms used herein interchangeably may refer to a structured collection of records or information/data that is stored in a computer-readable storage medium, such as via a relational database, hierarchical database, and/or network database.

In one embodiment, the computing entity106may further include or be in communication with volatile media (also referred to as volatile storage, memory, memory storage, memory circuitry and/or similar terms used herein interchangeably). In one embodiment, the volatile storage or memory may also include one or more volatile storage or memory media as described above, such as RAM, DRAM, SRAM, FPM DRAM, EDO DRAM, SDRAM, DDR SDRAM, DDR2 SDRAM, DDR3 SDRAM, RDRAM, RIMM, DIMM, SIMM, VRAM, cache memory, register memory, and/or the like. As will be recognized, the volatile storage or memory media may be used to store at least portions of the databases, database instances, database management system entities, data, applications, programs, program modules, scripts, source code, object code, byte code, compiled code, interpreted code, machine code, executable instructions, and/or the like being executed by, for example, the processing element. Thus, the databases, database instances, database management system entities, data, applications, programs, program modules, scripts, source code, object code, byte code, compiled code, interpreted code, machine code, executable instructions, and/or the like may be used to control certain aspects of the operation of the computing entity106with the assistance of the processing element and the operating system.

As indicated, in one embodiment, the computing entity106may also include one or more network and/or communications interfaces for communicating with various computing entities, such as by communicating data, content, information, and/or similar terms used herein interchangeably that can be transmitted, received, operated on, processed, displayed, stored, and/or the like. Such communication may be executed using a wired data transmission protocol, such as fiber distributed data interface (FDDI), digital subscriber line (DSL), Ethernet, asynchronous transfer mode (ATM), frame relay, data over cable service interface specification (DOCSIS), or any other wired transmission protocol. Similarly, computing entity106may be configured to communicate via wireless external communication networks using any of a variety of protocols, such as embedded sim (cSIM), remote sim provisioning (RSP), general packet radio service (GPRS), Universal Mobile Telecommunications System (UMTS), Code Division Multiple Access 200 (CDMA200), CDMA200 1× (1×RTT), Wideband Code Division Multiple Access (WCDMA), Global System for Mobile Communications (GSM), Enhanced Data rates for GSM Evolution (EDGE), Time Division-Synchronous Code Division Multiple Access (TD-SCDMA), Long Term Evolution (LTE), Evolved Universal Terrestrial Radio Access Network (E-UTRAN), Evolution-Data Optimized (EVDO), High Speed Packet Access (HSPA), High-Speed Downlink Packet Access (HSDPA), IEEE 802.11 (Wi-Fi), Wi-Fi Direct, 802.16 (WiMAX), ultra-wideband (UWB), IR protocols, NFC protocols, RFID protocols, IR protocols, ZigBee protocols, Z-Wave protocols, 6LoWPAN protocols, Wibree, Bluetooth protocols, wireless universal serial bus (USB) protocols, and/or any other wireless protocol. The computing entity106may use such protocols and standards to communicate using Border Gateway Protocol (BGP), Dynamic Host Configuration Protocol (DHCP), Domain Name System (DNS), File Transfer Protocol (FTP), Hypertext Transfer Protocol (HTTP), HTTP over TLS/SSL/Secure, Internet Message Access Protocol (IMAP), Network Time Protocol (NTP), Simple Mail Transfer Protocol (SMTP), Telnet, Transport Layer Security (TLS), Secure Sockets Layer (SSL), Internet Protocol (IP), Transmission Control Protocol (TCP), User Datagram Protocol (UDP), Datagram Congestion Control Protocol (DCCP), Stream Control Transmission Protocol (SCTP), HyperText Markup Language (HTML), and/or the like.

As will be appreciated, one or more of the computing entity's106components may be located remotely from other computing entity106components, such as in a distributed system. Furthermore, one or more of the components may be aggregated and additional components performing functions described herein may be included in the computing entity106. Thus, the computing entity106can be adapted to accommodate a variety of needs and circumstances, such as including various components described with regard to a mobile application executing on the user computing entity108, including various input/output interfaces.

As depicted inFIG.1, the system100comprises a user computing entity108. In various embodiments, the user computing entity108may be or comprise one or more mobile devices, wearable computing devices, and/or the like. An example user computing entity108may include an antenna, a transmitter (e.g., radio), a receiver (e.g., radio), and a processing element that provides signals to and receives signals from the transmitter and receiver, respectively. The signals provided to and received from the transmitter and the receiver, respectively, may include signaling information/data in accordance with an air interface standard of applicable wireless systems to communicate with various devices, such as a computing entity (e.g., central server), another user computing entity108, and/or the like. In an example embodiment, the transmitter and/or receiver are configured to communicate via one or more SRC protocols. For example, the transmitter and/or receiver may be configured to transmit and/or receive information/data, transmissions, and/or the like of at least one of Bluetooth protocols, low energy Bluetooth protocols, NFC protocols, RFID protocols, IR protocols, Wi-Fi protocols, ZigBee protocols, Z-Wave protocols, 6LoWPAN protocols, and/or other short range communication protocol. In various embodiments, the antenna, transmitter, and receiver may be configured to communicate via one or more long range protocols, such as GPRS, UMTS, CDMA200, 1×RTT, WCDMA, GSM, EDGE, TD-SCDMA, LTE, E-UTRAN, EVDO, HSPA, HSDPA, Wi-Fi, Wi-Fi Direct, WiMAX, and/or the like. The user computing entity108may also include one or more network and/or communications interfaces for communicating with various computing entities, such as by communicating data, content, information, and/or similar terms used herein interchangeably that can be transmitted, received, operated on, processed, displayed, stored, and/or the like. In this regard, the user computing entity108may be capable of operating with one or more air interface standards, communication protocols, modulation types, and access types. More particularly, the user computing entity108may operate in accordance with any of a number of wireless communication standards and protocols. In a particular embodiment, the user computing entity108may operate in accordance with multiple wireless communication standards and protocols, such as GPRS, UMTS, CDMA200, 1×RTT, WCDMA, TD-SCDMA, LTE, E-UTRAN, EVDO, HSPA, HSDPA, Wi-Fi, WiMAX, UWB, IR protocols, Bluetooth protocols, USB protocols, and/or any other wireless protocol.

Via these communication standards and protocols, the user computing entity108can communicate with various other devices using concepts such as Unstructured Supplementary Service information/data (USSD), Short Message Service (SMS), Multimedia Messaging Service (MMS), Dual-Tone Multi-Frequency Signaling (DTMF), and/or Subscriber Identity Module Dialer (SIM dialer). The user computing entity108can also download changes, add-ons, and updates, for instance, to its firmware, software (e.g., including executable instructions, applications, program modules), and operating system.

According to one embodiment, the user computing entity108may include location determining aspects, devices, modules, functionalities, and/or similar words used herein interchangeably to acquire location information/data regularly, continuously, or in response to certain triggers.

The user computing entity108may also comprise a user interface device comprising one or more user input/output interfaces (e.g., a display and/or speaker/speaker driver coupled to a processing element and a touch interface, keyboard, mouse, and/or microphone coupled to a processing element). For example, the user interface may be configured to provide a mobile application, browser, interactive user interface, dashboard, webpage, and/or similar words used herein interchangeably executing on and/or accessible via the user computing entity108to cause display or audible presentation of information/data and for user interaction therewith via one or more user input interfaces. Moreover, the user interface can comprise or be in communication with any of a number of devices allowing the user computing entity108to receive information/data, such as a keypad (hard or soft), a touch display, voice/speech or motion interfaces, scanners, readers, or other input device. In embodiments including a keypad, the keypad can include (or cause display of) the conventional numeric (0-9) and related keys (#, *), and other keys used for operating the user computing entity108and may include a full set of alphabetic keys or set of keys that may be activated to provide a full set of alphanumeric keys. In addition to providing input, the user input interface can be used, for example, to activate or deactivate certain functions, such as screen savers and/or sleep modes. Through such inputs the user computing entity108can capture, collect, store information/data, user interaction/input, and/or the like.

The user computing entity108can also include volatile storage or memory and/or non-volatile storage or memory, which can be embedded and/or may be removable. For example, the non-volatile memory may be ROM, PROM, EPROM, EEPROM, flash memory, MMCs, SD memory cards, Memory Sticks, CBRAM, PRAM, FORAM, RRAM, SONOS, racetrack memory, and/or the like. The volatile memory may be RAM, DRAM, SRAM, FPM DRAM, EDO DRAM, SDRAM, DDR SDRAM, DDR2 SDRAM, DDR3 SDRAM, RDRAM, RIMM, DIMM, SIMM, VRAM, cache memory, register memory, and/or the like. The volatile and non-volatile storage or memory can store databases, database instances, database management system entities, information/data, applications, programs, program modules, scripts, source code, object code, byte code, compiled code, interpreted code, machine code, executable instructions, and/or the like to implement the functions of the user computing entity108.

As depicted inFIG.1, any two or more of the illustrative components of the system100ofFIG.1may be configured to communicate with one another via one or more networks105. The networks105may include, but are not limited to, any one or a combination of different types of suitable communications networks such as, for example, cable networks, public networks (e.g., the Internet), private networks (e.g., frame-relay networks), wireless networks, cellular networks, telephone networks (e.g., a public switched telephone network), or any other suitable private and/or public networks. Further, the networks105may have any suitable communication range associated therewith and may include, for example, global networks (e.g., the Internet), MANS, WANs, LANs, or PANs. In addition, the networks105may include any type of medium over which network traffic may be carried including, but not limited to, coaxial cable, twisted-pair wire, optical fiber, a hybrid fiber coaxial (HFC) medium, microwave terrestrial transceivers, radio frequency communication mediums, satellite communication mediums, or any combination thereof, as well as a variety of network devices and computing platforms provided by network providers or other entities.

WhileFIG.1provides an example system100, it is noted that the scope of the present disclosure is not limited to the example shown inFIG.1. In some examples, the system100may comprise one or more additional and/or alternative elements, and/or may be different from that illustrated inFIG.1.

Referring now toFIG.2, a schematic diagram depicting an example portion of a conveyor200with motorized and non-motorized conveyor rollers in accordance with various embodiments of the present disclosure is provided. In some embodiments, the example portion of a conveyor200may define a particular section or zone of a conveyor system.

As depicted inFIG.2, the example conveyor200may comprise one or more motorized conveyor rollers, e.g., motorized conveyor roller202, and one or more non-motorized conveyor rollers, e.g., non-motorized conveyor roller204. In the embodiment depicted inFIG.2, the example conveyor200further comprises at least a first rail206and a second rail208. As depicted inFIG.2, the plurality of motorized conveyor rollers and non-motorized conveyor rollers (e.g., motorized conveyor roller202and non-motorized conveyor roller204) are mechanically/operatively coupled to the first rail206and the second rail208. In some embodiments, the first rail206and the second rail208may include one or more sets of apertures configured to receive the plurality of motorized conveyor rollers and non-motorized conveyor rollers (e.g., motorized conveyor roller202and non-motorized conveyor roller204).

In some embodiments, as depicted inFIG.2, the non-motorized conveyor rollers (e.g., non-motorized conveyor roller204) may be or comprise idler rollers or driven rollers. Additionally, the motorized conveyor rollers (e.g., motorized conveyor roller202) may be or comprise drive rollers. In various embodiments, the motorized conveyor rollers/drive rollers are configured to drive the non-motorized conveyor rollers/idler rollers. For example, the motorized conveyor rollers/drive rollers may include drive bands, e.g., drive band210. The example drive bands may comprise O-drive bands to drive the non-motorized conveyor rollers/idler rollers. As depicted inFIG.2, in some examples, the motorized conveyor rollers/drive rollers and the non-motorized conveyor roller/idler rollers are connected to each other through a series of drive bands, e.g, drive band210, in order to drive the non-motorized conveyor rollers/idler rollers. As further depicted, each of the drive bands, e.g., drive band210, is reeved around a tracking ring, e.g., tracking ring212, provided on the motorized conveyor rollers/drive rollers and the non-motorized conveyor rollers/idler rollers. The example tracking ring212may operate to ensure that the drive band210does not slip out of the drive rollers and the idler rollers when operating at full speed. The example drive band210may be connected to idler pulleys provided on/attached to either the first rail206or the second rail208of the conveyor200to maintain a target tension between the example drive band210and the motorized conveyor rollers/drive rollers and the non-motorized conveyor rollers/idler rollers (e.g., motorized conveyor roller202and non-motorized conveyor roller204).

WhileFIG.2depicts an example conveyor200, it is noted that the scope of the present disclosure is not limited to the example shown inFIG.2. An example conveyor200in accordance with the present disclosure may comprise one or more additional and/or alternative elements, and/or may be different from that illustrated inFIG.2.

Referring now toFIG.3, a schematic diagram depicting a perspective view of an example integrated motorized conveyor roller300in accordance with various embodiments of the present disclosure is provided. In various embodiments, the example integrated motorized conveyor roller300may be part of a conveyor/conveyor system (e.g., the conveyor200described above in connection withFIG.2) and may be configured to drive one or more non-motorized conveyor rollers that are operatively coupled thereto. The conveyor/conveyor system may be part of an automated or semi-automated warehousing system in which objects may be stored, retrieved, conveyed, and/or the like in response to system instructions and/or user interactions via a computing entity (such as the user computing entity108described above in connection withFIG.1). For example, the example integrated motorized conveyor roller300may be configured to convey objects along at least a portion of a conveyor based at least in part on system instructions.

As depicted inFIG.3, the example integrated motorized conveyor roller300comprises a housing301(e.g., roller tube) configured to contain one or more components/elements of the integrated motorized conveyor roller300(e.g., a controller component, as discussed in further detail below). In some examples, the housing301(e.g., roller tube) of the integrated motorized conveyor roller300comprises a hollow cylindrical body and may comprise metal, plastic, combinations thereof, and/or the like.

As further illustrated inFIG.3, the example integrated motorized conveyor roller300comprises a first end cap305defining a first end/surface of the example integrated motorized conveyor roller300. As depicted, the first end cap305comprises a first appendage302configured to be operatively coupled to a conveyor (e.g., disposed between a first rail and a second rail, such as within an aperture of the first rail).

Additionally, as depicted, the example integrated motorized conveyor roller300comprises a second end cap307defining a second end/surface of the example integrated motorized conveyor roller300. As depicted, the second end cap307comprises a second appendage304configured to be operatively coupled to a conveyor (e.g., disposed between a first rail and a second rail, such as within an aperture of the second rail). As further depicted inFIG.3, the integrated motorized conveyor roller300comprises a power cable303disposed adjacent the second end cap307that is configured to be connected to a power supply. Additionally and/or alternatively, the power cable303may also be configured to provide a connection for data transfer.

Referring now toFIG.4, a schematic diagram depicting a side section view of an example integrated motorized conveyor roller400in accordance with various embodiments of the present disclosure is provided. The example integrated motorized conveyor roller400may be similar or identical to the integrated motorized conveyor roller300discussed above in connection withFIG.3. The example integrated motorized conveyor roller400may be part of a conveyor/conveyor system and may be configured to drive one or more non-motorized conveyor rollers that are operatively coupled thereto. The example integrated motorized conveyor roller400may be configured to convey objects along at least a portion of a conveyor based at least in part on system instructions and/or user interactions via a computing entity (such as the user computing entity108described above in connection withFIG.1). As illustrated inFIG.4, the example integrated motorized conveyor roller400comprises a power cable403, a first end cap405, a second end cap407, a motor assembly411, a load sensor413, a drive assembly415, a controller component417and a bearing assembly419. In various embodiments, the elements/components of the integrated motorized conveyor roller400(e.g., the motor assembly411, the load sensor413and the drive assembly415) are in electronic communication with the controller component417such that they can exchange data/information with one another.

As noted above, and as depicted inFIG.4, the example integrated motorized conveyor roller400comprises a housing401(e.g., roller tube) configured to contain one or more components/elements of the integrated motorized conveyor roller300. In particular, as depicted, the example integrated motorized conveyor roller400is configured to contain at least the motor assembly411, the load sensor413, the drive assembly415, the controller component417and the bearing assembly419. In various examples, the housing401(e.g., roller tube) of the integrated motorized conveyor roller400comprises a hollow cylindrical body and may comprise metal, plastic, combinations thereof, and/or the like.

As further illustrated inFIG.4, the example integrated motorized conveyor roller400comprises a first end cap405defining a first end/surface of the example integrated motorized conveyor roller400. As depicted, the first end cap405comprises a first appendage402configured to be operatively coupled to a conveyor (e.g., disposed between a first rail and a second rail, such as within an aperture of the first rail).

As noted above, and as depicted inFIG.4, the example integrated motorized conveyor roller400comprises a motor assembly411, a drive assembly415and at least one bearing assembly419that operate to drive/rotate the housing401(e.g., roller tube) of the integrated motorized conveyor roller400with respect to a central axis406of the integrated motorized conveyor roller400. In some embodiments, each of the motor assembly411and the drive assembly415are at least partially disposed within the housing401(e.g., roller tube) of the integrated motorized conveyor roller400. For example, as shown, at least a surface of the motor assembly411and at least a surface of the drive assembly415are in contact with an inner surface of the housing401(e.g., roller tube) of the integrated motorized conveyor roller400. The drive assembly415may be configured to transfer torque from the motor assembly411to the housing401(e.g., roller tube) of the integrated motorized conveyor roller. Additionally, as illustrated, the example integrated motorized conveyor roller400comprises a bearing assembly419configured to, in conjunction with the motor assembly411and drive assembly415, facilitate rotation of the integrated motorized conveyor roller400about the central axis406. As shown, the bearing assembly419is disposed adjacent and operatively coupled to the first end cap405of the integrated motorized conveyor roller400. In some embodiments, the drive assembly415may be fixed relative to the housing401(e.g., roller tube), while the motor assembly411is fixed relative to a frame supporting the roller tube, such that the motor assembly411can rotate the drive assembly415and the roller tube.

As further depicted, the example integrated motorized conveyor roller400comprises a second end cap407defining a second end/surface of the example integrated motorized conveyor roller300. As depicted, the second end cap407comprises a second appendage404configured to be operatively coupled to a conveyor (e.g., disposed between a first rail and a second rail, such as within an aperture of the second rail). As noted above, the integrated motorized conveyor roller400comprises a power cable403disposed adjacent the second end cap407that is configured to be connected to a power supply. In some embodiments, the second end cap407comprises a light emitting diode (LED) element409that is configured to provide a visual alert in response to a detected condition of the integrated motorized conveyor roller400.

In some embodiments, as further depicted inFIG.4, the example integrated motorized conveyor roller400comprises a load sensor413. As shown, the load sensor413is disposed within the housing401(e.g., roller tube) of the integrated motorized conveyor roller400between the motor assembly411and the drive assembly415. The load sensor413is configured to determine a weight of an object disposed on at least a portion of the integrated motorized conveyor roller400, such as by converting a weight of an object into a measurable electrical signal. For example, as an object moves along a conveyor and is incident on the motor assembly411, the load sensor413can generate a measurable electrical signal (e.g., voltage output) corresponding with a weight of the object. In various embodiments, the load sensor413may be or comprise one or more strain gauges, piezoelectric sensors and/or the like.

As noted above, and as depicted inFIG.4, the integrated motorized conveyor roller400comprises a controller component417. As depicted, the controller component417may be at least partially disposed within the housing401(e.g., roller tube) of the integrated motorized conveyor roller400. As depicted, the controller component417is disposed between the bearing assembly419and the drive assembly415. In various embodiments, the controller component417may be or comprise one or more printed circuit boards (PCBs). For example, as depicted, the controller component417comprises a PCB stack comprising three PCB boards configured to be in electronic communication with one another. In various embodiments, the controller component417comprises a controller module that is configured to control operations of the motor assembly411, drive assembly415, load sensor413and/or the like. In some embodiments, the controller component417comprises a wireless module that is configured to provide a communication interface (e.g., Bluetooth, Bluetooth Low Energy (BLE), low-power wide-area network such as Long Range (LoRa), and/or the like) between the integrated motorized conveyor roller400and one or more other motorized conveyor rollers. Additionally, in some embodiments, the controller component417comprises a power module that is configured to control operations of electronic elements (e.g., circuitry, sensing element and/or the like) of the integrated motorized conveyor roller400.

WhileFIG.4depicts an example integrated motorized conveyor roller400, it is noted that the scope of the present disclosure is not limited to the examples shown inFIG.4. An example integrated motorized conveyor roller400in accordance with the present disclosure may comprise one or more additional and/or alternative elements, and/or may be different from that illustrated inFIG.4. For example, an integrated motorized conveyor roller in accordance with the present disclosure may comprise more than one load sensor413.

Referring now toFIG.5, a schematic diagram depicting a side section view of another example integrated motorized conveyor roller500in accordance with various embodiments of the present disclosure is provided. The example integrated motorized conveyor roller500may be similar or identical to the integrated motorized conveyor roller300discussed above in connection withFIG.3. The example integrated motorized conveyor roller500may be part of a conveyor/conveyor system and may be configured to drive one or more non-motorized conveyor rollers that are operatively coupled thereto. The example integrated motorized conveyor roller500may be configured to convey objects along at least a portion of a conveyor based at least in part on system instructions and/or user interactions via a computing entity (such as the user computing entity108described above in connection withFIG.1). As illustrated inFIG.5, the example integrated motorized conveyor roller500comprises a power cable503, a first end cap505, a second end cap507, a motor assembly511, a load sensor513, a drive assembly515and a bearing assembly519. In various embodiments, the elements/components of the integrated motorized conveyor roller500(e.g., the motor assembly511, the load sensor513and the drive assembly515) are in electronic communication with one or more controller components (e.g., a first controller component517A and a second controller component517B) such that they can exchange data/information with one another.

As noted above, and as depicted inFIG.5, the example integrated motorized conveyor roller500comprises a housing501(e.g., roller tube) configured to contain one or more components/elements of the integrated motorized conveyor roller300. In particular, as depicted, the example integrated motorized conveyor roller500is configured to contain at least the motor assembly511, the load sensor513, the drive assembly515and the bearing assembly519. In various examples, the housing501(e.g., roller tube) of the integrated motorized conveyor roller500comprises a hollow cylindrical body and may comprise metal, plastic, combinations thereof, and/or the like.

As further illustrated inFIG.5, the example integrated motorized conveyor roller500comprises a first end cap505defining a first end/surface of the example integrated motorized conveyor roller500. As depicted, the first end cap505comprises a first appendage502configured to be operatively coupled to a conveyor (e.g., disposed between a first rail and a second rail, such as within an aperture of the first rail). Additionally, as depicted inFIG.5, the first end cap505comprises a first controller component517A integrated therein. The first controller component517A may be similar or identical to the controller component417discussed above in connection withFIG.4.

As noted above, and as depicted inFIG.5, the example integrated motorized conveyor roller500comprises a motor assembly511, a drive assembly515and at least one bearing assembly519that operate to drive/rotate the housing501(e.g., roller tube) of the integrated motorized conveyor roller500with respect to a central axis506of the integrated motorized conveyor roller500. In some embodiments, each of the motor assembly511and the drive assembly515are at least partially disposed within the housing501(e.g., roller tube) of the integrated motorized conveyor roller500. For example, as shown, at least a surface of the motor assembly511and at least a surface of the drive assembly515are in contact with an inner surface of the housing501(e.g., roller tube) of the integrated motorized conveyor roller500. The drive assembly515may be configured to transfer torque from the motor assembly511to the housing501(e.g., roller tube) of the integrated motorized conveyor roller. Additionally, as illustrated, the example integrated motorized conveyor roller500comprises a bearing assembly519configured to, in conjunction with the motor assembly511and drive assembly515, facilitate rotation of the integrated motorized conveyor roller500about the central axis506. As shown, the bearing assembly519is disposed adjacent and operatively coupled to the first end cap505of the integrated motorized conveyor roller500.

As further depicted, the example integrated motorized conveyor roller500comprises a second end cap507defining a second end/surface of the example integrated motorized conveyor roller300. As depicted, the second end cap507comprises a second appendage504configured to be operatively coupled to a conveyor (e.g., disposed between a first rail and a second rail, such as within an aperture of the second rail). Additionally, as depicted inFIG.5, the second end cap507comprises a second controller component517B integrated therein. The second controller component517B may also be similar or identical to the controller component417discussed above in connection withFIG.4. As noted above, the integrated motorized conveyor roller500comprises a power cable503disposed adjacent the second end cap507that is configured to be connected to a power supply. In some embodiments, the second end cap507comprises an LED element509that is configured to provide a visual alert in response to a detected condition of the integrated motorized conveyor roller500. In various embodiments, the first controller component517A and the second controller component517B may provide a redundant system where either the first controller component517A and the second controller component517B can be utilized to continue operations of the integrated motorized conveyor roller500in an instance in which the other component fails. Additionally, by integrating the first controller component517A and the second controller component517B into the first end cap505and the second end cap507respectively, detrimental effects attributable to heat generated by the moving elements/components (e.g., the motor assembly511and/or drive assembly515) on the first controller component517A and the second controller component517B can be significantly reduced.

In some embodiments, as further depicted inFIG.5, the example integrated motorized conveyor roller500comprises a load sensor513. As shown, the load sensor513is disposed within the housing501(e.g., roller tube) of the integrated motorized conveyor roller500between the motor assembly511and the drive assembly515. The load sensor513is configured to determine a weight of an object disposed on at least a portion of the integrated motorized conveyor roller500, such as by converting a weight of an object into a measurable electrical signal.

WhileFIG.5depicts an example integrated motorized conveyor roller500, it is noted that the scope of the present disclosure is not limited to the examples shown inFIG.5. An example integrated motorized conveyor roller500in accordance with the present disclosure may comprise one or more additional and/or alternative elements, and/or may be different from that illustrated inFIG.5. For example, an integrated motorized conveyor roller in accordance with the present disclosure may comprise a single controller component or more than two controller components.

Referring now toFIG.6, a schematic diagram depicting a side section view of another example integrated motorized conveyor roller600in accordance with various embodiments of the present disclosure is provided. The example integrated motorized conveyor roller600may be part of a conveyor/conveyor system and may be configured to drive one or more non-motorized conveyor rollers that are operatively coupled thereto. The example integrated motorized conveyor roller600may be configured to convey objects along at least a portion of a conveyor based at least in part on system instructions and/or user interactions via a computing entity (such as the user computing entity108described above in connection withFIG.1). As illustrated inFIG.6, the example integrated motorized conveyor roller600comprises a power cable603, a first end cap605, a second end cap607, a motor assembly611, a load sensor613, a drive assembly615and a bearing assembly619. In various embodiments, the elements/components of the integrated motorized conveyor roller600(e.g., the motor assembly611, the load sensor613and the drive assembly615) are in electronic communication with one or more controller components (e.g., a first controller component617A and a second controller component617B) such that they can exchange data/information with one another.

As noted above, and as depicted inFIG.6, the example integrated motorized conveyor roller600comprises a housing601(e.g., roller tube) configured to contain one or more components/elements of the integrated motorized conveyor roller300. In particular, as depicted, the example integrated motorized conveyor roller600is configured to contain at least the motor assembly611, the load sensor613, the drive assembly615and the bearing assembly619. In various examples, the housing601(e.g., roller tube) of the integrated motorized conveyor roller600comprises a hollow cylindrical body and may comprise metal, plastic, combinations thereof, and/or the like.

As further illustrated inFIG.6, the example integrated motorized conveyor roller600comprises a first end cap605defining a first end/surface of the example integrated motorized conveyor roller600. As depicted, the first end cap605comprises a first appendage602configured to be operatively coupled to a conveyor (e.g., disposed between a first rail and a second rail, such as within an aperture of the first rail). Additionally, as depicted inFIG.6, the first end cap605comprises a first controller component617A integrated therein. The first controller component617A may be similar or identical to the controller component417discussed above in connection withFIG.4. As further depicted inFIG.6, the first end cap605comprises a first sensing element608disposed on a top surface of the first end cap605. In various embodiments, the first sensing element608may be or comprise one or more photo eyes, light detection and ranging (LiDAR) sensors, radio detection and ranging (RADAR) sensors, infrared (IR) cameras, 3D cameras, 360° Cameras, photoelectric sensors (e.g., photo eyes) or proximity sensors. The first sensing element608may be in electronic communication with the first controller component617A and/or the second controller component617B such that it can exchange data/information therewith. The first sensing element608may be configured to obtain sensor data (e.g., image data) relating to the integrated motorized conveyor roller600, a conveyor associated therewith, objects disposed on the conveyor, and/or the like. For example, utilizing the first sensing element608, the integrated motorized conveyor roller can determine a presence/absence, weight, location and/or condition of an object on a conveyor. In some embodiments, the integrated motorized conveyor roller600may be configured to store and/or transfer at least a portion of the sensor data obtained by the first sensing element608with another computing entity such as a user computing entity or another motorized conveyor roller. The sensor data may be associated with and/or stored in conjunction with a timestamp. Accordingly, sensor data obtained from more than one motorized conveyor roller may be correlated (e.g., based at least in part on timestamp data associated therewith) in order to determine a location of a plurality of objects disposed on a particular portion of a conveyor. Additionally and/or alternatively, in some embodiments, the integrated motorized conveyor roller may include an integrated barcode scanner (e.g., Radio frequency identification (RFID) scanner to facilitate sortation operations).

As noted above, and as depicted inFIG.6, the example integrated motorized conveyor roller600comprises a motor assembly611, a drive assembly615and at least one bearing assembly619that operate to drive/rotate the housing601(e.g., roller tube) of the integrated motorized conveyor roller600with respect to a central axis606of the integrated motorized conveyor roller600. In some embodiments, each of the motor assembly611and the drive assembly615are at least partially disposed within the housing601(e.g., roller tube) of the integrated motorized conveyor roller600. For example, as shown, at least a surface of the motor assembly611and at least a surface of the drive assembly615are in contact with an inner surface of the housing601(e.g., roller tube) of the integrated motorized conveyor roller600. The drive assembly615may be configured to transfer torque from the motor assembly611to the housing601(e.g., roller tube) of the integrated motorized conveyor roller. Additionally, as illustrated, the example integrated motorized conveyor roller600comprises a bearing assembly619configured to, in conjunction with the motor assembly611and drive assembly615, facilitate rotation of the integrated motorized conveyor roller600about the central axis606. As shown, the bearing assembly619is disposed adjacent and operatively coupled to the first end cap605of the integrated motorized conveyor roller600.

As further depicted, the example integrated motorized conveyor roller600comprises a second end cap607defining a second end/surface of the example integrated motorized conveyor roller300. As depicted, the second end cap607comprises a second appendage604configured to be operatively coupled to a conveyor (e.g., disposed between a first rail and a second rail, such as within an aperture of the second rail). Additionally, as depicted inFIG.6, the second end cap607comprises a second controller component617B integrated therein. The second controller component617B may also be similar or identical to the controller component417discussed above in connection withFIG.4. As further depicted inFIG.6, the second end cap607comprises a second sensing element610disposed on a top surface of the second end cap607. The second sensing element610may be similar or identical to the first sensing element608. In some embodiments, the second sensing element610may be different from the first sensing element608. In various embodiments, the second sensing element610may be or comprise one or more photo eyes, light detection and ranging (LiDAR) sensors, radio detection and ranging (RADAR) sensors, infrared (IR) cameras, 3D cameras, 360° Cameras, photoelectric sensors or proximity sensors. The second sensing element610may be in electronic communication with the first controller component617A and/or the second controller component617B such that it can exchange data/information therewith. The second sensing element610may be configured to obtain sensor data (e.g., image data) relating to the integrated motorized conveyor roller600, a conveyor associated therewith, objects disposed on the conveyor, and/or the like. For example, utilizing the second sensing element610, the integrated motorized conveyor roller600can determine a weight, location and/or condition of an object on a conveyor. In some embodiments, the integrated motorized conveyor roller600may be configured to store and/or transfer at least a portion of the sensor data obtained by the second sensing element610with another computing entity such as a user computing entity or another motorized conveyor roller. The sensor data may be associated with and/or stored in conjunction with a timestamp. Accordingly, sensor data obtained from more than one motorized conveyor roller may be correlated (e.g., based at least in part on timestamp data associated therewith) in order to determine a weight of a plurality of objects disposed on a particular portion of a conveyor.

As noted above, the integrated motorized conveyor roller600comprises a power cable603disposed adjacent the second end cap607that is configured to be connected to a power supply. In some embodiments, the second end cap607comprises an LED element609that is configured to provide a visual alert in response to a detected condition of the integrated motorized conveyor roller600.

In some embodiments, as further depicted inFIG.6, the example integrated motorized conveyor roller600comprises a load sensor613. As shown, the load sensor613is disposed within the housing601(e.g., roller tube) of the integrated motorized conveyor roller600between the motor assembly611and the drive assembly615. The load sensor613is configured to determine a weight of an object disposed on at least a portion of the integrated motorized conveyor roller600, such as by converting a weight of an object into a measurable electrical signal.

WhileFIG.6depicts an example integrated motorized conveyor roller600, it is noted that the scope of the present disclosure is not limited to the examples shown inFIG.6. An example integrated motorized conveyor roller600in accordance with the present disclosure may comprise one or more additional and/or alternative elements, and/or may be different from that illustrated inFIG.6. For example, an integrated motorized conveyor roller in accordance with the present disclosure may comprise a single sensing element or more than two sensing elements.

Referring now toFIG.7, a schematic diagram depicting an example controller component700in electronic communication with a motor assembly709, sensing element(s)711and load sensor(s)713of an motorized conveyor roller in accordance with various embodiments of the present disclosure is provided. As shown, the controller component700comprises processing circuitry701, a communication element703, input/output element705, a memory707and/or other components configured to perform various operations, procedures, functions or the like described herein.

In some embodiments, the controller component700may be or comprise a PCB. In some examples, the controller component700(e.g., PCB) may further comprise one or more of a full bridge motor driver, a hall sensor, one or more thermal sensors, one or more user interfaces, one or more protection circuits, configuration management circuitry809, a wireless interface, sensing element circuitry (e.g., image sensor circuitry), an interface connector, power control circuitry, gate driver circuitry and/or the like.

The processing circuitry701may be embodied as 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, but not limited to, an application specific integrated circuit (ASIC) or field programmable gate array (FPGA), or some combination thereof. Accordingly, although illustrated inFIG.7as a single processor, in an embodiment, the processing circuitry701may include a plurality of processors and signal processing modules. The plurality of processors may be embodied on a single electronic device or may be distributed across a plurality of electronic devices collectively configured to function as the circuitry of the integrated motorized conveyor roller. 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 circuitry of the integrated motorized conveyor roller as described herein. In an example embodiment, the processing circuitry701may be configured to execute instructions stored in the memory707or otherwise accessible to the processing circuitry701. These instructions, when executed by the processing circuitry701, may cause the circuitry of the integrated motorized conveyor roller to perform one or more of the functionalities, as described herein.

Whether configured by hardware, firmware/software methods, or by a combination thereof, the processing circuitry701may include an entity capable of performing operations according to embodiments of the present disclosure while configured accordingly. Thus, for example, when the processing circuitry701is embodied as an ASIC, FPGA or the like, the processing circuitry701may include specifically configured hardware for conducting one or more operations described herein. Additionally, or alternatively, when the processing circuitry701is embodied as an executor of instructions, such as may be stored in the memory707, the instructions may specifically configure the processing circuitry701to perform one or more algorithms and operations described herein.

Thus, the processing circuitry701used herein may refer to a programmable microprocessor, microcomputer or multiple processor chip or chips that can be configured by software instructions (applications) to perform a variety of functions, including the functions of the various embodiments described above. In some devices, multiple processors may be provided dedicated to wireless communication functions and one processor dedicated to running other applications. Software applications may be stored in the internal memory before they are accessed and loaded into the processors. The processors may include internal memory sufficient to store the application software instructions. In many devices, the internal memory may be a volatile or nonvolatile memory, such as flash memory, or a combination thereof. The memory can also be located internal to another computing resource (e.g., enabling computer readable instructions to be downloaded over the Internet or another wired or wireless connection).

The memory707may include suitable logic, circuitry, and/or interfaces that are adapted to store a set of instructions that is executable by the processing circuitry701to perform predetermined operations. Additionally or alternately, the memory707may be configured to store data/information, application programs, instructions, and etc., so that the controller component700can execute various functions according to the embodiments of the present disclosure. For example, in at least some embodiments, the memory707is configured to cache input data for processing by the processing circuitry701. Thus, in at least some embodiments, the memory707is configured to store program instructions for execution by the processing circuitry701. The memory707may store information in the form of static and/or dynamic information. When the functions are executed, the stored information may be stored and/or used by the controller component700. Example memory implementations may include, but are not limited to, 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. In an example embodiment, the memory707may be integrated with the processing circuitry701on a single chip, without departing from the scope of the disclosure.

The communication element703may be implemented as any apparatus included in a circuit, hardware, a computer program product or a combination thereof, which is configured to receive and/or transmit data from/to another component or apparatus. The computer program product comprises computer-readable program instructions stored on a computer-readable medium (for example, the memory707) and executed by a processing component700(for example, the processing circuitry701). In some embodiments, the communication element703(as with other components discussed herein) may be at least partially implemented as the processing circuitry701or otherwise controlled by the processing circuitry701. In this regard, the communication element703may communicate with the processing circuitry701, for example, through a bus. The communication element703may comprise, for example, antennas, transmitters, receivers, transceivers, network interface cards and/or supporting hardware and/or firmware/software, and is used for establishing communication with another apparatus. The communication element703may be configured to receive and/or transmit any data that may be stored by the memory707by using any protocol that can be used for communication between apparatuses. The communication element703may additionally or alternatively communicate with the memory707, the input/output element705and/or any other component of the processing component700, for example, through a bus.

In some embodiments, the processing component700may comprise an input/output element705. The input/output element705may communicate with the processing circuitry701to receive instructions input by the user and/or to provide audible, visual, mechanical or other outputs to the user. Therefore, the input/output element705may comprise supporting devices, such as a keyboard, a mouse, a display, a touch screen display, and/or other input/output mechanisms. Alternatively, at least some aspects of the input/output element705may be implemented on a device used by the user to communicate with the processing component700. The input/output element705may communicate with the memory707, the communication element703and/or any other component, for example, through a bus. One or a plurality of input/output modules and/or other components may be included in the processing component700.

Referring now toFIG.8, a schematic diagram depicting an example controller component800of an integrated motorized conveyor roller in accordance with various embodiments of the present disclosure is provided. In some examples, the controller component800may be similar or identical to the controller component417described above in connection withFIG.4.

In some embodiments, as depicted, the controller component800may be or comprise a PCB stack comprising a plurality of PCB boards in electronic communication with one another via interface connectors. In particular, as depicted, the controller component800comprises a power module801, a controller module803and a wireless module805.

As depicted inFIG.8, the power module801comprises a first PCB board configured to control operations of electronic elements of the integrated motorized conveyor roller. In the depicted embodiment, the power module801is configured to receive/condition a power supply and comprises at least a Hall sensing circuit, a thermal sensor, interface connector(s), one or more protection circuits, a full bridge motor driver, a gate driver, one or more user interfaces and a power section.

As noted above, the controller component800comprises a controller module803. The controller module803comprises a second PCB board that is configured to control various operations of the integrated motorized conveyor roller. In the depicted embodiment, the controller module803comprises at least one sensing element (e.g., photo eye) circuit, interface connector(s), a micro controller unit (MCU) and an motorized conveyor roller configuration management circuit.

As noted above, the controller component800comprises a wireless module805. The wireless module805comprises a third PCB board that is configured to provide a communication interface (e.g., Bluetooth, BLE, LoRa, and/or the like). For example, between the integrated motorized conveyor roller and one or more other motorized conveyor rollers.

As further depicted inFIG.8, the wireless module805comprises a power supply (e.g., back-up rechargeable coin cell) a BLE and/or LoRa interface, a communication element, a monitoring circuit and interface connector(s).

In some embodiments, as depicted inFIG.8, the controller component800/motorized conveyor roller may comprise a monitoring circuit for monitoring operations and/or operational conditions of the integrated motorized conveyor roller (e.g., providing self-check functionality) via one or more sensing elements. By way of example, a monitoring circuit of the controller component800may be operatively coupled to a magnetic sensing element (e.g., an inductor or transformer). During operations, the rotation of the integrated motorized conveyor roller motor assembly generates a magnetic field which in turn generates a measurable electrical signal (e.g., voltage output) across the magnetic sensing element coupled thereto. An output of a comparator circuit may be used to provide an output describing one or more parameters associated with motorized conveyor roller (e.g., a lifetime motor operational time, number of rotations, loading conditions, vibrational information, installation issues, belt wear out, and/or the like). In some embodiments, at least a portion of the output of the comparator circuit may be measured and stored in memory. In some examples, the controller component800may provide a control indication to actuate an LED element in response to detecting certain conditions (e.g., complete loss of motor function or overload scenario). In various embodiments, the controller component800may be operatively coupled to other types of sensing elements including pressure sensors, vibrational sensors, temperature sensors, position sensors, and/or the like.

In various embodiments, the controller component800may store (e.g., periodically and/or in response to requests) information/data describing various operational parameters of the integrated motorized conveyor roller including lifetime motor operational time, object information (e.g., information describing presence/absence of an object and/or other characteristics, image data or the like).

WhileFIG.8depicts an example controller component800(e.g., PCB stack), it is noted that the scope of the present disclosure is not limited to the example shown inFIG.8. An example controller component800in accordance with the present disclosure may comprise one or more additional and/or alternative elements, and/or may be different from that illustrated inFIG.8. For example, an integrated motorized conveyor roller in accordance with the present disclosure may comprise a single PCB board or more than three PCB boards.

Referring now toFIG.9, a schematic diagram depicting an example system900in accordance with various embodiments of the present disclosure is provided. As depicted, the example system900comprises a plurality of integrated motorized conveyor rollers in communication with one another. In particular, the system900comprises a first integrated motorized conveyor roller901, a second integrated motorized conveyor roller903, a third integrated motorized conveyor roller905and a fourth integrated motorized conveyor roller907. In some embodiments, each of the first integrated motorized conveyor roller901, the second integrated motorized conveyor roller903, the third integrated motorized conveyor roller905and the fourth integrated motorized conveyor roller907may be associated with a particular zone, segment and/or the like of an example conveyor.

In various embodiments, each of the first integrated motorized conveyor roller901, the second integrated motorized conveyor roller903, the third integrated motorized conveyor roller905and the fourth integrated motorized conveyor roller907may be associated with a unique addressable identifier (e.g., machine readable code or string). Each unique addressable identifier may further be associated with (e.g., tagged with) a particular physical location of a conveyor system. As discussed herein, each of the first integrated motorized conveyor roller901, the second integrated motorized conveyor roller903, the third integrated motorized conveyor roller905and the fourth integrated motorized conveyor roller907may comprise a wireless module/component to enable wireless communication with one another and/or other computing entities. In some embodiments, each of the first integrated motorized conveyor roller901, the second integrated motorized conveyor roller903, the third integrated motorized conveyor roller905and the fourth integrated motorized conveyor roller907may be configured to be associated with a particular zone and/or operate as a master or slave with respect to the other integrated motorized conveyor rollers in the zone. In some embodiments, a plurality of integrated integrated motorized conveyor rollers (e.g., the first integrated motorized conveyor roller901, the second integrated motorized conveyor roller903, the third integrated motorized conveyor roller905and the fourth integrated motorized conveyor roller907) may be configured in MESH network (e.g., as nodes within a local network) and may be configured to communicate with other integrated motorized conveyor rollers associated with other conveyors and/or zones.

Referring now toFIG.10, a flowchart diagram illustrating example operations1000in accordance with various embodiments of the present disclosure is provided. In some examples, the method1000may be performed by various system components (for example, but not limited to, processing circuitry of a computing entity106described above with regard toFIG.1). The computing entity106may be or comprise a central server. In some examples, the processing circuitry may be electrically coupled to and/or in electronic communication with other circuitries, such as, but not limited to, one or more integrated motorized conveyor rollers (such as, for example, integrated motorized conveyor rollers901,903,905and907described above in connection withFIG.9).

The example method1000begins at step/operation1001. At step/operation1001, processing circuitry (such as, but not limited to, the processing circuitry of the computing entity106described above in connection withFIG.1) transmits configuration data to one or more integrated motorized conveyor rollers (e.g., a plurality of integrated motorized conveyor rollers associated with a particular zone and/or conveyor). In some examples, transmitting configuration data may comprise establishing a connection with one or more motorized conveyor roller such that the integrated motorized conveyor roller and the processing circuitry (e.g., computing entity) can exchange data/information with one another. In some examples, the configuration data may comprise target parameters and/or operational data such as an operating mode (e.g., singulation, slug or zero pressure accumulation (ZPA)), a direction or motion, an acceleration time and/or deceleration time.

Subsequent to step/operation1001, the method1000proceeds to step/operation1003. At step/operation1003, the processing circuitry transmits a request (e.g., to one or more motorized conveyor rollers) for operational data. In some embodiments, the processing circuitry may transmit the request to a master integrated motorized conveyor roller associated with a particular zone/plurality of motorized conveyor rollers. In some examples, transmitting the request for operational data may comprise establishing a connection with one or more integrated motorized conveyor rollers such that the one or more integrated motorized conveyor rollers and the processing circuitry (e.g., computing entity) can exchange data/information with one another.

Subsequent to step/operation1003, the method1000proceeds to step/operation1005. At step/operation1005, the processing circuitry receives an indication (e.g., from one or more example integrated motorized conveyor roller) comprising the requested operational data. The operational data may comprise sensor data obtained via one or more sensing elements of the one or more motorized conveyor rollers (e.g., image sensors, magnetic sensors, pressure sensors, load sensors, vibrational sensors, and/or the like). In some embodiments, the processing circuitry may transmit a request for operational data or the operational data may be provided in response to certain predetermined triggers or operational conditions being detected (e.g., an overload condition or motor failure). In some embodiments, the operational data may be associated with a particular integrated motorized conveyor roller and/or zone such that an operator can easily identify and address issues in the field in real-time. In some embodiments, operational data may be provided on a zonal basis so that pairings with other integrated motorized conveyor rollers and critical parameters that are out of range with other motorized conveyor rollers in a particular zone can be identified.

Referring now toFIG.11, a flowchart diagram illustrating example operations1100in accordance with various embodiments of the present disclosure is provided. In some examples, the method1100may be performed by various system components (for example, but not limited to, controller component800of the integrated motorized conveyor roller described above with regard toFIG.8). In some examples, the processing circuitry may be electrically coupled to and/or in electronic communication with other circuitries, such as, but not limited to, one or more computing entities (such as, but not limited to, computing entity106described above in connection withFIG.1) a memory (such as, for example, random access memory (RAM) for storing computer program instructions), and/or the like.

The example method1100begins at step/operation1101. At step/operation1101, controller component (such as, but not limited to, the controller component800of the integrated motorized conveyor roller illustrated with regard toFIG.8, discussed above) receives configuration data (e.g., from the processing circuitry of the computing entity106described above in connection withFIG.1). As noted above, the configuration data may comprise target parameters such as an operating mode (e.g., singulation, slug or ZPA), a direction of motion, an acceleration time and/or deceleration time.

Subsequent to step/operation1101, the method1100proceeds to step/operation1103. At step/operation1103, controller component performs operations based at least in part on the received configuration data.

Subsequent to step/operation1103, the example method1100proceeds to step/operation1105. At step/operation1105, controller component obtains sensor data (e.g., via at least one sensing element, such as, but not limited to, sensing element(s)711described above in connection withFIG.7). The at least one sensing element may include image sensors, magnetic sensors and/or the like. By way of example, controller component obtains sensor data (e.g., image data, load sensor data) describing location(s) and/or characteristics of one or more objects on at least a portion of the conveyor associated therewith. For example, the processing component may be configured to process the sensor data, such as by computer-executable instructions, that indicate which data is to be used in the analysis, provide one or more algorithms or functions for performing the analysis, provide one or more coefficients and/or parameters to be used in accordance with an algorithm for performing the analysis, perform one or more guidelines for providing a response indicating a result in the analysis, and/or the like. In example embodiments, the computer executable instructions may be configured in accordance with a standardized computer programming language. In an example embodiment, the computer-executable instructions may comprise a reference to a function repository and/or one or more coefficients and/or parameters to be used in the calculation and or determination of the result of the referenced instructions, function or algorithm. In some embodiments, at least a portion of the analysis may be performed by another computing entity (such as, for example, without limitation, the one or more computing entities106described above with regard toFIG.1). In such examples, the computing entity may perform at least a portion of the analysis and provide (e.g., transmit or send) the results of the analysis to the processing component of the integrated motorized conveyor roller. Additionally and/or alternatively, controller component obtains sensor data relating to operations of the integrated motorized conveyor roller (e.g., a lifetime motor operational time, number of rotations, loading conditions, vibrational information, installation issues, belt wear out, and/or the like).

Subsequent to step/operation1103, the example method1100proceeds to step/operation1105. At step/operation1105, controller component transmits an indication comprising operational data. In various examples, the indication requesting additional operational data may be transmitted to a computing entity (e.g., central server) in electronic communication with the integrated motorized conveyor roller.

Using the methods and techniques described above, integrated motorized conveyor rollers may perform self-check, prognostic and/or diagnostic operations and provide associated data/information to another computing entity (e.g., central server). Additionally, a computing entity (e.g., central server) can remotely configure and/or provide configuration data to one or more integrated motorized conveyor rollers in real-time thus eliminating the need for time consuming, manual configuration operations in the field (e.g., performed by human agents via a wired connection to a motorized conveyor roller).

In some examples, one or more of the procedures described inFIG.10andFIG.11may be embodied by computer program instructions, which may be stored by a memory (such as a non-transitory memory) of a system employing an embodiment of the present disclosure and executed by a processing component/circuitry of the system. These computer program instructions may direct the system to function in a particular manner, such that the instructions stored in the memory circuitry produce an article of manufacture, the execution of which implements the function specified in the flow diagram step/operation(s). Further, the system may comprise one or more other circuitries. Various circuitries of the system may be electronically coupled between and/or among each other to transmit and/or receive energy, data and/or information. In some examples, embodiments may take the form of a computer program product on a non-transitory computer-readable storage medium storing computer-readable program instruction (e.g., computer software). 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.

Many modifications and other embodiments of the present disclosure set forth herein will come to mind to one skilled in the art to which these embodiments pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the disclosure are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Moreover, although the foregoing descriptions and the associated drawings describe example embodiments in the context of certain example combinations of elements and/or functions, it should be appreciated that different combinations of elements and/or functions may be provided by alternative embodiments without departing from the scope of the appended claims. In this regard, for example, different combinations of elements and/or functions than those explicitly described above are also contemplated as may be set forth in some of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.