Patent ID: 12258218

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 can 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 can or can not be present in various embodiments of the present disclosure described herein such that embodiments can include fewer or more components than those shown in the figures while not departing from the scope of the present disclosure. Some components can 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 can be included in at least one embodiment of the present disclosure, and can 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 embodiments.

If the specification states a component or feature “can,” “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 can be optionally included in some embodiments, or can be excluded.

The term “electronically coupled” or “in electronic communication with” in the present disclosure can 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) can 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 can 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 can 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 can 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 can be configured to rotate the drive assembly and roller tube.

In some embodiments, motorized rollers can be utilized in conveyers with different section shapes including, for example, one or more curved sections and straight-line sections. At a curved section of a conveyer frame, a motorized roller can have a first diameter at an outside edge of a conveyer frame and taper towards a second diameter at an inside edge of the conveyer frame to help items maintain their position on the conveyor as they are moved around the curved section. At a non-curved, straight-line section, of the conveyer frame, a motorized roller can have a first diameter at the outside edge and the inside edge of the conveyer frame. To accommodate for the differences in roller diameters for curved and straight-line sections of a conveyer, different types of motorized rollers can be used at each section. For instance, a tapered motorized roller with a first diameter at a first edge and a second, different diameter at a second edge of the roller can be used to form, at least in part, a curved section of a conveyer, whereas a non-tapered motorized roller with first diameter at a first edge and a second edge of the roller can be used to form, at least in part, a straight-line, non-curved section of the conveyer. This results in fixed conveyor setups with undesirable flexibility and requires maintaining multiple stock keeping units, tooling, assembly setups, and inventory of such difference motorized rollers.

Additionally, motorized rollers can include shoe sorters to sort items as the items are moved along a conveyor section. Shoe sorters are typically independently configured for a section of a conveyor and require specific expertise to maintain. Moreover, shoe sorters are only compatible for certain motorized or non-motorized rollers which further reduces the flexibly of conventional conveyor setups and requires further maintenance of stock keeping units, tooling, assembly setups, and inventory.

In accordance with various embodiments of the present disclosure, example methods, apparatuses, computer program products and systems are provided that, in some examples provide a motorized roller design that can be reconfigured between tapered and straight configurations and/or inbuilt shoe sorters in motorized rollers.

For example, the present disclosure can provide a reconfigurable motorized conveyor roller including a housing with a first end and a second end opposite to the first end. The housing can include a plurality of curved plates that at least partially form a cylindrical tube. The reconfigurable motorized conveyor roller can include 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. The reconfigurable motorized conveyor roller can include a housing adjustment assembly disposed within the housing that is operable to modify one or more dimensions of the housing.

In addition, or alternatively, the reconfigurable motorized conveyor roller can include an integrated shoe sorter assembly that includes a shoe slider component at least partially disposed on an exterior surface of the housing and a shoe adjustment component disposed within the housing that is operable to modify a position of the shoe slider component relative to the housing.

As such, the present disclosure provides a reconfigurable motorized conveyor roller that includes a flexible design for configuring straight, curved, and right-angle conveyer sections. The flexible design can be utilized, in some examples, to dynamically ease belt tracking and tightening problems found in conventional motorized and non-motorized rollers. Moreover, the reconfigurable motorized conveyor roller of the present disclosure allows for dynamic diversion of items as well as efficient packet switching using inbuilt shoe sorters. This enables minimization of stock keeping units, and reduces costs associated with making multiple designs, and maintaining multiple separate tooling, assembly setups, and inventory.

Referring now toFIG.1, a schematic diagram depicting an example system100in accordance various embodiments of the present disclosure is provided. As depicted, the example system100includes 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 system100can operate to convey objects within a particular location or environment.

In various embodiments, the conveyor102can be configured to transport objects within a particular location or environment utilizing one or more motorized conveyor rollers. In some embodiments, the conveyor102includes 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 system100can 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 system100includes one or more computing entities106. In general, the terms computing device, entity, device, system, and/or similar words used herein interchangeably can 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 can 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 entity106can 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 entity106can 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 can 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, FeRAM, RRAM, SONOS, racetrack memory, and/or the like. As will be recognized, the non-volatile storage or memory media can 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 can 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 entity106can 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 can 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 can 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 can 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 entity106can 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 can 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 entity106can be configured to communicate via wireless external communication networks using any of a variety of protocols, such as embedded sim (eSIM), 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 entity106can 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 can be located remotely from other computing entity106components, such as in a distributed system. Furthermore, one or more of the components can be aggregated and additional components performing functions described herein can 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 system100includes a user computing entity108. In various embodiments, the user computing entity108can be or include one or more mobile devices, wearable computing devices, and/or the like. An example user computing entity108can 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, can 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 can 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 can 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 entity108can 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 entity108can be capable of operating with one or more air interface standards, communication protocols, modulation types, and access types. More particularly, the user computing entity108can operate in accordance with any of a number of wireless communication standards and protocols. In a particular embodiment, the user computing entity108can 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 entity108can 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 entity108can include 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 can 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 include 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 can include a full set of alphabetic keys or set of keys that can 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 can be removable. For example, the non-volatile memory can be ROM, PROM, EPROM, EEPROM, flash memory, MMCs, SD memory cards, Memory Sticks, CBRAM, PRAM, FeRAM, RRAM, SONOS, racetrack memory, and/or the like. The volatile memory can 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.1can be configured to communicate with one another via one or more networks105. The networks105can 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 networks105can have any suitable communication range associated therewith and can include, for example, global networks (e.g., the Internet), MANs, WANs, LANs, or PANs. In addition, the networks105can include any type of medium over which network traffic can 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 system100can include one or more additional and/or alternative elements, and/or can be different from that illustrated inFIG.1.

Referring now toFIG.2A, a schematic diagram depicting an example straight line portion225of 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 conveyor200can define a particular section or zone of a conveyor system.

As depicted inFIG.2A, the example conveyor200can include 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 some embodiments, the conveyor200can include 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 rail208can 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.2A, the non-motorized conveyor rollers (e.g., non-motorized conveyor roller204) can be or include idler rollers or driven rollers. Additionally, the motorized conveyor rollers (e.g., motorized conveyor roller202) can 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 can include drive bands, e.g., drive band210. The example drive bands can 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 ring212can 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 band210can 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).

FIG.2Aone example portion225of the conveyor200. The conveyer200can include a plurality of different portions, each including a plurality of motorized and/or non-motorized conveyor rollers. The example portion225can be configured as a straight, non-curved section of the conveyer200in the which the first rail206and the second rail208include straight and/or semi-straight rails. In some embodiments, each of the conveyor rollers (e.g., motorized conveyor roller202, non-motorized conveyor rollers204, etc.) used in a straight, non-curved section of the conveyer can include a constant diameter at each end of the respective conveyor rollers. For instance, the motorized conveyor roller202and the non-motorized roller204can include a first end with a first dimension and a second end opposite to the first end with the same first dimension. As one example, the first end and the second end of a straight conveyer roller can include a common diameter such as, for example, one or more inches, etc.

The conveyer200can include a plurality of different portions with one or more configurations. For example,FIG.2Bis a schematic diagram depicting an example curved portion250of the conveyor200with motorized and non-motorized conveyor rollers in accordance with various embodiments of the present disclosure is provided. The example curved portion250, for example, can include a curved section of the conveyer200.

As depicted inFIG.2B, the example curved portion250of the conveyor200can include one or more motorized conveyor rollers, e.g., motorized conveyor roller252and one or more non-motorized conveyor rollers, e.g., non-motorized conveyor roller254. The conveyor200can include at least a first rail256and a second rail258. As depicted inFIG.2, the plurality of motorized conveyor rollers and non-motorized conveyor rollers (e.g., motorized conveyor roller252and non-motorized conveyor roller254) are mechanically/operatively coupled to the first rail256and the second rail258. In some embodiments, the first rail256and the second rail258can 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 roller252and non-motorized conveyor roller254).

The example portion250can be configured as a curved section of the conveyer200in the which the first rail256and the second rail258include at least partially curved rails. The first rail256and the second rail258can be curved at any angle such as, for example, a 90-degree angle, etc. The curved section can include a tapered conveyor roller255to help items maintain their position on a conveyer as they are transported by the conveyer200. The tapered conveyor roller255, for example, can include a first end260with a first dimension and a second end265opposite to the first end260with a second dimension different from the first dimension. The second end265, for example, can include a larger diameter than the diameter of the first end260. By way of example, the first end260can include a first diameter (e.g., one or more centimeters, inches, etc.) and the second end265can include second diameter (e.g., one or more centimeters, inches, etc.) that is larger than the first diameter.

The first diameter and the second diameter can reference an inner diameter of a conveyor roller, an outer diameter of the conveyor roller, or both. For example, in some embodiments, the first diameter and the second diameter can reference the outer diameter at a respective side of the conveyor roller. The outer diameter, for example, can include the length of a line through a center axis of the conveyor roller that touches two points on the outermost exterior surface of the conveyor roller. As illustrated herein, the outermost exterior surface can include an exterior surface of a cylindrical housing of the conveyor roller.

WhileFIGS.2A-Bdepicts an example conveyor200, it is noted that the scope of the present disclosure is not limited to the examples shown inFIGS.2A-B. An example conveyor200in accordance with the present disclosure can comprise one or more additional and/or alternative elements, and/or can be different from that illustrated inFIG.2A-B.

Conventional conveyers can utilize one type of conveyer rollers (e.g., motorized conveyor roller202and non-motorized conveyor roller204) with constant dimensions (e.g., a constant diameter) at a straight-line portion225of the conveyer and a second type of conveyer rollers (e.g., motorized conveyor roller252and non-motorized conveyor roller254) with a different set of constant dimensions (e.g., a set of diameters) at curved portions250of the conveyer. Accordingly, a plurality of different types of conveyer rollers may be used for different sections of a conveyor frame which results in fixed conveyor setups without flexibility. This requires maintenance of multiple stooking units, tooling, assembly setups, etc. and increases inventory necessary for different conveyer configurations. A reconfigurable motorized conveyer is therefore advantageous.

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 roller300can be part of a conveyor/conveyor system (e.g., the conveyor200described above in connection withFIGS.2A-B) and can be configured to drive one or more non-motorized conveyor rollers that are operatively coupled thereto. The conveyor/conveyor system can be part of an automated or semi-automated warehousing system in which objects can 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 roller300can 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 can comprise metal, plastic, combinations thereof, and/or the like. As discussed herein, the cylindrical body can include an expandable body.

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 cable303can 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 roller400can be similar or identical to the integrated motorized conveyor roller300discussed above in connection withFIG.3. The example integrated motorized conveyor roller400can be part of a conveyor/conveyor system and can be configured to drive one or more non-motorized conveyor rollers that are operatively coupled thereto. The example integrated motorized conveyor roller400can 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 can 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 roller400can include one or more of a motor assembly411, a drive assembly415and a 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 assembly415can be in contact with an inner surface of the housing401(e.g., roller tube) of the integrated motorized conveyor roller400. In some embodiments, the housing401can include multiple sections. The at least one surface of the motor assembly411and the drive assembly415can be in contact at least one section (e.g., an inner section), while an outer section may be reconfigured without disrupting the functions of the motor assembly411and the drive assembly415.

The drive assembly415can 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 assembly415can 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 sensor413can 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 component417can 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 component417can be or comprise one or more printed circuit boards (PCBs). For example, as depicted, the controller component417comprises a PCB stack comprising three PCBs 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 can comprise one or more additional and/or alternative elements, and/or can be different from that illustrated inFIG.4. For example, a motorized conveyor roller in accordance with the present disclosure can include adjustable components to modify the dimensions of the motorized conveyor roller for use in different sections of a conveyor frame.

FIG.5A, for example, provides a schematic diagram depicting a reconfigurable motorized conveyor roller500in accordance with various embodiments of the present disclosure. The reconfigurable motorized conveyor roller500can be similar to the integrated motorized conveyor rollers300and400discussed above in connection withFIGS.3and4. For instance, the reconfigurable motorized conveyor roller500can be part of a conveyor/conveyor system and can be configured to drive one or more non-motorized conveyor rollers that are operatively coupled thereto. The reconfigurable motorized conveyor roller500can 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).

The reconfigurable motorized conveyor roller500comprises a reconfigurable housing configured to include and/or contain one or more components/elements of the integrated motorized conveyor rollers300and400ofFIGS.3and4. For instance, the reconfigurable housing can include an at least partially hollow body, a first end cap defining a first end/surface of the reconfigurable housing, a first appendage configured 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), a second end cap defining a second end/surface of the housing, and/or a second appendage configured 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 described herein with reference to the example integrated motorized conveyor roller300ofFIG.3. In addition, or alternatively, the reconfigurable motorized conveyor roller500can include any one of the power cable, first end cap, second end cap, motor assembly, load sensor, drive assembly, controller component and/or bearing assembly as described herein with reference to the example integrated motorized conveyor roller400ofFIG.4.

As depicted, the reconfigurable motorized conveyor roller500can be converted between a plurality of configurations including, for example, a straight configuration525and a tapered configuration550. The straight configuration525can include a straight housing505with a constant diameter across the length of the straight housing505. The tapered configuration550can include a tapered housing510with a tapered diameter across the length of the tapered housing510.

For example, the reconfigurable housing of the reconfigurable motorized conveyor roller500can include a first end/surface and a second end/surface opposite to the first end/surface.

The straight housing505can include a first end/surface502with first dimensions515and a second end/surface504with second dimensions525. In the straight configuration525, the first dimensions515and the second dimensions525can include a constant and/or the same diameter. This can form the straight housing505with a constant diameter across the length of the straight housing505.

The tapered housing510can include a first end/surface502with first dimensions520and a second end/surface504with second dimensions530. In the tapered configuration550, the first dimension520and the second dimension530can include different diameters. By way of example, the second dimension530can include a larger diameter than the first dimension520. This can form the tapered housing510with a tapered diameter across the length of the tapered housing510.

The reconfigurable housing can be converted from the straight housing505to the tapered housing510by increasing the diameter of the reconfigurable housing at the first end/surface502relative to the second end/surface504and/or increasing the diameter of the reconfigurable housing at the second end/surface504relative the first end/surface502. The reconfigurable housing can be converted from the tapered housing510to the straight housing505by decreasing the diameter of the reconfigurable housing at the first end/surface502to achieve the same and/or similar diameter of the second end/surface504and/or decreasing the diameter of the reconfigurable housing at the second end/surface504to achieve the same and/or similar diameter of the first end/surface502.

The reconfigurable motorized conveyor roller500can include a housing adjustment assembly disposed within the housing that is operable to modify one or more dimensions of the reconfigurable housing. The housing adjustment assembly can be disposed proximate to the first end/surface502, the second end/surface504, or both to modify a diameter of the reconfigurable housing at the first end/surface502, the second end/surface504, or both.

For instance, the housing adjustment assembly575can be disposed at a first position555proximate to the first end/surface502and can be operable to modify the diameter of the housing at the first end/surface502. In addition, or alternatively, the housing adjustment assembly575can be disposed at a second position560proximate to the second end/surface504and can be operable to modify the diameter of the housing at the second end/surface504.

As one example, the housing adjustment assembly can be disposed at the second position560and can be operable to increase the diameter of the housing at the second end/surface504to form the tapered housing510. As another example, the housing adjustment assembly575can be disposed at the second position560and can be operable to decrease the diameter of the housing at the second end/surface504to form the straight housing505.

FIG.5Billustrates cross-section side views of an example housing adjustment assembly integrated within a reconfigurable housing of the reconfigurable motorized conveyor roller500in accordance with various embodiments of the present disclosure.FIG.5Bdepicts a first cross-section side view and a second cross-section view. The first cross-section view depicts a housing adjustment assembly and reconfigurable housing in a contracted state570. The second cross-section view depicts the housing adjustment assembly and reconfigurable housing in an expanded state575.

The reconfigurable housing can include an expandable material and/or can include a plurality of separate sections that can expand and contract to modify the diameter of at least a portion of the reconfigurable housing.

For instance, in example embodiments, the reconfigurable housing can include a plurality of curved plates such as curved plate580that at least partially form a cylindrical tube. The plurality of curved plates can be separable to expand the diameter of the reconfigurable housing (e.g., from the contracted state570to the expanded state575). In some embodiments, the plurality of curved plates can be at least partially covered by a sleeve. The sleeve, for example, can include an elastic material that can expand and compress around the exterior surface of the housing. In addition, or alternatively, the expandable sleeve can include a removable conveyer roller cover, sleeve, etc. that can be fitted to exterior of the reconfigurable housing.

As an example,FIG.5Cdepicts a cross-section side view of an example reconfigurable housing of a reconfigurable motorized conveyor roller500in accordance with various embodiments of the present disclosure. The reconfigurable housing can be reconfigured between an expanded state595B and a contracted state595A (and any dimensions there between). As describe herein, the reconfigurable housing can include a plurality of curved plates such as curved plates580A and580B. Each of the curved plates can be separated by a respective surface gap of the reconfigurable housing. For example, the curved plate580A can be separated from the curved plate580B by a surface gap582. As depicted, the curved plates can be moved in a direction588out from a center axis586of the reconfigurable motorized conveyor roller500to expand the diameter of the reconfigurable housing (and width of the surface gap582accordingly). In addition, or alternatively, the curved plates can be moved in a direction592in towards the center axis586of the reconfigurable motorized conveyor roller500to compress the diameter of the reconfigurable housing (and width of the surface gap582accordingly).

In some embodiments, the reconfigurable motorized conveyor roller500can contract to a full tube design (e.g., with no surface gaps) in which the curved plates fit together with no surface gaps therebetween. In addition, or alternatively, as shown in the contracted state595A, the reconfigurable motorized conveyor roller500can contract to a partial tube design with at least one surface gap between each of the curved plates. As described above, the surface gaps can be covered, in some embodiments, by an expandable sleeve.

In some embodiments, the reconfigurable housing include an inner tube584disposed therein. The inner tube584can include plastic, metal, or any other material cylindrical tube disposed within the reconfigurable housing. The inner tube584can include a plurality of prominences such as prominence594outwardly (e.g., relative to the center axis586) protruding from the exterior surface of the inner tube584. Each prominence can be configured to fit to a respective surface gap when the reconfigurable housing is a contracted state595A as shown.

The inner tube584can include a solid cylindrical tube or an at least partially hollow cylindrical tube. For example, while described with reference to motorized conveyor rollers (e.g., such as motorized conveyor roller202ofFIG.2) for illustrative purposes, the techniques and mechanisms described can be equally applicable to non-motorized conveyor rollers (e.g., non-motorized conveyor roller204ofFIG.2). In some embodiments, the inner tube584can include a solid cylindrical tube when implemented in a non-motorized conveyor roller. In some embodiments, the inner tuber584can include an at least partially hollow cylindrical tube when implemented in a motorized conveyor roller. In this manner, components described herein with reference to the motorized rollers can be disposed within the inner tube584.

Turning back toFIG.5B, the housing adjustment assembly can be employed in the reconfigurable motorized conveyor roller500to cause the plurality of curved plates to expand and/or compress to convert the configuration of the reconfigurable motorized conveyor roller500.

The housing adjustment assembly575can include a cam slotted gear585and a drive gear590. The cam slotted gear585and the drive gear590can be disposed within the reconfigurable housing. Each curved plate of the plurality of curved plates (e.g., curved plate580) can include and/or be coupled or attached to a respective plate rod (e.g., plate rod582). The respective plate rod (e.g., plate rod595) can be coupled, attached, affixed, fitted, etc. to a respective cam slot (e.g., cam slot584) of the cam slotted gear585.

The cam slotted gear585can be fit to a drive gear590that is configured to cause rotation of the cam slotted gear585to increase or decrease a diameter of the at least a portion of the reconfigurable housing. For example, the drive gear590can be rotated to cause a corresponding rotation of the cam slotted gear585. The cam slotted gear585can be rotated to convert between the contracted state570and the expanded state575. Rotating the cam slotted gear585can cause each of the respective plate rods and their corresponding curved plates to move to expand and/or compress the diameter of at least a portion of the reconfigurable housing. In this manner, different configurations of a reconfigurable motorized conveyor roller500can be dynamically achieved from a single design.

In some embodiments, the drive gear590can be operatively coupled to an actuator. The actuator can cause the drive gear590to rotate automatically. For example, as discussed with reference toFIG.4, the reconfigurable motorized conveyor roller500can include 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 reconfigurable motorized conveyor roller. In some embodiments, the drive gear590is operatively coupled to the motor assembly and the motor assembly can be configured to rotate the drive gear590to cause the rotation of the cam slotted gear585.

In some embodiments, an actuator can cause the drive gear590to automatically rotate in response to a stimulus (e.g., user input, etc.). For example, in some embodiments, as discussed with reference toFIG.4, the reconfigurable motorized conveyor roller500can include a controller component in electronic communication with the motor assembly, the drive assembly, and/or the housing adjustment assembly. In some embodiments, the controller component can be configured to cause the rotation of the drive gear590responsive to an input such as, for example, a user input.

The housing adjustment assembly can be employed in the reconfigurable motorized conveyor roller500for manually and/or automatically controlling the configuration of the reconfigurable motorized conveyor roller500to help form different sections of a conveyor line. In some embodiments, for example where the conveyor line includes a fixed frame, the reconfigurable motorized conveyor roller500can be controlled to change a configuration during the assembly process for a conveyor line. In addition, or alternatively, the reconfigurable motorized conveyor roller500can be controlled to dynamically change a configuration during use of the assembly line.

For example,FIG.5Dillustrates a flexible conveyor line571using example motorized conveyor rollers500in accordance with various embodiments of the present disclosure. The flexible conveyor line571can be reconfigured in different arrangements to modify a path of items578being transported by the flexible conveyor line571.

For example, the flexible conveyor line571can include a flexible frame. The flexible conveyor line571can be dynamically changed between (i) a straight configuration572with a plurality of motorized conveyor rollers500in a straight configuration525and/or (ii) one or more curved configurations573in which a plurality of motorized conveyor rollers500are in various tapered configurations550. The flexible conveyor line571can be dynamically changed between each configuration by modifying the configurations of the motorized conveyor rollers included in the flexible conveyor line571.

In this manner, motorized conveyor rollers500in a flexible conveyor frame can be configured in a straight or tapered shape with respect to the desired destination (e.g., a first bay574, a second bay576) of an item578. This dynamic property of the motorized conveyor rollers500allows one flexible conveyor line571to be used to unload and/or load containers (e.g., such as a tractor container577) to/from multiple areas such as, for example, the first bay574and the second bay576. The configuration of the flexible conveyor line571can be dynamically changed while the conveyor line is running to dynamically alter an end destination for the items578.

WhileFIGS.5A-Ddepict an example reconfigurable motorized conveyor roller500, it is noted that the scope of the present disclosure is not limited to the examples shown inFIGS.5A-D. An example reconfigurable motorized conveyor roller500in accordance with the present disclosure can comprise one or more additional and/or alternative elements, and/or can be different from that illustrated inFIGS.5A-D.

By way of example, although not explicitly shown inFIGS.5A-D, it should be noted that the housing adjustment assembly can be disposed at multiple positions within the reconfigurable housing. For instance, multiple housing adjustment assemblies can be disposed within the reconfigurable housing such as, for example, at the first position555and the second position560. The multiple housing adjustment assemblies can be advantageous to enable variable diameters at each side of the reconfigurable housing. The multiple adjustment assemblies can be simultaneously adjusted to uniformly increase and/or decrease a diameter of the reconfigurable motorized conveyor roller500in a straight configuration525or a tapered configuration550.

In addition, or alternatively, multiple reconfigurable motorized conveyor rollers500can be attached to create one or more different modular configurations.FIG.6, for example, provides a schematic diagram depicting a modular reconfigurable motorized conveyor roller600in accordance with various embodiments of the present disclosure. The modular reconfigurable motorized conveyor roller600can include multiple reconfigurable motorized conveyor rollers605,610, and615that can be connected to form an aggregate motorized conveyor roller620. In some embodiments, the modular reconfigurable motorized conveyor roller600can include a roller belt625disposed thereon. Using the techniques described herein, the aggregate motorized conveyor roller620can be adjusted to maintain enough intact between aggregate motorized conveyor roller620and the roller belt625to prevent belt slip due low tension between aggregate motorized conveyor roller620and the roller belt625.

WhileFIG.6depicts an example modular reconfigurable motorized conveyor roller600, it is noted that the scope of the present disclosure is not limited to the examples shown inFIG.6. An example modular reconfigurable motorized conveyor roller600in accordance with the present disclosure can comprise one or more additional and/or alternative elements, and/or can be different from that illustrated inFIG.6.

FIG.7illustrates an example shoe integrated motorized conveyor roller700in accordance with various embodiments of the present disclosure. The shoe integrated motorized conveyor roller700can be similar the reconfigurable motorized conveyor roller500discussed above in connection withFIGS.5A-D. For instance, the shoe integrated motorized conveyor roller700can be part of a conveyor/conveyor system and can be configured to drive one or more non-motorized conveyor rollers that are operatively coupled thereto. The shoe integrated motorized conveyor roller700can 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).

The shoe integrated motorized conveyor roller700can include a housing705. The housing705can include the reconfigurable housing of the reconfigurable motorized conveyor roller500discussed above in connection withFIGS.5A-D. In addition, or alternatively, the housing705can include a different housing. For example, the housing705can include a non-configurable housing with a hollow cylindrical body and can comprise a solid metal, plastic, and/or combinations thereof.

The housing705can be configured to include and/or contain one or more components/elements of the reconfigurable motorized conveyor roller500. For instance, the reconfigurable housing can include an at least partially hollow body, a first end cap defining a first end/surface of the reconfigurable housing, a first appendage configured 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), a second end cap defining a second end/surface of the housing, and/or a second appendage configured 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 described herein with reference to the example integrated motorized conveyor roller300ofFIG.3. In addition, or alternatively, the housing705can include any one of the power cable, first end cap, second end cap, motor assembly, load sensor, drive assembly, controller component and/or bearing assembly as described herein with reference to the example integrated motorized conveyor roller400ofFIG.4. In some embodiments, the housing705can include the housing adjustment assembly as described herein with reference to the example reconfigurable motorized conveyor roller500ofFIG.5.

The shoe integrated motorized conveyor roller700can include an integrated shoe sorter assembly710. The integrated shoe sorter assembly710can include a shoe slider component (partially shown inFIG.7) at least partially disposed on an exterior surface of the housing705and a shoe adjustment component (not shown inFIG.7) disposed within the housing705that is operable to modify a position of the shoe slider component relative to the housing705. For instance, the shoe slider component can be moveable between the first end702and the second end704of the housing705.

In some embodiments, the shoe slider component can be connected to the shoe adjustment component through a surface gap715of the housing705. The housing705, for example, can include at least one surface gap715. By way of example, the housing can include a plurality of curved plates as described herein with reference to the example reconfigurable motorized conveyor roller500ofFIG.5. In some embodiments, the housing can include a plurality of surface gaps (e.g., surface gap715) including at least one surface gap between each of the plurality of curved plates. The shoe slider component can be connected to the shoe adjustment component through at least one surface gap (e.g., surface gap715) of the housing705.

In addition, or alternatively, the shoe slider component can be connected to the shoe adjustment component through the surface of the housing705, for example, using one or more magnetic mechanisms to create a connection through a solid material.

WhileFIG.7depicts an example shoe integrated motorized conveyor roller700, it is noted that the scope of the present disclosure is not limited to the examples shown inFIG.7. An example integrated shoe sorter assembly710in accordance with the present disclosure can comprise one or more additional and/or alternative elements, and/or can be different from that illustrated inFIG.7.

Turning toFIGS.8A-B,FIGS.8A-8Billustrate an example integrated shoe sorter assembly710in accordance with various embodiments of the present disclosure.FIG.8Adepicts an example shoe adjustment component800in accordance with various embodiments of the present disclosure.FIG.8Bdepicts an example shoe slider component850in accordance with various embodiments of the present disclosure. For ease of explanation, the shoe adjustment component800and the shoe slider component850are discussed herein with reference to the shoe integrated motorized conveyor roller700discussed above in connection withFIG.7. The shoe adjustment component800and the shoe slider component850are not limited to shoe integrated motorized conveyor roller700and can be integrated with any conveyor roller (e.g., drive conveyer rollers, non-drive conveyor rollers, etc.).

As depicted, the example shoe adjustment component800can include a lead screw805. The lead screw805can include a mechanical linear actuator that converts rotational motion into linear motion. The lead screw805is provided as one embodiment of the shoe adjustment component800. The shoe adjustment component800can include any other mechanism capable of causing linear motion for an object such as, for example, one or more solenoids, linear motors, or any other mechanism.

The lead screw805can be disposed within the housing705of the shoe integrated motorized conveyor roller700and extend linearly along the length of the housing705. For instance, the lead screw805can linearly extend from the first end702to the second704of the housing705. The lead screw805can be disposed in one or more alternative positions within the housing705including, for example, at a central axis of the housing705of the housing705, an offset center of the housing705including a threshold distance from the central axis of the housing705, etc. In some embodiments, the shoe adjustment component800can include a plurality of lead screws (or other linear actuating mechanism) disposed at each of a plurality of positions within the housing705.

The shoe adjustment component800can include the lead screw805extending along the length of the housing705and a nut810coupled to the lead screw805. The nut810can be include interior threads compatible with exterior threads of the lead screw805such that rotation of the lead screw805causes the nut810to move in a direction relative to the length of the housing705. For instance, the rotation of the lead screw805can linearly move the nut810between the first end702and the second end704of the housing. The lead screw850can be rotated independent of the movement of the housing705.

The example shoe slider component850can include an exterior ring855that, at least partially, encircles the exterior surface860of the housing705. In some embodiments, the exterior ring855can include an expandable ring that encircles the exterior surface860of the housing705. This can be advantageous to allow the housing705to expand and compress in accordance with various embodiments of the present disclosure.

The example shoe slider component850can be attached, affixed, coupled, etc. to the shoe adjustment component800. As one example, the exterior ring855of the shoe slider component850can be attached to one or more connecting links (e.g., connecting link865) and the one or more connecting links can be attached to the nut810of the shoe adjustment component800. The connecting links (e.g., connecting link865) can cause the exterior ring855to linearly move with the nut810of the shoe adjustment component800.

In some embodiments, the lead screw805can be operatively coupled to an actuator. The actuator can cause the lead screw805to rotate automatically. For example, as discussed with reference toFIG.4, the shoe integrated motorized conveyor roller700can include a motor assembly and a drive assembly at least partially disposed within the housing705that are configured to cause rotation of at least a portion of the shoe integrated motorized conveyor roller700. In some embodiments, the lead screw805can be operatively coupled to the motor assembly and the motor assembly can be configured to rotate the lead screw805to cause the nut810to move linearly along the length of the housing. It is noted that the lead screw850is rotated independent of the rotation of the housing705. The lead screw810can be stationary while the housing705is rotating or can be rotating at a faster or slower rate than the rotation of the housing705. The lead screw805can be rotated while the housing705is stationary.

In some embodiments, an actuator can cause the lead screw805to automatically rotate in response to a stimulus (e.g., user input, etc.). For example, in some embodiments, as discussed with reference toFIG.4, the shoe integrated motorized conveyor roller700can include a controller component in electronic communication with the motor assembly, the drive assembly, and/or the integrated shoe sorter assembly710. In some embodiments, the controller component can be configured to cause the rotation the lead screw805responsive to an input such as, for example, a user input.

WhileFIGS.8A-Bdepict an example integrated shoe sorter assembly710, it is noted that the scope of the present disclosure is not limited to the examples shown inFIGS.8A-B. An example integrated shoe sorter assembly710in accordance with the present disclosure can comprise one or more additional and/or alternative elements, and/or can be different from that illustrated inFIGS.8A-B.

FIG.9provides a schematic diagram depicting a cross-section side view of an example integrated shoe sorter assembly900in accordance with various embodiments of the present disclosure. In some embodiments, the integrated shoe sorter assembly900can be integrated in a reconfigurable motorized conveyor roller with a reconfigurable housing as discussed herein with reference toFIG.5. The housing can include a plurality of separate sections that can expand and contract to modify the diameter of at least a portion of the reconfigurable housing. For instance, in example embodiments, the reconfigurable housing can include a plurality of curved plates such as curved plate905that at least partially form a cylindrical tube. The each of the plurality of curved plates can be separated by a respective surface gap such as surface gap910.

The housing can include a surface gap910between at least two of the plurality of curved plates. The exterior ring855can include a prominence915extending through housing. The prominence915can be fitted within the surface gap910. In some embodiments, the housing can include a plurality of surface gaps (e.g., surface gap910). The exterior ring855can include one or a plurality of prominences (e.g., prominence915) corresponding to one or more of the surface gaps. In some embodiments, the exterior ring855can include a plurality of prominences that include a respective prominence fitted to each respective surface gap.

The exterior ring855can be attached to the nut810of the shoe adjustment component by a connecting link865attached to the prominence915fitted within the surface gap910. In some embodiments, the exterior ring855can be attached to the nut810by a plurality of connecting links (e.g., connecting link865). For instance, the plurality connecting links can include a respective connecting link for one or more of the prominences of the exterior ring855.

The nut810can be coupled to the lead screw810disposed within the interior of the housing. The lead screw810can be positioned at one or more positions within the housing. For instance, the lead screw810can be positioned at an offset center of the housing interior. The offset center of the housing interior can include a threshold distance from a center shaft920disposed within the housing. The center shaft920, for example, can be disposed along a center axis of the housing and the lead screw810can be positioned a threshold distance from the center axis.

WhileFIG.9depicts an example integrated shoe sorter assembly900, it is noted that the scope of the present disclosure is not limited to the examples shown inFIG.9. An example integrated shoe sorter assembly900in accordance with the present disclosure can comprise one or more additional and/or alternative elements, and/or can be different from that illustrated inFIG.9.

Referring now toFIG.10, a schematic diagram depicting an example controller component1000in electronic communication with a motor assembly1009, integrated shoe sorter assembly1011and housing adjustment assembly1013of a motorized conveyor roller in accordance with various embodiments of the present disclosure is provided. As shown, the controller component1000comprises processing circuitry1001, a communication element1003, input/output element1005, a memory1007and/or other components configured to perform various operations, procedures, functions or the like described herein.

In some embodiments, the controller component1000can be or comprise a printed circuited board (PCB). In some examples, the controller component1000(e.g., PCB) can 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 circuitry, 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 circuitry1001can 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.10as a single processor, in an embodiment, the processing circuitry1001can include a plurality of processors and signal processing modules. The plurality of processors can be embodied on a single electronic device or can be distributed across a plurality of electronic devices collectively configured to function as the circuitry of the motorized conveyor roller. The plurality of processors can be in operative communication with each other and can be collectively configured to perform one or more functionalities of the circuitry of the motorized conveyor roller as described herein. In an example embodiment, the processing circuitry1001can be configured to execute instructions stored in the memory1007or otherwise accessible to the processing circuitry1001. These instructions, when executed by the processing circuitry1001, can cause the circuitry of the 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 circuitry1001can include an entity capable of performing operations according to embodiments of the present disclosure while configured accordingly. Thus, for example, when the processing circuitry1001is embodied as an ASIC, FPGA or the like, the processing circuitry1001can include specifically configured hardware for conducting one or more operations described herein. Additionally, or alternatively, when the processing circuitry1001is embodied as an executor of instructions, such as can be stored in the memory1007, the instructions can specifically configure the processing circuitry1001to perform one or more algorithms and operations described herein.

Thus, the processing circuitry1001used herein can 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 can be provided dedicated to wireless communication functions and one processor dedicated to running other applications. Software applications can be stored in the internal memory before they are accessed and loaded into the processors. The processors can include internal memory sufficient to store the application software instructions. In many devices, the internal memory can 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 memory1007can include suitable logic, circuitry, and/or interfaces that are adapted to store a set of instructions that is executable by the processing circuitry1001to perform predetermined operations. Additionally, or alternately, the memory1007can be configured to store data/information, application programs, instructions, etc., so that the controller component1000can execute various functions according to the embodiments of the present disclosure. For example, in at least some embodiments, the memory1007is configured to cache input data for processing by the processing circuitry1001. Thus, in at least some embodiments, the memory1007is configured to store program instructions for execution by the processing circuitry1001. The memory1007can store information in the form of static and/or dynamic information. When the functions are executed, the stored information can be stored and/or used by the controller component1000. Example memory embodiments can 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 memory1007can be integrated with the processing circuitry1001on a single chip, without departing from the scope of the disclosure.

The communication element1003can 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 memory1007) and executed by a processing component1000(for example, the processing circuitry1001). In some embodiments, the communication element1003(as with other components discussed herein) can be at least partially implemented as the processing circuitry1001or otherwise controlled by the processing circuitry1001. In this regard, the communication element1003can communicate with the processing circuitry1001, for example, through a bus. The communication element1003can 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 element1003can be configured to receive and/or transmit any data that can be stored by the memory1007by using any protocol that can be used for communication between apparatuses. The communication element1003can additionally or alternatively communicate with the memory1007, the input/output element1005and/or any other component of the processing component1000, for example, through a bus.

In some embodiments, the processing component1000can comprise an input/output element1005. The input/output element1005can communicate with the processing circuitry1001to receive instructions input by the user and/or to provide audible, visual, mechanical, or other outputs to the user. Therefore, the input/output element1005can 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 element1005can be implemented on a device used by the user to communicate with the processing component1000. The input/output element1005can communicate with the memory1007, the communication element1003and/or any other component, for example, through a bus. One or a plurality of input/output modules and/or other components can be included in the processing component1000.

Referring now toFIG.11, a schematic diagram depicting an example controller component1100of an integrated motorized conveyor roller in accordance with various embodiments of the present disclosure is provided. In some examples, the controller component1100can be similar or identical to the controller component417described above in connection withFIG.4.

In some embodiments, as depicted, the controller component1100can be or comprise a PCB stack comprising a plurality of PCBs in electronic communication with one another via interface connectors. In particular, as depicted, the controller component1100comprises a power module1101, a controller module1103and a wireless module1105.

As depicted inFIG.11, the power module1101comprises a first PCB configured to control operations of electronic elements of the motorized conveyor roller. In the depicted embodiment, the power module1101is configured to receive/condition a power supply and comprises one or more of 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 component1100comprises a controller module1103. The controller module1103comprises a second PCB that is configured to control various operations of the integrated motorized conveyor roller. In the depicted embodiment, the controller module1103comprises at least one sensing element (e.g., photo eye) circuit, interface connector(s), a micro controller unit (MCU) and a motorized conveyor roller configuration management circuit.

As noted above, the controller component1100comprises a wireless module1105. The wireless module1105comprises a third PCB 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.11, the wireless module1105comprises 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.11, the controller component1100/motorized conveyor roller can 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 component1100can 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 can 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 can be measured and stored in memory. In some examples, the controller component1100can 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 component1100can 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 component1100can 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.11depicts an example controller component1100(e.g., PCB stack), it is noted that the scope of the present disclosure is not limited to the example shown inFIG.11. An example controller component1100in accordance with the present disclosure can comprise one or more additional and/or alternative elements, and/or can be different from that illustrated inFIG.11. For example, an integrated motorized conveyor roller in accordance with the present disclosure can comprise a single PCB or more than three PCBs.

Referring now toFIG.12, a flowchart diagram illustrating example operations1200in accordance with various embodiments of the present disclosure is provided. In some examples, the example operations1200can be performed by various system components (for example, but not limited to, processing circuitry of a computing entity106described above with regard toFIG.1). The system components can be or comprise a central server. In some examples, the system components can include processing circuitry that can be electrically coupled to and/or in electronic communication with other circuitries, such as, but not limited to, one or more motorized conveyor rollers (such as, for example, the integrated motorized conveyor roller400, the reconfigurable motorized conveyor roller500, modular reconfigurable conveyor roller600, shoe integrated motorized conveyor roller700, described above in connection withFIGS.5-8).

The example operations1200can include an operation1205. At operation1205, the processing circuitry can receive input comprising configuration data. In some embodiments, the configuration data can identify a desired configuration for a motorized conveyor roller. The configuration data, for example, can indicate a taper configuration, a straight configuration, and/or any other configuration for a conveyor roller. In some embodiments, the configuration data can include instructions to increase and/or decrease a dimension (e.g., a diameter) of at least a portion a housing of the reconfigurable motorized conveyor roller. The configuration data can include manual input received from an operator of a conveyor system.

The example operations1200can include an operation1210. At operation1210, the processing circuitry can cause, by the controller component and based at least in part on the configuration data, a movement (e.g., a rotation, etc.) of at least a portion of a housing adjustment assembly of the motorized roller to modify one or more dimensions of a housing of the motorized roller. For example, the controller component can interface with an actuator to cause a rotation (or other movement) of at least the portion of the housing adjustment assembly. The actuator can include a motor such as, for example, a motor assembly integrated with the motorized conveyor roller. In addition, or alternatively, the actuator can include another motor assembly.

Referring now toFIG.13, a flowchart diagram illustrating example operations1300in accordance with various embodiments of the present disclosure is provided. In some examples, the example operations1300can be performed by various system components (for example, but not limited to, processing circuitry of a computing entity106described above with regard toFIG.1). The system components can be or comprise a central server. In some examples, the system components can include processing circuitry that can be electrically coupled to and/or in electronic communication with other circuitries, such as, but not limited to, one or more motorized conveyor rollers (such as, for example, the integrated motorized conveyor roller400, the reconfigurable motorized conveyor roller500, modular reconfigurable conveyor roller600, shoe integrated motorized conveyor roller700, described above in connection withFIGS.5-8).

The example operations1300can include an operation1305. At operation1305, the processing circuitry can receive input comprising configuration data. The configuration data, for example, can identify a desired movement for an integrated shoe sorter assembly of a motorized conveyor roller. The configuration data can specify a position for an exterior shoe of the shoe shorter assembly, a desired movement for the exterior shoe, a timing for the desired movement, and/or any other information associated with the movement of the integrated shoe sorter assembly. The configuration data can include manual input received from an operator of a conveyor system.

The example operations1300can include an operation1310. At operation1310, the processing circuitry can cause, by the controller component and based at least in part on the configuration data, at least a portion of the integrated shoe sorter assembly of the motorized conveyor roller to cause a movement of a shoe slider component along an exterior of the housing of the motorized conveyor roller. For example, the controller component can interface with an actuator to cause the rotation (or other movement) of at least the portion of the integrated shoe sorter assembly. The actuator can include a motor such as, for example, a motor assembly integrated with the motorized conveyor roller. In addition, or alternatively, the actuator can include another motor assembly.

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 is 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 can 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 can 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.