CN113905962A

CN113905962A - Multi-stage conveyor unit for separating parcels

Info

Publication number: CN113905962A
Application number: CN202080040007.XA
Authority: CN
Inventors: S·V·施罗亚德; R·B·哈格曼; T·R·赫曼
Original assignee: Fives Intralogistics Corp
Current assignee: Fives Intralogistics Corp
Priority date: 2019-03-27
Filing date: 2020-03-27
Publication date: 2022-01-07
Anticipated expiration: 2040-03-27
Also published as: EP3956252A1; EP3956252A4; CN113905962B

Abstract

A multi-stage, multi-channel singler conveyor system for separating side-by-side packages in stages. A first conveying path having a high friction surface is combined with and in lateral flow communication with a second conveying path adjacent thereto having a lower friction conveying surface including forward and lateral conveying forces for urging parcels forward and away from the first conveying path. The conveying surface of the second conveying channel may form an inclined plane extending above the inner lateral receiving edge of an adjacent third conveying channel having a high-friction surface. Each high friction transport channel may utilize multiple narrow bands to vary the area of the high friction surface. Assembling one or more multiple lanes comprising narrow belts end-to-end on a conveyor, or assembling multiple lane conveyors end-to-end, provides a means to control the dwell time and lateral movement of articles.

Description

Multi-stage conveyor unit for separating parcels

Reference to related applications

This application claims priority to U.S. provisional application serial No. 62/824,557 filed on day 27, 3/2019 and U.S. provisional application serial No. 16/833,493 filed on day 27, 3/2020, both of which are incorporated herein by reference in their entireties.

Technical Field

The present invention generally relates to a multi-stage conveyor system having conveying surfaces arranged in an adjacent side-by-side configuration for separating side-by-side packages in multiple stages.

Background

The present invention relates to material handling and in particular to a method and apparatus for conveying packages and a mechanism for controlling the position of packages on a conveyor.

Conventional conveyor systems convey large quantities of packages at high speeds, particularly in the package delivery industry, where packages are sorted according to a desired category. The efficiency of handling packages is severely reduced when a plurality of smaller packages, irregularly sized or shaped articles or a mixture of large and small articles are passed together as a single unit on a conveyor.

Problems arise in scanning and separating packages and parcels traveling through a conveyor system as an aggregate unit rather than as a single queue. Large packages obscure small packages, while side-by-side small packages can cause problems as they pass through the barcode scanner at the same time, leading to confusion and sorting problems. Furthermore, packages such as bags or other flexible containers having unevenly distributed weight or where the width and length of the container are very large or where the container is soft or only partially full (such as a soft partially filled bag of mail) tend to present sorting problems in that they do not move in a predictable lateral pattern.

The use of a collating conveyor, sometimes referred to as a singulator, uses a plurality of driven rollers or belts, the axes of which extend obliquely to the conveying direction, causing the packages to be displaced laterally towards one side of the conveyor and become aligned behind one another.

A typical single-selector conveyor system for sorting packages in a typical application includes the equipment used to take randomly arranged articles and convert a random stream into a single stream of articles in line. The articles are conveyed forward under forward and side forces and aligned along one side. The apparatus may be placed after the aligned stream of articles and articles that do not reach all the way to the wall of the aligned side are separated laterally away from the main wrap stream. Typical configurations direct laterally removed articles and recycle them back to the skewed roller section for another pass and have an opportunity to align with the wall for passage with the main flow line. The articles are conveyed forward under forward and side forces and aligned along one side.

The current technology is well suited for rigid packages, such as boxes, but items that do not behave like rigid items, like flexible packages or big bags containing several small items, are separated according to their center of gravity and tend to be removed from the side-by-side stream even if the item is not side-by-side with another item.

Rearranging strings of articles into a single queue is difficult to achieve with packages having one dimension that is significantly larger than the other. Conventional article conveyors have difficulty separating side-by-side pairs of articles into individual queues, particularly over short distances and dwell times, if multiple packages, partially filled bags or cases, or long, elongated articles of manufacture are conveyed side-by-side with uneven loading. Packages of unequal weight, irregular size, and offset center of gravity may be repeatedly transferred to the output of the singulating conveyor. Sometimes, instead of being positioned in a single queue, some packages may be conveyed alongside one another, i.e. in two side-by-side travelling in side-by-side relationship. The combined width of the two packages may present problems at a location downstream of the conveyor system.

There is a need for a singulator conveyor with separation capability that effectively separates side-by-side articles, including packages and packs of unequal load capacity, such as different size packages (e.g., boxes, flat packages, and soft packages), partially filled bags or cases, or long, elongated articles with an offset center of gravity, into one or more rows of singulated articles over a short distance and dwell time.

The present invention ensures that two or more small articles side by side with each other are separated while allowing large articles to pass through the singler even when the articles are a large pocket of small articles.

Conventional conveying systems of the prior art are well suited for rigid packages (e.g., boxes), but items that do not behave as rigid items, such as large bags of small items, tend to be removed from the side-by-side flow even when the item is not side-by-side with another item. The present invention provides a device and method that can separate rigid parcels from big and small bags.

The singulator conveyor system includes a selected number of conveyors or conveyor conveying lanes arranged in an adjacent side-by-side configuration for separating side-by-side packages and parcels having unequal loads, such as different sized packages (e.g., boxes, flat packages, and soft packages), partially filled bags or bins, or long elongated articles having an offset center of gravity into one or more rows of singulated articles over short distances and dwell times. The singler delivery system ensures that two or more small items side-by-side with each other are separated while allowing large items to pass through the singler even when the items are a large bag of small items.

Furthermore, the present invention provides a multi-stage conveyor having a plurality of conveying channels capable of separating packages by conveying the packages (forward) or (forward and lateral) on high and/or low friction conveying surfaces positioned at selected lateral angles.

Disclosure of Invention

A multi-stage conveyor system having conveying surfaces arranged in an adjacent side-by-side configuration for separating side-by-side packages in stages. A first conveying path having a high friction surface for conveying articles forward may be combined with a second conveying path adjacent thereto having a lower friction conveying surface, the second conveying path including forward and lateral conveying forces urging parcels forward and away from the first conveying path. The lateral receiving edge of the second conveyor channel may be positioned below the outer lateral edge of the first conveyor channel. The second conveyor channel may be laterally inclined and angled laterally upwardly, with a raised outer edge that is flush with or below the lateral receiving edge of the adjacent third conveyor channel. The conveying surface of the second conveying channel may form an inclined plane extending above the inner lateral receiving edge of an adjacent third conveying channel having a high-friction surface. The dwell time and lateral movement of packages on selected conveying lanes of a multi-stage conveyor can be controlled by selecting the amount of high friction conveying surface of selected adjacent conveying lanes. Each high friction transport channel may utilize multiple narrow bands to vary the area of the high friction surface. The width or number of high friction channels is increased to increase the high friction conveying surface area adjacent to the inner conveyor or walls on the first channel side and to decrease the width of the conveyor away from the channel side to incline the low friction roller conveying surface with power therebetween. Typically, an increase in width on the inner channel side corresponds to a decrease in width on the outer channel on the exit side of the conveyor. Assembling a plurality of channels end-to-end in a single conveyor or assembling at least two conveyor ends end-to-end of a multi-channel conveyor having different arrangements in forward and lateral flow communication provides a multi-stage conveyor for forming high surface areas at selected locations in lateral flow communication with a conveyor channel having a low friction conveying surface and controlling movement of parcels.

In a preferred embodiment, the width of the high friction surface of the first conveyor channel increases and the width of the high surface area of the third conveyor channel decreases on the side facing away from the channel. The width of the low-friction second conveyance path provided between the first conveyance path and the third conveyance path is changed in accordance with the change in the width of the first conveyance path and the second conveyance path. The variation in the width of the high friction first conveyor channel and the high friction third conveyor channel varies accordingly such that the width of the first conveyor surface, the second conveyor surface and the third conveyor surface is the same from the feed end of the conveyor to the discharge end of the conveyor.

The present invention relates to a conveying system for conveying, aligning and organizing into a single queue relationship articles comprising a random supply of side-by-side articles received from an infeed conveyor. The articles are conveyed to a singulator apparatus having separation capability, which includes a single or multi-stage and/or multi-channel conveyor assembly following the infeed conveyor. The multi-channel singler unit may include several stages that vary the width of the high-friction conveying surface and the lower-friction conveying surface adjacent to each other at selected lateral angles to provide laterally inclined planes to control lateral movement of the packages or parcels. A singleton is disposed in alignment downstream of the infeed conveyor for receiving articles therefrom.

Articles received from the infeed conveyor are conveyed through a conveyor assembly defining a singler including three conveyors arranged in an adjacent side-by-side configuration, which may have a plurality of conveying lanes for conveying articles in a single file row in spaced apart relation. The three conveyors define first, second and third conveying paths which are arranged alongside one another and are driven in such a way as to exert mutually divergent conveying forces for separating and moving the side-by-side packages or articles. A multi-stage singulator conveyor system has conveying surfaces arranged in an adjacent side-by-side configuration for separating side-by-side packages in each stage. By selecting the amount of high friction conveying surface provided by one or more adjacent conveying channels, the forward and lateral movement of packages on the multi-stage singulating conveyor can be controlled. The apparatus may be placed after the aligned stream of articles, articles or packages such that articles that do not reach all the way to the wall on the aligned side are separated laterally away from the main stream of articles.

In a single stage singulator conveyor unit, a first stage includes a conveyor unit that includes a first high friction surface conveying path for conveying articles forward along an inner vertical sidewall. A second lower friction surface conveyance lane adjacent thereto and in lateral flow communication therewith includes both forward and lateral conveyance forces that urge articles forward and away from the first conveyance lane and vertical side walls. The second low-friction conveying path typically includes a series of driven rollers whose axes of rotation are inclined relative to the longitudinal direction of travel so that the packages are conveyed both longitudinally forward and laterally outward away from the first conveyor. The lateral receiving edge of the second conveyor passage is below the outer lateral edge of the first conveyor passage, and the second conveyor passage is laterally inclined and angled laterally upward so as to have a raised outer edge that is flush with or below the lateral receiving edge of the adjacent third conveyor passage. The conveying surface of the second conveying channel forms an inclined plane extending above the inner lateral receiving edge of an adjacent third conveying channel having a high-friction surface. Packages resting on the first conveyor or the first and second conveyors are conveyed through the singulator. Packages falling from the first conveyor, onto the second conveyor, or resting entirely on the second conveyor, are moved forward and laterally toward the third conveyor until the centers of gravity of the packages extend past the longitudinal edges of the third conveyor, transferring control to the third conveyor and the packages fall above an inclined plane or drop zone for recirculation or rerouting.

It is contemplated that the speeds of the first, second, or third conveyors and/or the conveying channels may be adjusted relative to each other to align articles thereon. In addition, the speeds of the conveying channels may be adjusted relative to each other to increase the separation capacity of the singler conveyor assembly.

It is an object of the present invention to provide a singler including a multi-lane conveyor assembly having at least three driven conveyor lanes disposed adjacent to one another in side-by-side relation. The transfer channel is located in a horizontal plane along its lateral axis. The laterally positioned side walls extend along the sides of a first conveying path which tends to convey articles forward and along the laterally positioned side walls.

It is an object of the present invention to provide a driven first conveying path including belts or rollers having high friction surfaces for conveying articles along vertical sidewalls along which incoming articles are positioned at a selected speed.

It is an object of the invention to provide for a package resting on a first conveyor lane with a high friction surface and an object resting on the first conveyor lane and a second conveyor lane with a lower friction surface to be moved forward.

It is an object of the present invention to provide a second conveyor having a lower friction surface conveyor lane that includes both forward and lateral conveying forces. The edge of the second conveying channel adjacent to the first conveying channel is arranged at a slightly lower level along the lateral axis of the first conveying channel, thus providing a drop (drop off). The lateral force of the second conveying path pulls the articles located on the second conveying path away from the first conveying path and the main flow sidewall, thereby separating two small articles that may enter alongside one another.

It is an object of the present invention to angle the lower friction conveying surface of the second conveying path vertically at a selected angle to the first conveying path to provide an inclined plane extending upwardly from the outer lateral edge of the first conveying path downwardly toward the third conveying path so that the inclined conveying plane of the second conveying path extends above the inner lateral receiving edge of the adjacent third conveying path.

It is an object of the present invention to provide a driven tertiary transport path having a high friction surface positioned laterally side by side with the secondary transport path on the side opposite the primary flow side of the primary transport path. In a preferred embodiment, the third conveyor channel is raised to the same height as the first conveyor channel. The conveying surface of the third conveying channel is higher than the level of the carrying surface of the second conveying channel, where they cooperate along their lateral edges.

It is an object of the invention to provide that the plane of the third conveyor channel extends above the edge of the surface of the second conveyor channel.

It is an object of the present invention to provide a device for separating packages travelling alongside one another so that packages or articles that do not come into contact with the surface of the first conveying channel and rest on the surface of the second conveying channel are carried forward and sideways at an upward angle towards the outer edge of the second conveying channel, forming a plane that extends just above the receiving edge of the third high-friction conveying channel. A portion of each article or package extending over the third conveyor lane will move up and over the third conveyor lane until the center of gravity extends beyond the inner lateral receiving edge of the third conveyor and the package drops onto the high friction surface of the third conveyor lane. Thus, when two articles are brought alongside one another into the singler, the articles located on the outside are transferred forwards and laterally until the centre of gravity exceeds the lateral edge of the second conveying path, at which point a clearly controlled transfer will take place, as the articles fall and rest on top of the third conveying path.

The object of the invention is that the speeds of the first, second and third conveyor paths can be adjusted relative to each other.

It is an object of the present invention that the first and third transfer lanes travel at the same speed rate so that large parcels resting on the first and third transfer lanes are transferred by the singler conveyor device.

Another feature of the present invention addresses the problem related to packages having convexly curved bottoms. It will be appreciated that such a curved bottom, even though it may overlap the first and second conveying paths, may tend to contact only the second conveying path and thus be unnecessarily fed to the return conveyor. However, the curved bottom is likely to make at least line contact with the first conveyor channel, while the second conveyor channel surface is positioned slightly below the surface of the first conveyor channel and slopes slightly downward toward the first channel at a selected angle of up to 30 degrees and preferably 1 to 10 degrees. Thus, the curved bottom of the package will tend to become oriented so as to come into contact with at least the edge of the high friction surface of the first conveying channel. Due to the high friction coefficient of the conveying surface of the first conveying channel, the first conveying channel will control the direction of travel of the packages.

Other objects, features and advantages of the present invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings which illustrate preferred embodiments of the invention.

Drawings

The invention will be better understood by reference to the following description taken in conjunction with the accompanying drawings, in which like reference numerals refer to like parts throughout the several views, and in which:

FIG. 1 is a top view showing an infeed conveyor including a plurality of powered oblique rollers that conveys articles along laterally positioned side walls onto an singler having: a first conveying path surface having a high friction surface adjacent to and juxtaposed with a side wall having a path width equal to the minimum article width; a second conveyor lane surface having a low friction surface comprising skewed rollers juxtaposed adjacent to the first conveyor lane; and a third carryway surface having a high-friction surface adjacent to and juxtaposed with the second carryway, wherein the bags or pouches are disposed on the infeed conveyor;

FIG. 2 is a top end view of FIG. 1 showing the conveying surface of the second conveying path angled vertically upward to form an inclined plane extending above the lateral receiving edge of the third conveying path, with the inner lower receiving edge of the second conveying path extending below the outer edge of the first conveying path, and with the outer lateral edge of the second conveying path being flush with or below the inner lateral receiving edge of the third conveying path surface.

Fig. 3 shows a multi-stage multi-channel singler conveyor unit having adjacent lateral conveying surfaces that are in flow communication with one another, the conveyor unit comprising: a first inner channel having a high friction conveying surface comprising one or more narrow high friction belts; a second intermediate channel having a lower friction conveying surface comprising skewed rollers or a lower friction belt; and a third outer channel having a high-friction conveying surface comprising one or more narrow bands.

FIG. 4 shows the multi-level multi-lane singler conveyor unit of FIG. 3 supporting a plurality of side-by-side cases on first, second and third conveyors, and a drop ramp;

FIG. 5 shows the first conveyor horizontal to the third conveyor and the lateral receiving edge of the second conveyor is below the outer edge of the first conveyor and angled upward so that the outer edge of the second conveyor is below the receiving edge of the third conveyor but the plane formed by the transverse angle extends above the third conveyor;

FIG. 6 is an enlarged view of a portion of FIG. 2 showing the outer lateral edge of the lower friction conveying surface of the second conveying path disposed at a height below the height of the conveying surface of the third conveying path, and the plane of the second conveying path extending above the surface of the third conveying path;

FIG. 7(a) is a downstream end view of the multi-stage conveyor showing the positioning of the high friction surfaces of the first and third conveying lanes relative to the lower friction surface of the intermediate or second conveying lane, showing the gap between the oblique rollers of the second lane, the second conveying lane being angled laterally to form an oblique plane of the conveying surface including the second plane of the second conveying lane extending above (DIM C) the conveying surface of the third high friction conveying lane;

FIG. 7(b) is an upstream end view of the multi-stage conveyor showing the positioning of the high friction surfaces of the first and third conveying lanes relative to the lower friction surface of the intermediate or second conveying lane, showing the gap between the oblique rollers of the second lane, the second conveying lane being angled laterally to form an oblique plane of the conveying surface including the second plane of the second conveying lane extending above (DIM C) the conveying surface of the third high friction conveying lane;

FIG. 8(a) is a downstream end view of the multi-stage conveyor showing the positioning of the high friction surfaces of the first and third conveying lanes relative to the lower friction surface of the intermediate or second conveying lane, showing the gap between the oblique rollers of the second lane disposed at a lateral angle, thereby forming a conveying surface having a plane extending above the adjacent lateral edges of the high friction belt and a gap therebetween;

FIG. 8(b) is an upstream end view of the multi-stage conveyor showing the positioning of the high friction surfaces of the first and third conveying lanes relative to the lower friction surface of the intermediate or second conveying lane, showing the gap between the oblique rollers of the second lane disposed at a lateral angle, thereby forming a conveying surface having a plane extending above the adjacent lateral edges of the high friction belt and a gap therebetween;

FIG. 9(a) is a downstream end view of the multi-stage conveyor showing the positioning of the high friction surfaces of the first and third conveying lanes relative to the lower friction surface of the intermediate or second conveying lane, showing the lateral angle formed by the second lane extending upwardly from beneath the surface of the first lane having an outer lateral edge terminating adjacent the lateral receiving edge of the conveying surface of the third lane and beneath the plane of the conveying surface of the second plane extending above the plane of the outer high friction narrow band;

FIG. 9(b) is an upstream end view of the multi-stage conveyor showing the positioning of the high friction surfaces of the first and third conveying lanes relative to the lower friction surface of the intermediate or second conveying lane, showing the lateral angle formed by the second lane extending upward from below the surface of the first lane having an outer lateral edge terminating adjacent the lateral receiving edge of the conveying surface of the third lane and below the plane of the second planar conveying surface extending above the outer high friction narrow belt plane;

fig. 10 shows a large package abutting a vertical sidewall, the large package supported by a first high friction conveying surface comprising a belt, wherein a portion of the package extends across an intermediate low friction conveying surface comprising a plurality of rollers;

FIG. 11 is an enlarged view of a portion of FIG. 10 showing a package supported by the high friction surface of the first conveying path and the lower friction surface of the second conveying path, wherein the high friction surface prevents the package from moving laterally away from the vertical side wall;

figure 12 shows a multi-stage conveyor with small packages aligned with and conveyed directly through a first conveying path comprising a plurality of high friction narrow strips, and outward displacement of large packages having a portion located on a second conveying path comprising low friction skewed rollers positioned at a lateral angle of up to 30 degrees, and a portion of the cases extending over a third high friction conveying path comprising at least one narrow strip;

FIG. 13 shows the multi-stage conveyor of FIG. 12, wherein small packages are conveyed on a first high-friction conveying path comprising two narrow belts abutting the vertical side walls, while large packages have been transferred from a second conveying path low-friction skewed roller and supported by a third conveying path comprising a high-friction narrow belt, wherein a portion of the packages are suspended above the lower-friction conveying surfaces of the rollers;

fig. 14 is an isometric view showing a multi-stage conveyor having a first package conveyed forward and straight through along a vertical wall on a plurality of inner narrow high friction belts, a second package adjacent thereto conveyed forward and laterally upward on a second conveying path of lower friction skewed rollers angled upward toward a pair of narrow high friction belts, and a third package conveyed forward by a third adjacent second package, whereby the third package is conveyed forward by a third conveying path comprising a pair of outer high friction narrow belts;

FIG. 15 is a top plan view showing a small package that is narrower in width than the inner high friction conveying surface belt adjacent the vertical side walls and showing a large package with side edges supported by the inner high friction belt and outer edges of the package supported by the lower friction conveying rollers whereby the packages do not separate;

FIG. 16 is an end view showing a single-stage conveyor having a single package extending across first and third high-friction conveying lanes above a second, lower-friction conveying lane surface, allowing the package to pass through the conveyor;

fig. 17 is a top view showing a partially filled small wrap bag shown prior to entering a conveyor, wherein the bag is to be positioned and supported by first, second and third conveyor lanes, wherein the high friction surface of the first lane controls and limits lateral movement to move the bag through the conveyor;

figure 18 is an end view showing the partially filled small packets on the first, second and third transport paths with the high friction surfaces of the first and third paths controlling and restricting lateral movement so that the packets pass through the conveyor;

fig. 19 depicts a top view of a two-stage, multi-channel conveyor unit in which a first conveyor channel having a high friction surface comprises: a narrow three inch wide high friction inner belt adjacent the vertical wall, the inner belt extending the entire length of the conveyor; and includes six additional adjacently aligned three inch wide inner belts extending from a selected location near the center of the conveyor to the end of the conveyor in the second stage, an

A second conveying path having a lower friction surface is in lateral flow communication with the first conveying path, and a second intermediate conveying path includes a plurality of oblique rollers extending the entire length of the conveyor adjacent the first conveying path, outwardly displaced in a second stage, and having a lateral angle of up to 30 degrees to provide forward and lateral movement thereover, and

a third conveying path having a high friction surface and being in lateral flow communication with the second conveying path, wherein the third conveying path includes a nine inch wide outer high friction belt extending to a selected location near the center of the conveyor defining the first stage, whereby six belts adjacent the second terminate, the second path is outwardly displaced, and the three outer narrow belts extend the entire length of the conveyor of the second stage.

FIG. 20 shows a three-stage multi-stage conveyor having a high friction conveying surface formed by a plurality of narrow belts of varying numbers and lengths in lateral flow communication with a lower friction surface to provide a displacement region having a high friction conveying surface and a lower friction conveying surface to control lateral movement of packages thereon;

FIG. 21 shows a five-stage multi-stage conveyor having a high friction conveying surface formed of multiple narrow belts of different numbers and lengths in flow communication with a low friction surface to provide a displacement region having a high friction conveying surface and a lower friction conveying surface to control lateral movement of packages thereon;

FIG. 22 shows a two-stage multi-stage conveyor unit including a package resting on an infeed conveyor aligned with and in flow communication with the package, wherein the first conveying path;

FIG. 23 shows the two-stage, multi-stage conveyor unit of FIG. 22, including parcels resting on the first and second conveying lanes of the first stage;

FIG. 24 shows the two-stage multi-stage conveyor unit of FIG. 22 including packages resting on the first and second conveying lanes moving onto the second stage;

FIG. 25 shows the two-stage, multi-stage conveyor unit of FIG. 22, including parcels resting on the first and second conveying lanes of the second stage;

FIG. 26 shows the two-stage, multi-stage conveyor unit of FIG. 22, including a package passing through the first conveying path and a package resting on the third conveying path of the third stage;

fig. 27 shows a two-stage multi-stage conveyor unit;

FIG. 28 shows the three-stage multi-stage conveyor unit of FIG. 27 including a package resting on a first conveying path and two side-by-side packages resting on a second conveying path of the first stage;

fig. 29 shows the three-stage multi-stage conveyor unit of fig. 27 having a third stage comprising a package resting on the first conveying channel of the third stage and two side-by-side packages, with an intermediate package resting on the second low-friction conveying channel surface consisting of oblique rollers and with adjacent outer packages being conveyed upwardly and outwardly towards a high-friction conveying surface comprising a belt;

FIG. 30 shows the three-stage multi-stage conveyor unit of FIG. 29 with inner wraps resting on the first conveying path comprising the high friction belt and against the vertical side walls at the end of the third stage of the conveyor; and the outer wrap is pushed laterally away from the outer high friction belt resting on the third conveyor lane of the third stage, whereby the intermediate wrap has crossed the second low friction conveyor lane surface consisting of skewed rollers and moved laterally up and outward over the laterally inner edge of the third high friction belt, thereby resting the intermediate wrap on the outer high friction conveyor surface;

FIG. 31 shows a two-stage multi-stage conveyor with a parcel resting on a first conveying path of the second stage and a parcel resting on a second conveying path of the second stage;

FIG. 32 shows the two-stage multi-stage conveyor of FIG. 31 with a parcel resting on the first conveying path of the second stage passing to the receiving conveyor and a parcel resting on the third conveying path of the second stage traveling to the drop ramp;

FIG. 33 shows a two-stage multi-stage conveyor with a parcel resting on a first conveying path of the second stage and a parcel resting on a second conveying path of the second stage;

FIG. 34 shows the two-stage multi-stage conveyor of FIG. 33 with a parcel resting on the first high friction conveying corridor of the second stage passing to the receiving conveyor and a parcel resting on the third high friction conveying corridor of the second stage traveling to the drop ramp and an additional parcel resting on the second conveying corridor, the parcel falling if the center of gravity extends onto the drop ramp;

FIG. 35(a) is an isometric view of a multi-stage conveyor showing a first small box on a first inner conveying channel having a high friction surface comprising three spaced apart aligned narrow strips adjacent a vertical wall in flow communication with a second intermediate conveying channel comprising a plurality of oblique rollers positioned to have a lateral angle of 1-30 degrees and provide forward and lateral movement for a second large box supported thereon, a portion of the distal end of the box extending over an adjacent receiving edge of a third outer conveying channel having a high friction surface comprising a pair of narrow high friction strips;

FIG. 35(b) is an isometric view of the multi-stage conveyor of FIG. 35(a) showing the forward and lateral movement of the second large box on the second conveying path;

FIG. 35(c) is an isometric view of the multi-stage conveyor of FIG. 35(b) showing the forward and lateral movement of the second large box on the second conveying path;

FIG. 35(d) is an isometric end view of the multi-stage conveyor of FIG. 35(c) wherein the lateral momentum of the boxes on the second conveying path including the powered oblique rollers carries the second large box upward, wherein the center of gravity causes the box to fall onto the edge of the third conveying path which pulls the box forward until the center of gravity shifts, causing the box to fall from the third conveyor onto the exit ramp;

FIG. 35(e) is an isometric end view of the multi-stage conveyor of FIG. 35(d) with the center of gravity of the second large box extending over the edge of the ramp adjacent the third conveying channel and a portion of the second large box falling onto the ramp;

FIG. 35(f) is an isometric downstream view of the multi-stage conveyor of FIG. 35(e) with the second large box falling onto the ramp for recirculation or removal;

FIG. 36(a) is a downstream cross-sectional view of the multi-stage conveyor of FIGS. 35(a-f) showing a first small box on a first inner conveying channel having a high friction surface comprising two spaced apart aligned narrow high friction bands adjacent a vertical wall in flow communication with a second low friction intermediate conveying channel comprising a plurality of powered oblique rollers positioned to have a lateral angle of 1-30 degrees and providing forward and lateral movement for a second large box supported thereon, a portion of the distal end of the box extending over an adjacent receiving edge of a third outer high friction conveying channel having a high friction surface comprising a single narrow band;

FIG. 36(b) is a downstream end view of the multi-stage conveyor of FIG. 36(a) in which the lateral momentum of the boxes on the second conveying path carries the second largest box over the edge of the third conveying path, wherein the boxes are supported by the third conveying path;

FIG. 36(c) is a downstream end view of the multi-stage conveyor of FIG. 36(b) wherein the lateral momentum of the boxes on the second conveying path carries the second large box over the edge of the second conveying path and onto the third high friction conveying path, wherein the center of gravity of the second large box extends above the third high friction belt conveying path and the momentum carries the box down onto the discharge ramp;

FIG. 36(d) is a downstream end view of the multi-stage conveyor of FIG. 36(c) with the center of gravity of the second large box extending over the edge of the ramp adjacent the third conveying path and a portion of the second large box falling onto the ramp;

FIG. 36(e) is a downstream end view of the multi-stage conveyor of FIG. 36(d) with the second large box falling onto the ramp for recirculation or removal;

FIG. 37(a) is an upstream end view of the multi-stage conveyor of FIGS. 35(a-f) and FIG. 36(a-d) is an upstream view showing a first small bin on a first inner conveying channel having a high friction surface comprising three spaced apart aligned narrow strips adjacent a vertical wall in flow communication with a second intermediate conveying channel comprising a plurality of skewed rollers positioned to have a lateral angle of 1-30 degrees and provide forward and lateral movement to a second large bin supported thereon, a portion of the distal end of the bin extending over an adjacent receiving edge of a third outer conveying channel having a high friction surface comprising a single narrow strip;

FIG. 37(b) is an upstream end view of the multi-stage conveyor of FIG. 37(a) showing the forward and lateral movement of a second large box on the second conveying path;

FIG. 37(c) is an upstream isometric view of the multi-stage conveyor of FIG. 37(b) and shows the forward and lateral movement of the second large box on the second conveying path;

FIG. 37(d) is an isometric upstream view of the multi-stage conveyor of FIG. 37(c) wherein the lateral momentum of the boxes on the second conveying path carries the second large box over the edge of the second path, whereby the high friction narrow band of the third conveying path pulls the boxes forward until the center of gravity extends over the third path and the boxes are ejected;

FIG. 37(e) is a downstream end view of the multi-stage conveyor of FIG. 37(d) in which the lateral momentum of a box on the second conveying path carries a second large box over the edge of the second path, wherein the center of gravity of the second large box causes it to fall onto a third high friction conveying path that pulls the box forward, wherein the momentum causes the box to fall from the edge of the third conveying path onto a falling ramp;

FIG. 37(f) is a view of the downstream end of the multi-stage conveyor of FIG. 37 showing the outer bin not resting on a single high friction belt, but rather being moved laterally under the force of the second conveying channel and pulled forward by a third narrow high friction conveying channel to fall from the third conveying channel onto a ramp for recirculation or removal;

FIG. 38(a) is a top view of the multi-stage conveyor of FIGS. 35(a-f) and 36(a-d) and 37(a-f) showing a first small bin on a first inner conveying channel having a high friction surface comprising three spaced apart aligned narrow strips adjacent a vertical wall in flow communication with a second intermediate conveying channel comprising a plurality of skewed rollers positioned to have a lateral angle of 1-30 degrees and provide forward and lateral movement for a second large bin supported thereon, a portion of the distal end of the bin extending over an adjacent receiving edge of a third outer conveying channel having a high friction surface comprising a single narrow strip;

FIG. 38(b) is a top view of the multi-stage conveyor of FIG. 38(a) showing forward movement of a first box on a first lane and a second large box on a second transport lane;

fig. 38 is a top view of the multi-stage conveyor of fig. 38(b) and shows the forward and lateral movement of the second large boxes on the second conveying path;

fig. 38(d) is a top view of the multi-stage conveyor of fig. 38 wherein, after the centers of gravity of the boxes have passed over the side edges of the second conveying path and the narrow high friction third conveying path, the lateral momentum of the boxes on the second conveying path carries the second large boxes over the edges of the third conveying path due to the angular momentum from the transition from the inclined plane formed by the transverse angle of the second low friction powered skew roller conveyor;

FIG. 38(e) is a top view of the multi-stage conveyor of FIG. 38(d) with the center of gravity of the second large box extending over the edge of the ramp adjacent the third conveying path and a portion of the second large box falling onto the ramp;

FIG. 38(f) is an isometric view of the multi-stage conveyor of FIG. 38(e) with the second large box falling onto the ramp for recycling or removal;

fig. 39(a) shows an upstream end view of a multi-stage conveyor showing a first inner conveying channel with a high friction surface comprising three spaced apart aligned narrow strips adjacent to a vertical wall in flow communication with a second intermediate conveying channel comprising a plurality of oblique rollers positioned with a lateral upward angle of 1-30 degrees, said oblique rollers having thereon: a first box moving in a forward and lateral movement toward a third outer conveying path having a high friction surface comprising a pair of narrow belts; and a second box adjacent to the first box, wherein the second box is balanced and supported by the third conveying path; and a third box, wherein the center of gravity has pulled the third box over the third belt and onto the ramp;

FIG. 39(b) is an isometric upstream view of the multi-stage conveyor of FIG. 39 (a);

FIG. 39(c) is an isometric downstream view of the multi-stage conveyor of FIG. 39 (a);

FIG. 39(d) is a downstream end view of the multi-stage conveyor of FIG. 39 (a);

FIG. 40(a) shows an upstream end view of a multi-stage conveyor showing a first inner conveying channel having a high friction surface comprising three spaced apart aligned narrow belts adjacent a vertical wall in flow communication with a second intermediate conveying channel comprising a plurality of skewed rollers positioned with a lateral upward angle of 1-30 degrees, the skewed rollers having boxes thereon moving in forward and lateral movement toward a third outer conveying channel having a high friction surface comprising a pair of narrow belts;

FIG. 40(b) is an upstream end view of the multi-stage conveyor of FIG. 40(a) wherein the lateral momentum of the bins on the second conveying path carries a portion past the edge of the third conveying path even though the center of gravity is still on the second conveying path;

fig. 40 is an upstream end view of the multi-stage conveyor of fig. 40(a) with the cases balanced and supported by the third conveying path;

FIG. 41 is an upstream end view of the multi-stage conveyor showing the first inner conveying channel having a high friction surface comprising two spaced apart aligned narrow belts adjacent a vertical wall in flow communication with a second intermediate conveying channel comprising a plurality of skewed rollers positioned with a lateral upward angle of 1-30 degrees, wherein a box is supported by the two narrow belts of the first conveying channel adjacent vertical side walls;

FIG. 42 is an upstream end view of the multi-stage conveyor showing a first internal conveying path having a high friction surface including two spaced apart aligned narrow belts adjacent a vertical wall in flow communication with a second intermediate conveying path including a plurality of skewed rollers positioned to have a laterally upward angle of 1-30 degrees, wherein a first box is supported by the two narrow belts of the first conveying path adjacent vertical side walls and a second box laterally adjacent thereto is positioned on the second conveying path;

fig. 43(a) is an upstream end view of a multi-stage conveyor showing: a first internal conveying run comprising two high friction surface conveying surfaces comprising two spaced apart aligned narrow strips adjacent vertical walls in flow communication with a second intermediate conveying run comprising a plurality of skewed rollers positioned with a lateral upward angle of 1-30 degrees; and a third conveying path having a high friction surface comprising two spaced apart narrow strips, wherein the first conveying path and the third conveying path are at a height higher than an outer edge of the second conveying path, and the boxes are supported by two narrow strips of the first conveying path adjacent to the vertical side walls and two narrow strips of the third conveying path above the second conveying path, thus passing the boxes there over;

FIG. 43(b) is a top view showing a large flat box aligned with vertical walls supported by a powered skewed roller low friction conveying path prior to entering a multi-stage conveyor;

FIG. 43(c) is a top view of the multi-lane conveyor of FIG. 43(b) showing a large flat box offset on a vertical side wall supported by two high friction inner conveying lanes and two high friction outer conveying lanes supported above a skewed roller low friction conveying lane therebetween;

FIG. 43(d) is a top view of the multi-lane conveyor of FIG. 43(a) showing one large flat box offset on the vertical side wall supported by two high friction inner conveying lanes and two high friction outer conveying lanes supported above the skewed roller low friction conveying lanes therebetween;

FIG. 43(e) is an isometric view of the multi-lane conveyor of FIG. 43(d) showing large flat boxes supported by a powered skewed roller low friction conveying lane prior to entering the multi-lane conveyor;

FIG. 43(f) is a top view of the multi-lane conveyor of FIG. 43(a) showing a large flat box offset on the vertical side wall supported by three high friction inner conveying lanes and one high friction outer conveying lane supported above the skewed roller low friction conveying lane therebetween;

FIG. 43(g) is the cross-sectional view of FIG. 43(d) of the multi-channel conveyor of FIG. 43(a) showing a large flat box offset on a vertical side wall supported by three high friction inner transport channels and one high friction outer transport channel supported above a skewed roller low friction transport channel therebetween, wherein the width of the first transport channel increases and the width of the outer transport channel decreases as articles are conveyed forward;

fig. 44 is an isometric view of the multi-stage conveyor showing: a first internal conveying passage having a high friction surface comprising two spaced apart aligned narrow strips adjacent a vertical wall in flow communication with a second intermediate conveying passage comprising a plurality of oblique rollers positioned with a lateral upward angle of 1-30 degrees; and a third conveying channel having a high friction surface comprising two spaced apart narrow strips, wherein the first conveying channel and the third conveying channel are at a higher elevation than the outer edge of the second conveying channel, and the elongated boxes are supported by two narrow strips of the first conveying channel adjacent to the vertical side wall and two narrow strips of the third conveying channel above the second conveying channel, thus passing the boxes thereover;

fig. 45 shows an isometric view of a multi-stage conveyor, showing: a first internal conveying passage having a high friction surface comprising three spaced apart aligned narrow strips adjacent to vertical walls in flow communication, with a first box supported thereon; and a second intermediate transport way comprising a plurality of oblique rollers positioned with a lateral upward angle of 1-30 degrees, having thereon a second box and a third box laterally adjacent to the first box and to each other and moving in a forward and lateral upward motion toward a third outer transport way having a high friction surface comprising a pair of narrow belts and having a fourth box adjacent to the first box, the second box and the third box, wherein the fourth box is balanced and supported by the third transport way, and a fifth box adjacent to the fourth box, wherein the center of gravity of the fifth box has pulled the fifth box over the narrow belts of the third transport way and onto the discharge ramp;

FIG. 46(a) is a top view of the multi-stage conveyor showing the interior vertical sidewalls extending the length of the conveyor;

a first conveying path having a high friction surface, the high friction surface comprising: a first inner belt of the first stage in flow communication with a second inner belt of the second stage for moving the article in a forward direction; a third inner belt extending along the entire length of the conveyor from the first stage to the second stage, spaced from and adjacent to the first and second inner belts; an adjacent fourth inner narrow band beginning at a selected downstream location defining a second stage near the center of the conveyor extending to the end of the conveyor for moving articles in a forward direction;

a second conveying path having a low friction surface positioned adjacent the outer edges of the second and third inner belts and extending the entire length of the conveyor from the first stage to the second stage comprising a plurality of oblique rollers positioned with a lateral upward angle of up to 30 degrees for moving articles in forward and lateral directions away from the first conveying path, wherein the low friction conveying path is positioned with a lateral angle of 1-30 degrees; and

a third conveying path having a high friction surface, the high friction surface comprising: a fifth outer belt beginning at the upper end of the first stage of the conveyor and being in lateral flow communication with the second conveying passage and terminating a selected distance downstream at the end of the first stage proximate the middle of the conveyor; and a sixth outer strip extending the entire length of the conveyor from the first stage to the second stage, adjacent the outer edge of the fifth outer strip, having a downstream portion in flow communication with the portion of the low-friction conveying passage adjacent thereto.

FIG. 46(b) is a top view of FIG. 46(a) showing a narrow first box adjacent the vertical sidewall and a wide second box adjacent and spaced from the first box, both boxes supported by an upstream conveyor feeding the multi-stage multi-channel conveyor;

fig. 46(b) is a top view of fig. 46(b) showing a first box adjacent the vertical side wall and a second box adjacent the first box, both supported by an upstream conveyor feeding the multi-stage, multi-lane conveyor, whereby the first box is conveyed by the first and third inner narrow belts and the second box is aligned with the second conveying lane having a low friction surface;

FIG. 46(d) is a top view of FIG. 46(b) showing a first box conveyed on the first and second inner narrow bands of the first conveying path adjacent the vertical side wall and a second box adjacent thereto and spaced apart conveyed forwardly and laterally on the second conveying path of the first stage having a low friction surface;

FIG. 46(e) is a top view of FIG. 46(b) showing a first box conveyed on the first and second inner narrow belts of the first conveying path adjacent the vertical side wall and a second box conveyed forward and laterally on the second conveying path at the end of the first stage adjacent thereto and spaced therefrom prior to entering the second stage, wherein the first conveying path and the second conveying path are displaced toward the outer edge of the conveyor;

FIG. 46(f) is a top view of FIG. 46(b) showing a first box conveyed on the first and third inner narrow belts of the first conveying path of the second stage and spaced therefrom a second box conveyed forwardly and laterally on the second conveying path conveyor of the second stage adjacent the sixth outer narrow third conveying path;

FIG. 46(g) is a top view of FIG. 46(b) showing a first box conveyed on the first and second inner narrow belts of the first conveying path of the second stage and a second box adjacent thereto and spaced apart therefrom moving forward and laterally from the second conveying path and being balanced and supported on the third conveying path of the second stage;

FIG. 46(h) is a top view of FIG. 46(b) showing a first box conveyed on the first and second inner narrow belts of the first conveying path at the end of the second stage and a second box adjacent thereto and spaced apart therefrom and balanced and supported on the third conveying path at the end of the second stage;

FIG. 46(I) is a top view of FIG. 46(b) showing a first box conveyed on the first and second inner narrow belts of the first conveying passage at the end of the second stage transition to the downstream conveyor and a second box adjacent thereto and moving forward and laterally away from the end of the second stage toward the exit ramp;

FIG. 46(j) is a top view of FIG. 46(b) showing a first box conveyed on the first and second inner narrow belts of the first conveying path at the end of the second stage transfer to the downstream conveyor and a second box removed adjacent thereto and spaced apart therefrom from the third conveying path at the end of the second stage to exit the ramp;

FIG. 47(a) is a top view showing an inner box adjacent a vertical sidewall, a second intermediate box adjacent a first box, and a third outer box adjacent a second intermediate box, aligned and spaced apart, supported by an upstream powered oblique-roller conveyor feeding a multi-stage, multi-channel conveyor;

FIG. 47(b) is an isometric view showing an inner box adjacent a vertical sidewall, a second intermediate box adjacent a first box, and a third outer box adjacent a second intermediate box, aligned and spaced apart, supported by an upstream powered oblique-roller conveyor feeding a multi-stage, multi-channel conveyor;

fig. 47 is a plan view showing: an inner box adjacent to the vertical sidewall, the inner box supported by a first conveying path having two narrow high friction belts; a second intermediate tank; and an adjacent third outer box supported by a second conveying path having a plurality of low friction powered oblique conveyor rollers;

fig. 47(d) is an isometric view of fig. 51 showing an inner box adjacent the vertical side wall supported by a first conveyor lane having two narrow high friction belts, a second intermediate box supported by a second conveyor lane having a plurality of low friction powered oblique conveyor rollers, and an adjacent third outer box;

FIG. 47(e) is a top view showing an inner box adjacent a vertical sidewall supported by a first conveying path having two forward moving narrow high friction belts, a second intermediate box supported by a second conveying path having a plurality of low friction powered diagonal conveyor rollers moving the second intermediate box forward and laterally outward, and a third outer box supported by a third conveying path having two narrow high friction belts moving the third outer box forward;

FIG. 47(f) is an isometric view of FIG. 47(e) showing the inner box adjacent the vertical side wall supported by a first conveying path having two narrow high friction belts moving forward, a second intermediate box supported by a second conveying path having a plurality of low friction powered oblique conveyor rollers moving the second intermediate box forward and laterally outward, and a third outer box supported by a third conveying path having two narrow high friction belts moving the third outer box forward;

fig. 47(g) is a top view showing: an inner box adjacent the vertical sidewall supported by a first conveying path having two narrow high friction belts that transition to three narrow high friction belts moving forward; a second intermediate box supported by a second conveying path having a plurality of low friction powered diagonal conveyor rollers that move the second intermediate box forward and laterally outward; and a third outer box supported by a third conveying path, the third conveying path transitioning from two narrow high friction belts to one narrow high friction belt, the one narrow high friction belt moving the third outer box forward whereby the width of the high friction surface of the inner first conveying path increases and the width of the high surface area of the third conveying path decreases outwardly from the open path side;

fig. 47(h) is an isometric view of fig. 47(g) showing: an inner box adjacent the vertical sidewall supported by a first conveying path having two narrow high friction belts that transition to three narrow high friction belts that move the inner box forward; a second intermediate box supported by a second conveying path having a plurality of low friction powered diagonal conveyor rollers that move the second intermediate box forward and laterally outward; and a third outer box supported by an outer third conveying path, the third conveying path transitioning from two narrow high friction belts to one narrow high friction belt, the one narrow high friction belt moving the third outer box forward whereby the width of the high friction surface of the inner first conveying path increases and the width of the high surface area of the third conveying path decreases on the side of the outer exit opening;

fig. 47(I) is a top view showing: an inner box adjacent the vertical side wall supported by a first conveying path having three narrow high friction belts that move the inner box forward; a second intermediate bin supported by a second transport path having a plurality of low friction powered diagonal transport rollers that move the second intermediate bin forwardly and laterally outwardly to contact a third transport path high friction belt; and a third outer box moving laterally from the second conveying path over and onto a third conveying path having a single narrow band of high friction, whereby the third outer box centre of gravity causes the outer box to fall onto the narrow high friction band and onto the falling ramp for removal or recirculation;

fig. 47(J) is an isometric view showing: an inner box adjacent the vertical side wall supported by a first conveying path having three narrow high friction belts that move the inner box forward; a second intermediate bin supported by a second transport path having a plurality of low friction powered diagonal transport rollers that move the second intermediate bin forwardly and laterally outwardly to contact a third transport path high friction belt; and a third outer box moving laterally from the second conveying path over and onto a third conveying path having a single narrow band of high friction, whereby the third outer box centre of gravity causes the outer box to fall onto the narrow high friction band and onto the falling ramp for removal or recirculation;

FIG. 47(K) is a top view showing the inner box adjacent the vertical side wall supported by the first conveyor run with three narrow high friction belts moving the inner box forward, the second intermediate box having moved laterally onto the third conveyor run high friction belts, and the third outer box having been discharged;

FIG. 47(L) is an isometric view showing the inner box adjacent the vertical side wall supported by the first conveyor lane having three narrow high friction belts moving the inner box forward, the second intermediate box having moved laterally onto the third conveyor lane high friction belts, and the third outer box having been discharged;

FIG. 47(m) is a top view showing an inner box adjacent a vertical side wall supported by a first conveyor run having three narrow high friction bands which move the inner box forward and a second intermediate box laterally from the second conveyor run onto a third conveyor run having a single narrow high friction band whereby the third outer box center of gravity causes the outer box to fall over the narrow high friction band and onto a drop ramp for removal or recycling;

FIG. 47(n) is an isometric view showing an inner box adjacent a vertical side wall supported by a first conveyor run having three narrow high friction belts moving the inner box forward and a second intermediate box laterally from the second conveyor run onto a third conveyor run having a single narrow high friction belt, whereby the third outer box center of gravity causes the outer box to fall over the narrow high friction belt and onto a drop ramp for removal or recycling;

FIG. 48(a) is a top view of the multi-stage conveyor showing the inner vertical sidewalls extending the length of the conveyor;

a first conveying path having a high friction surface including a first inner belt extending from the first stage through the third stage along the entire length of the conveyor and a second inner belt extending from the second stage through the third stage in spaced apart alignment with the first inner belt and a third inner belt extending from an end of the second stage through the third stage in spaced apart alignment with an end of the second inner belt for moving articles in a forward direction,

a second conveying path having a low friction surface positioned adjacent to an outer edge of the first conveying path, outwardly displaced along an outer edge of the first inner belt, the second inner belt, and a third inner belt in lateral flow communication therewith, and extending the entire length of the conveyor comprising a plurality of skewed rollers passing from the first stage through the third stage for moving articles in forward and lateral directions away from the first conveying path, wherein the low friction second conveying path is positioned to have a lateral angle of up to 30 degrees; and

a third carryway having a high-friction surface in lateral flow communication with the second carryway and including a fourth outer belt extending across the first conveyor stage terminating in the second stage, a fifth outer belt extending across the first and second conveyor stages spaced from and aligned with the fourth outer belt, and a sixth outer belt extending from the first stage to the third stage displaced outwardly along the outer edge of the second carryway.

FIG. 48(b) is a top view of FIG. 48(a) showing a first box conveyed on the first inner belt of the first conveying run adjacent the vertical side wall, a second box conveyed forward on the second conveying run adjacent thereto and spaced therefrom, and a third box conveyed forward on the second conveying run adjacent to and spaced therefrom;

fig. 48 is a top view of fig. 48(a) showing a first box conveyed on the first inner narrow strip of the first conveying path adjacent the vertical side wall, a second box conveyed forward on the second conveying path adjacent thereto and spaced therefrom, and a third box conveyed forward on the second conveying path adjacent thereto and spaced therefrom, and a bag of small packages conveyed by the aligned upstream infeed conveyors for conveyance on the first, second and third conveying paths;

FIG. 48(d) is a top view of FIG. 48(a) showing a first box conveyed on the first inner belt of the first conveying path adjacent the vertical side wall, a second box conveyed forward and laterally on the second path having been shifted and balanced on the sixth outer belt of the third stage, and a third box shifted onto the first discharge ramp;

FIG. 48(f) is a top view of FIG. 48(a) showing a first box conveyed along the vertical side wall on the first inner narrow belt of the first conveying path and transferred by the third stage to the downstream conveyor, a second box adjacent thereto and spaced therefrom moving forward over the sixth outer narrow belt of the third conveying path and turning toward a second ramp located at the end of the third conveying path;

FIG. 49(a) is a top view of the multi-stage conveyor showing the inner vertical sidewalls extending the length of the conveyor;

a first conveying path having a high friction surface comprising seven inner narrow belts, wherein the first inner narrow belt extends along the entire length of the conveyor, and the second, third, fourth, fifth, sixth and seventh inner narrow belts have progressively decreasing lengths forming diagonal high friction surface regions extending from the right front corner to the left rear corner;

a second conveying path having a low friction surface positioned adjacent the outer edge of the first conveying path, displaced diagonally outwardly along the outer edge of the inner belt, including a plurality of short skewed rollers for moving articles in forward and lateral directions away from the first conveying path; and

a third conveying path having a high friction surface in transverse flow communication with the second conveying path, including eighth, ninth, tenth, and eleventh, twelfth, thirteenth, and fourteenth outer belts extending through the progressive length of the outwardly displaced conveyor in spaced apart and aligned relation with the outer edge of the second conveying path.

FIG. 49(b) is a top view of FIG. 49(a) showing a first box resting on the first conveying path adjacent a vertical side wall passing through the conveyor, a second box spaced from and adjacent the first box resting on the second conveying path, and a third box having a portion resting on the second conveying path and another portion resting on the second and third inner narrow strips of the third conveying path;

FIG. 49(c) is a top view of FIG. 49(a) showing a first box resting on the first conveying path adjacent a vertical side wall passing through the conveyor, a second box resting on the second conveying path spaced from and adjacent the first box, and a third box having a portion resting on the second conveying path and another portion resting on the second and third inner narrow strips of the third conveying path, wherein the small wrap bag rests on an upstream infeed conveyor aligned with the first, second and second conveying paths;

FIG. 49(d) is a top view of FIG. 49(a) showing a first box conveyed on a first conveying path adjacent the vertical side wall passing through a conveyor in flow communication with a downstream conveyor, a second box conveyed forward and laterally adjacent a third conveying path, and a third box moved forward and laterally displaced over and onto a fourteenth outer strip of the third conveying path;

FIG. 49(e) is the top view of FIG. 49(a) showing a first box conveyed on the first conveying path adjacent the vertical side wall through the conveyor in flow communication with the downstream conveyor, a second box conveyed forwardly and laterally displaced over and onto the fourteenth outer narrow strip of the third conveying path, and a fourth box laterally displaced onto the falling ramp;

FIG. 50(a) is a top view of the multi-stage conveyor showing the inner vertical sidewalls extending the length of the conveyor;

a third conveying channel having a high friction surface in lateral flow communication with the second conveying channel, including eighth, ninth, tenth, and eleventh, twelfth, thirteenth, and fourteenth outer narrow belts extending through the progressive length of the outwardly displaced conveyor in spaced apart and aligned relation with the outer edge of the second conveying channel.

FIG. 50(b) is a top view of FIG. 50(a) showing a first box resting on the first conveying path adjacent a vertical sidewall passing through the conveyor, a second box spaced from and adjacent the first box resting on the second conveying path, and a third box having a portion resting on the second conveying path and another portion resting on the second and third inner narrow strips of the third conveying path;

FIG. 50(c) is a top view of FIG. 50(a) showing a first box passing through the conveyor resting on the first conveying path adjacent the vertical side wall, a second box spaced from and adjacent the first box resting on the second conveying path, and a third box conveyed forward and laterally toward the drop ramp at the outer edge of the conveyor; and

FIG. 50(d) is the top view of FIG. 50 showing a first box conveyed on the first conveying path adjacent the vertical side wall through the conveyor in flow communication with the downstream conveyor, a second box conveyed forward and laterally displaced over and onto a fourteenth outer strip of the third conveying path, the fourteenth outer strip of the third conveying path being aligned with the end discharge ramp, and a third box discharged from the outer ramp;

FIG. 51(a) is an upstream top view of a large bag with a small parcel on a multi-stage conveyor showing a first internal conveying path comprising two spaced adjacent juxtaposed narrow belts having high friction conveying surfaces adjacent vertical sidewalls and in lateral flow communication with a second intermediate conveying path comprising a plurality of powered skewed rollers positioned with a lateral upward angle of 1-30 degrees for moving articles forward and laterally outward, and a third conveying path having a high friction conveying surface comprising two spaced narrow belts, wherein the inboard receiving edge of the third conveying path is at a higher elevation than the outboard edge of the second conveying path, which outboard edge is angled upward to form a conveying plane extending above the outboard edge of the third conveying path, whereby the large pockets of the small parcel boxes are moved forward and laterally toward the vertical side walls by the powered oblique roller upstream feed conveyor;

FIG. 51(b) is an upstream isometric view of the multi-stage conveyor showing a first interior conveying path comprising two spaced adjacent juxtaposed narrow belts having high friction conveying surfaces adjacent vertical sidewalls and in lateral flow communication with a second intermediate conveying path comprising a plurality of powered skewed rollers positioned with a lateral upward angle of 1-30 degrees for moving articles forward and laterally outward, and a third conveying path having high friction conveying surfaces comprising two spaced narrow belts, wherein the inner receiving edge of the third conveying path is at a higher elevation than the outer edge of the second conveying path angled upward to form a conveying plane extending above the outer edge of the third conveying path whereby large pockets of small parcel bins are moved forward and laterally toward vertical sidewalls by the powered skewed roller upstream feed conveyor (ii) a

Fig. 51 is a top view of a multi-stage conveyor, showing a first internal conveying path comprising two high friction surface conveying surfaces, the conveying surface comprising two spaced apart aligned narrow strips adjacent the vertical wall, the conveying surface being in flow communication with the second intermediate conveying passage, the second intermediate conveyance path includes a plurality of oblique rollers positioned to have a laterally upward angle of 1-30 degrees, and a third conveying path having a high friction surface comprising two spaced apart narrow bands, wherein the first conveying channel and the third conveying channel are at a higher level than the outer edge of the second conveying channel, and the big pockets of the small parcel boxes are supported by the two narrow strips of the first conveying lane adjacent to the vertical side walls and by the two narrow strips of the third conveying lane, thereby causing the high friction surfaces of the inner and outer transport channels to be greater than the lateral force of the low friction transport surfaces of the skewed rollers therebetween;

FIG. 51(d) is an isometric view of the multi-stage conveyor of FIG. 51 showing a first inner conveying path comprising two high-friction surface conveying surfaces comprising two spaced-apart aligned narrow belts adjacent to a vertical wall in flow communication with a second intermediate conveying path comprising a plurality of oblique rollers positioned with a lateral upward angle of 1-30 degrees and a third conveying path having a high-friction surface comprising two spaced-apart narrow belts, wherein the two narrow belts of the first and third conveying paths are at a higher elevation than the outer edge of the second conveying path and the large pocket of the small parcel box is supported by the two narrow belts of the first conveying path adjacent to the vertical side wall and the two narrow belts of the third conveying path, thus making the high-friction surface of the inner and outer conveying paths larger than the lateral low-friction conveying surface of the oblique rollers therebetween Force;

FIG. 51(e) is a top view of a multi-stage conveyor showing a first inner conveying channel comprising a high friction surface conveying channel comprising three spaced apart aligned narrow strips adjacent to a vertical wall in flow communication with an intermediate conveying channel comprising a plurality of skewed rollers positioned with a lateral upward angle of 1-30 degrees and a third outer conveying channel having a high friction surface comprising one spaced apart narrow strip, wherein the first conveying channel and the third conveying channel are at a higher elevation than the outer edge of the second conveying channel and a large pocket of a small parcel box is supported by one of the three narrow strips of the first conveying channel and the third conveying channel with a higher friction than the lateral force of the low friction conveying surface of the skewed rollers therebetween; and

fig. 51(f) is a top view of a multi-stage conveyor showing a first interior conveying path comprising a high friction surface conveying path comprising three spaced apart aligned narrow strips adjacent to a vertical wall in flow communication with an intermediate conveying path comprising a plurality of skewed rollers positioned with a lateral upward angle of 1-30 degrees and a third conveying path having a high friction surface comprising one spaced apart narrow strip, wherein the first conveying path and the third conveying path are at a higher elevation than an outer edge of the second conveying path and a large pocket of a small parcel box is supported by one narrow strip of the three narrow strips of the first conveying path and the third conveying path with a higher friction than a lateral force of a low friction conveying surface of the skewed rollers therebetween.

Detailed Description

The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms "comprises," "comprising," "including," and "having," are inclusive and therefore specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. Unless specifically identified as an order of execution, the method steps, processes, and operations described herein are not to be construed as necessarily requiring their execution in the particular order discussed or illustrated. It is also understood that additional or alternative steps may be employed.

When an element or layer is referred to as being "on," "engaged to," "connected to" or "coupled to" another element or layer, it may be directly on, engaged, connected or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being "directly on," "directly engaged to," "directly connected to" or "directly coupled to" another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a similar manner (e.g., "between.. versus" directly between.. versus, "adjacent" versus "directly adjacent," etc.). As used herein, the term "and/or" includes any and all combinations of one or more of the associated listed items.

Although the terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections, these elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as "first," "second," and other numerical terms used herein do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example embodiments.

Spatially relative terms, such as "inner," "outer," "below," "lower," "above," "upper," and the like, may be used herein for ease of description to describe one element or feature's relationship to another element or feature as illustrated in the figures. As used herein, the term "about" is reasonably understood by one skilled in the art to mean slightly above or slightly below the stated value, within a range of ± 10%.

The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, 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 be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like reference numerals refer to like elements throughout.

As shown, the present invention is directed to a delivery system for delivering and organizing and separating articles in side-by-side relation.

As best shown in the figures, articles such as bags or small packages or packs 6, 7 and 8 or large packages 9 are transferred from a feed conveyor 1 comprising a plurality of low friction powered oblique rollers onto a multi-stage singulator conveyor unit or assembly 11 having separation capability. Singlets 11 are arranged in alignment with, downstream of and below the lower end of the infeed conveyor 1 for receiving articles therefrom. The singler includes a central conveying surface that includes a plurality of driven skewed rollers disposed between a selected number of high friction surface conveying lanes that typically use high friction belts. The downstream conveyor receives articles from the singler in a single file along the vertical sidewall. It is contemplated that the vertical sidewalls may also use high friction tape.

Single-stage conventional belt width single selector unit

As shown in fig. 1-2, the single stage singler assembly 11 includes a first conveyor defining a high friction surface carryway 3, the carryway 3 including rollers or preferably belts having a high friction surface for conveying articles 6 along a vertical sidewall 2 along which incoming articles are positioned thereat. Packages resting on the vertical side wall 2 and on the first conveyor 3 will travel across the conveyor to the downstream conveyor 32. Typically, the first channel is sized to be no wider than the smallest article to be conveyed thereon. The second conveyor defining the lower friction surface conveying passage 4 is shown to include a plurality of rollers 34, the rollers 34 having inner edges 36 located below and adjacent to the outer lateral edges 38 of the first conveyor 3 and angled downwardly toward the first conveyor. The second conveyor 4 is typically at least as wide, typically wider, as the first conveyor 3. The second conveying path 4 typically comprises a series of driven rollers 34, the axes of rotation of which are inclined with respect to the longitudinal direction of travel, so that the packages are conveyed away from the first conveyor both laterally forwards and laterally outwards. The inner lateral receiving edge 36 of the second conveyor is located a selected distance below the outer lateral edge 38 of the first conveyor 3, positioned adjacent to the outer lateral edge 38 of the first conveyor 3 having a high friction surface. The second conveyor 4 has a lower friction surface for receiving packages falling therefrom. The lateral force of the second conveyor pulls the articles located on the second conveyor away from the first conveyor and the main flow sidewall to separate two small articles 7, 8 that may enter alongside each other. Packages that rest side-by-side or side-by-side with each other are separated such that a package on the first conveyor moves forward while an adjacent package that rests on the second conveyor is pulled off the first conveyor. The second conveyor has a lower lateral receiving edge located below the outer lateral edge of the first conveyor and extends laterally upwardly therefrom at a selected angle to form an inclined plane extending above the inner lateral receiving edge 40 and to form the conveying surface of an adjacent third conveyor defining the high friction surface conveying channel 5. The outer lateral edge 42 of the second conveyor is positioned flush with or below the inner lateral receiving edge 40 of the third conveying channel 5. The third transfer path 5 moves the articles laterally forward without lateral movement; however, it is contemplated that the speed of the first, second, or third conveyance paths may be adjusted relative to each other to align the articles thereon.

The singler assembly 11 includes a first conveyor 3 defining a first conveying path that includes rollers or preferably belts having a high friction surface for conveying articles 6 along a vertical sidewall 2 along which incoming articles are positioned thereat. Packages resting on the vertical side wall 2 and on the first conveyor 3 will travel across the conveyor to the downstream conveyor 32. The first channel is sized to be no wider than the smallest item to be conveyed thereon.

The second conveyor 4 defining the second conveying path 4 with the lower friction surface is shown to include a plurality of rollers 34, the rollers 34 having inner edges 36 positioned below and adjacent to the outer lateral edges 38 of the first conveyor or first conveying path 3 and angled downwardly toward the first conveying path. The second conveying path 4 is generally at least as wide as the first conveying path 3, and is generally wider. The second conveying path 4 typically comprises a series of driven rollers 34, the axes of rotation of which are inclined with respect to the longitudinal direction of travel, so that the packages are conveyed away from the first conveying path both laterally forwards and laterally outwards. The inner lateral receiving edge 36 of the second conveying channel is located at a selected distance below the outer lateral edge 38 of the first conveyor 3, positioned adjacent to the outer lateral edge 38 of the first conveying channel having a high friction surface. The second conveying channel 4 has a lower friction surface for receiving packages falling from it. The lateral force of the second conveying path pulls the articles located on the second conveying path away from the first conveying path and the main flow side wall, thereby separating two small articles 7, 8 that may enter alongside each other. Packs that rest side by side or alongside each other are separated so that the packs on the first conveying path are moved forward while the adjacent packs that rest on the second conveying path are pulled away from the first conveying path. The second conveyor channel has a lower lateral receiving edge located below the outer lateral edge of the first conveyor channel and extends laterally upwardly therefrom at a selected angle to form an inclined plane extending above the inner lateral receiving edge 40 and to form a conveying surface of an adjacent third conveyor channel defining a third conveyor channel 5 having a high friction conveying surface. The outer lateral edge 42 of the second conveyor channel is positioned flush with or below the inner lateral receiving edge 40 of the third conveyor channel. The third transfer path moves the articles laterally forward without lateral movement; however, it is contemplated that the speed of the first, second, or third conveyance paths may be adjusted relative to each other to align the articles thereon. The inclined planes and angles of the rollers of the second conveying path 4 guide the articles and push them upwardly toward the third conveying path where the lateral momentum of the articles being laterally transferred will tend to locate the center of gravity of the articles so that the articles fall under the control of the forward conveying force of the third conveying path and are no longer influenced by the conveying force of the second path.

The driven first conveying path 3 comprises a first high friction conveying surface comprising a belt 3 having a first high friction surface for conveying articles 7, 8 along the vertical side wall 2, wherein incoming articles are positioned there along the vertical side wall 2 at a selected speed. The width of the conveying channel is determined by the size or dimensions of the package. The width of the first conveying channel is sized to be equal to or less than the minimum package width.

The second conveyor channel 4 with a lower friction surface comprises a forward and a sideways conveying force. The second conveying path 4 generally comprises a series of driven rollers 34, the rotation axes of which are inclined with respect to the lateral direction of travel, so that the packs are conveyed both laterally forwards and laterally outwards away from the first conveying path 3 and the side walls 2. As a result, the packages tend to form a single queue on the first conveyor path surface 3 running laterally along the side wall 2, or the centre of gravity or friction forces cause the packages to extend over the edge of the first conveyor path 3 and to rest partly on the second conveyor path 4 moving in the forward and lateral direction. As long as a part rests on the high-friction surface of the first conveying channel 3, the packages will still move forward. The width of the second conveying path 4 with the lower friction surface is generally greater than the width of the first conveying path 5 with the lower friction surface in order to allow lateral movement and separation of the packs thereon.

The width of the conveying channel is determined by the size or dimensions of the package. The width of the first conveying channel is sized to be equal to or less than the minimum package width.

The inner edge 36 of the second conveying channel adjacent to the outer edge 38 of the first conveying channel is arranged at a slightly lower level along the lateral axis, and the first conveying channel then provides a lower level 33 between the first and second conveying channels, so that packages resting on both the first and second conveying

channels

3,4 will be held firmly and pulled forward by the first conveying channel 3 with a high friction surface. The lower friction conveying surface of the second conveying path 4 is angled vertically upwards from the outer edge of the first conveying path at a selected angle of up to 30 degrees, and more preferably at a selected angle of 5-25 degrees, providing an inclined plane extending upwards towards the third conveying path, so that the outer lateral edge 45 of the second conveying path is equal to or slightly lower than the inner lateral edge 40 of the adjacent third conveying path, being removed laterally as the articles are gradually moved forwards on the slightly inclined plane.

The lower friction conveying surface of the second conveying path is arranged at the same level as the first conveying path at the place where it meets the first conveying path. The second conveyor path includes forward and lateral forces away from the first conveyor path and upward toward the third conveyor path. The outer lateral edge 42 of the angled second conveyor lane extends upwardly to a lateral transition zone 36 that is slightly below or flush with the lateral receiving edge 40 of the third conveyor lane.

Multi-stage multi-channel single selector unit

As shown in fig. 3 and 4, the multi-stage multi-channel singler conveyor unit 100 includes vertical sidewalls extending along the inner lateral edges and at least three adjacent and laterally disposed conveyor surfaces in lateral flow communication at a selected height.

As shown in fig. 3, the multi-stage multi-channel singler conveyor unit 100 includes adjacent lateral conveying surfaces in flow communication with each other, including at least one narrow internal high-friction conveying surface that includes at least one narrow high-friction belt and/or (two narrow high-

friction belts

101 and 102 as shown in fig. 3) or, optionally, multiple narrow high-friction belts. The lower friction conveying surface of at least one intermediate or central channel 105 comprises a plurality of skewed rollers or belts of selected size and width or having a lower friction surface. The third outer high friction conveying surface comprises at least one narrow high friction belt or alternatively (two narrow

high friction belts

103 and 104 as shown in fig. 3) or a plurality of narrow high friction belts.

The width of the conveying channel is generally determined by the size or dimensions of the package. The width of the first conveying path is typically sized to be equal to or less than the minimum package width separated by the singulator; however, multi-lane singlers utilize multiple narrow, high-friction belts, whereby the sum of the widths of the belts in the first conveying lane is generally equal to or less than the minimum package width separated by the singler. In addition, a plurality of spaced apart aligned narrow bands combine to form a pattern or area of high friction surfaces to control or resist movement of the package in contact with the high friction surface of one or more narrow bands. In a preferred embodiment, narrow may be defined functionally as requiring at least two strips to equal the width of the smallest package to be separated. Physically, the tape has a width of up to 12 inches, more preferably a width of 10 inches, more preferably a width of 8 inches, more preferably a width of 6 inches, more preferably a width of 2 to 4 inches, more preferably a width of 1 to 3 inches, or a width of 1/4 inches to 1 inch. By utilizing sets of belts positioned in spaced-apart aligned relation, the movement of packages through the high friction belts enables the formation of high friction areas on the conveyor having low friction areas to control the movement of packages thereon.

One of the multiple multi-channel conveyors is connected in end-to-end flow communication to form a multi-stage multi-channel singler assembly for singulating packages.

The driven first or inner transport path has a high friction transport surface for transporting articles in a forward direction in a generally horizontal plane. In contrast to single-stage singlers that use a single high-friction surface belt, the first conveyance path of a multi-path singler includes a plurality of high-friction surfaces that are spaced apart and a narrow belt that is juxtaposed. Of course, the high friction surface conveyor channels may be made from various combinations of widths of belts to achieve the optimum high friction surface area for various applications. Further, the individual feed lanes of the multi-lane singler may include a single belt extending the length of the conveyor unit or a plurality of short belts aligned end-to-end that terminate at selected locations along the conveyor. In fig. 3, two inner belts extend the length of the conveyor, while the third outer belt terminates at a selected position that is about half the length of the conveyor unit.

A driven second or intermediate conveyor defining a lower friction surface intermediate conveyor passage is positioned adjacent the outer lateral edge of the first conveyor passage. The second conveyor passage has a lower lateral receiving edge located below the outer lateral edge of the first conveyor passage and extends laterally upwardly from the first conveyor passage at a selected upward angle to form an inclined conveying surface. The second conveying path has a lower friction conveying surface formed by a series of driven rollers, the axis of rotation of which is inclined relative to the lateral direction of travel for conveying the packages simultaneously forwardly and laterally outwardly away from the first conveying path. The second conveying path extends laterally upwardly from the first conveying path at a selected angle whereby the lower friction surface forms an inclined plane extending above the inner lateral receiving edge and forms a conveying surface of an adjacent third conveyor defining a high friction surface conveying path. The inner edge of the second conveyor channel extends along and is in flow communication with the outer edge of the first conveyor channel, and the outer edge of the second conveyor channel extends along and is in flow communication with the inner edge of the third conveyor channel.

A driven third or outer conveyor defining a third conveying path has a plurality of high friction surface conveying paths for conveying articles in a forward direction in a generally horizontal plane forming the third conveying path disposed adjacent the outer lateral edge of the second conveyor. The second conveyor has an outer lateral edge extending upwardly toward an inner lateral receiving edge of the third conveyor. The outer lateral edge of the second conveyor is below or flush with the laterally inner receiving edge of the third conveyor for conveying articles upward and over the inner lateral receiving edge of the third conveyor. The inclined planes and angles of the rollers of the second conveyor 4 guide the articles and push them upwards towards the third conveyor where they fall on the inner lateral receiving edge 40 of the third conveyor and engage the high friction conveying surface of the third conveyor 5.

The driven third or outer transport path has a high friction conveying surface for conveying articles in a forward direction in a generally horizontal plane forming a third transport path disposed adjacent the outer lateral edge of the second conveyor. In contrast to single-stage singlers that use a single high-friction surface belt, the third feed path of the multi-channel singler includes one or more high-friction surfaces that are spaced apart and a narrow belt that is juxtaposed. Of course, the high friction surface conveyor channels may be made from various combinations of widths of belts to achieve the optimum high friction surface area for various applications. Further, the individual feed lanes of the multi-lane singler may include a single belt extending the length of the conveyor unit or a plurality of short belts aligned end-to-end that terminate at selected locations along the conveyor. In fig. 3, the third outer belt extends a selected distance and terminates at a selected location approximately one-half the length of the conveyor unit.

Separating mechanism and operation

The transfer of packages from the lower friction surface 104 of the second conveying channel 4 to the high friction conveying channel 5 is best illustrated in the representative cross-sectional views of fig. 5-9. The second conveyor run is angled sideways, forming an inclined plane comprising the second plane conveying surface of the second conveyor run 4 extending above (DIM C) the conveying surface 105 of the third high friction conveyor run of the third conveyor run 5. The outer lateral edge of the conveying surface of the second conveyor channel 5 is lower (DIM B) than the height of the outer lateral receiving edge of the third conveyor channel 3; however, the spacing between the second conveying channel and the third conveying channel allows the inclined plane of the low-friction conveying surface of the second conveying channel to extend beyond the inner lateral receiving edge of the third conveying channel for the transfer of packages from the second conveying channel over and into the third conveying channel. Fig. 7-9 illustrate the spatial relationship between the first feed channel and the third feed channel of the multi-channel conveyor shown in fig. 3 and 4.

As shown in fig. 10, the large packages suspended to one side of the first conveyor lane (with a portion resting on the second conveyor lane) are carried forward.

When packages placed side by side with each other on an infeed conveyor lane are fed onto the singulator, the forward force of the first conveyor lane pulls the packages forward and the lateral force of the second conveyor lane forces the adjacent packages away from the main flow sidewall to separate two articles that may enter side by side with each other in a single-stage conveyor as depicted in fig. 11 and in a multi-stage multi-channel conveyor as depicted in fig. 12-14. The somewhat larger items that enter and contact the first high friction conveying path and the second lower friction conveying path, both rigid and non-rigid, will not tend to shift laterally along the wall from the main flow side because of the significantly higher friction of the first high friction conveying path.

The driven third feed passage has a high friction surface located alongside the second feed passage on the opposite side of the primary flow side of the first feed passage. If the third conveyor having a receiving-side edge conveying surface is higher than the outer edge of the conveying surface of the second conveyor, the second conveyor conveying surface does not exert significant lateral forces on large articles passing through the first and third conveying lanes. The third conveyor lane is raised to the same height as the first conveyor lane so that the conveying surface of the third conveyor lane is higher than the conveying surface comprising the second conveyor lane so that large packages resting on the first and third conveyor lanes pass through the singler, as shown in fig. 15-16.

The conveyor speeds of the first, second, and third conveyors in the forward direction are independently controllable; however, it is desirable that the first and third conveyor lanes travel at the same rate so that large parcels resting on the high friction conveying surfaces of the first and third conveyor lanes are conveyed by the conveyor unit.

The big bag containing the small items is in contact with all three conveying channels due to its lack of rigidity; however, the combination of the frictional forces generated by the first high friction conveying path and the third high friction conveying path will tend to resist the lateral force exerted by the second low friction conveying path, thereby allowing the bag to pass directly through without being laterally displaced from the main flow along the wall, as shown in fig. 17-18.

The selected lateral angle of the second conveyance lane and the spacing between the second conveyance lane and the third conveyance lane determine the necessary angle of the lateral plane formed by the angled conveying surface of the second conveyance lane necessary for conveying articles transferred from the second conveyance lane over the lateral side receiving edge of the third conveyance lane, as shown in fig. 7-9.

The third conveying path utilizes a higher friction conveying surface than a second conveying path having a lower friction conveying surface so that articles moving forward and upward on the low friction oblique conveyor rollers in transition have sufficient momentum to carry them through the second path so that the edges of the articles extend beyond the third path and so that the articles land on the high friction conveying surface when the center of gravity is above the third conveying path. The portion of each article or package extending above the third conveyor will move upwardly and over the third conveyor path. The lateral momentum of the articles being laterally diverted will tend to position the center of gravity of the articles such that the articles fall under the control of the forward conveying force of the third high-friction lane, are no longer influenced by the conveying force of the second lane, and the third conveying lane and packages fall onto the high-friction surface of the third conveying lane.

The high-friction conveying paths of the first conveyor 3 and the third conveyor 5 may each be formed by an endless conveyor belt consisting of: rollers covered or coated with a high friction surface such as rubber or elastomeric compounds; a roller comprising a plastic or rubber compound or a solid or mesh belt comprising rubber, elastomer or polymer. The lower friction conveying path of the second conveyor 4 is typically constructed of a metal or plastic material such as aluminum, carbon steel, metal alloy or stainless steel, a graphite material or a tetrafluoroethylene "TEFLON" material. The second conveyor lane may be formed by using a plastic modular conveyor belt containing driven rollers exhibiting a conveying force with a lateral component.

The first and third conveyor high friction conveying paths may each be formed by a plurality of rollers having axes substantially horizontal and perpendicular to the main flow direction and comprising high friction surfaces. The first and third conveyance paths need not be of the same type, but preferably include endless belts or high friction surface rollers.

The second conveyor 4 channel may be formed by a plurality of lower friction surface rollers oriented to generate a conveying force that is forward in the main flow direction of the first high friction conveyor and also has a lateral component away from the first conveying channel and the main wall and includes an upward component in the lateral direction away from the main flow channel of the first conveying channel. The second, lower friction conveying channel may be formed by using a plastic modular conveyor belt, containing driven rollers exhibiting a conveying force with a lateral component.

The entire machine may not be arranged so that both high friction surfaces are horizontal, but may be arranged at an angle so that the second channel falls on a horizontal plane, or on a point where all three are angled, but maintains the relative position as described above.

It is contemplated that a vertical belt may extend along the inside of the first inner main conveyor in place of the vertical side walls for abutment and alignment of packages in flow communication therewith.

Example (c):

the following examples describe preferred embodiments of the invention. Other embodiments within the scope of the claims herein will be apparent to one skilled in the art from consideration of the specification or practice of the invention as disclosed herein. It is intended that the specification, together with the examples, be considered exemplary only, with the scope and spirit of the invention being indicated by the claims which follow the examples.

Example 1

By combining more separation steps using multiple narrow high friction surface conveying channels (such as narrow belts), additional stages are added to the singulator conveyor to provide a continuous path for the separation and removal of articles, such as packages positioned side-by-side to one another.

Fig. 19 depicts a two-stage, multi-channel conveyor unit comprising an inner vertical wall, a first high friction inner conveyor lane surface (such as a belt adjacent to the vertical wall), a second lower friction intermediate conveyor lane surface (comprising a plurality of skewed rollers that push articles outward from the first high friction conveyor lane and the vertical wall in lateral flow communication therewith), and a third high friction outer conveyor lane surface (comprising a high friction conveyor surface, such as a belt in lateral flow communication with the second lower friction intermediate conveyor lane). The first stage includes a first inner conveying channel having a first high friction surface portion and a 3 inch wide outer high friction belt, and the second stage extends forward to a 9 inch wide high friction belt and terminates at the end of the second stage at the center of the conveyor. The first stage includes: a 15 inch wide middle section comprising a plurality of inclined low friction surface rollers adjacent the first conveying path, the rollers extending to a second stage whereby the rollers are displaced 6 inches toward the outer edge; and a third conveying path having a high friction conveying surface 9 inches wide, the width of which drops down to a high friction conveying surface comprising a 3 inch wide belt in a second stage.

A second lower friction conveying path extends adjacent to and in lateral communication with the first conveying path for moving articles therebetween. The second conveying path includes a plurality of skewed rollers that are 15 inches wide from the first conveying path to provide forward and lateral conveying forces that push articles forward and away from the first conveying path. The second conveyance passage is displaced inwardly at the second stage, forming a second lower friction surface portion that remains adjacent to and in flow communication with the high friction surface portion of the first conveyance passage.

The third outer high friction surface conveyor channel extends 9 inches from the lateral edge of the second conveyor channel to the outer edge of the conveyor. The third conveying surface narrowed to 3 inches at the beginning of the second stage and terminated at the end of the conveyor. The width of the second stage first conveying surface belt widens six inches to the end of the conveyor.

The lateral receiving edge of the second conveyor passage is located below the outer lateral edge of the first conveyor passage, and the second conveyor passage is laterally inclined and angled laterally upward by having a raised outer edge that is flush with or below the lateral receiving edge of an adjacent third conveyor passage, and the conveying surface of the second conveyor passage forms an inclined plane that extends above the inner lateral receiving edge adjacent the third conveyor passage having a high friction surface. By selecting the amount of high friction conveying surface provided by one or more adjacent conveying channels, the lateral movement of packages on the multi-stage singulating conveyor can be controlled.

Example 2

Three-stage multi-stage and multi-channel conveyors are shown in fig. 20, in which the high friction conveying surface is depicted as a narrow high friction belt.

A first stage having a first high friction surface internal conveyance channel formed by five narrow high friction strips at the inner side adjacent to the vertical side wall. A second intermediate section in lateral flow communication with the first high friction surface inner conveying passage and comprising a low friction surface conveying passage formed by skewed rollers in lateral flow communication with a third high friction surface outer conveying passage formed by five narrow high friction belts.

The second stage is in lateral flow communication with the first stage; however, the two inner high friction conveying channels adjacent to the central portion terminate at the ends of the second stage.

The second stage includes a first inner conveying surface that includes two additional high friction narrow belts, for a total of seven belts. A central portion including a low friction surface intermediate transport channel formed by outwardly displaced skewed rollers. The low friction surface area extends further outside the second stage and increases the high friction surface area of the inner conveyor channel. The two outer high friction conveying channels of the second stage terminate near the third stage and the low friction surface conveying channels of the central portion are displaced outwardly so as to extend to the outer edge of the conveyor in the third stage.

The first internal high friction surface conveying path of the second stage includes two additional narrow belts of high friction surface, for a total of nine belts, which extend along the inner edge of the third stage of the conveyor and terminate at the end of the conveyor. The central portion includes a low friction surface conveyance channel formed with skewed rollers that extend from the first interior conveyance channel to provide a low friction surface area that extends to an outside edge of the third stage.

The number of strips comprising the high friction region may be any selected number.

The lateral receiving edge of the second intermediate delivery channel is located below the outer lateral edge of the first delivery channel, and the second delivery channel is laterally inclined and angled laterally upward by having a raised outer edge that is flush with or below the lateral receiving edge of an adjacent third delivery channel, and the delivery surface of the second delivery channel forms an inclined plane that extends above the inner lateral receiving edge of an adjacent third delivery channel having a high friction surface. By selecting the amount of high friction conveying surface provided by one or more adjacent conveying channels, the lateral movement of packages on the multi-stage singulating conveyor can be controlled.

Example 3

Fig. 21-26 show lower friction conveying paths including skewed rollers disposed between high friction conveying paths including multiple narrow bands to provide packs moving forward as shown having the width of the first conveying path and packs moving laterally and forward on adjacent lower friction surface intermediate conveying paths until it is removed by the conveyor. By adding more steps, a continuous path is provided for removing side-by-side packages as more stages are added.

Example 4

Fig. 27-30 show a solution to the 3-way side-by-side separation problem. Fig. 27-28 show that if three side-by-side parcels enter a three-stage multi-level multi-lane conveyor where the third high friction conveying lane is too narrow to support the parcel and momentum carries it through the narrow lane, the adjacent parcel may no longer be able to prevent lateral movement and prevent the remaining parcels from reaching a position for dropping onto the recirculation conveyor.

In addition, raising the central channel at a selected angle up to the third high friction conveying channel, as shown in fig. 29-30, may utilize a conveyor with additional stages.

Example 5

The two-stage multi-stage conveyor shown in fig. 31-34 illustrates the separation of two side-by-side articles.

As shown in fig. 31-32, one package is conveyed forward on the first high friction conveying lane and a second package is conveyed forward and laterally from the second lower friction conveyor lane and transferred to the third high friction conveying lane where it is removed to the recirculation conveyor. The packages in the first conveying path are conveyed onwards to the receiving conveyor.

Fig. 33-34 show that one package is conveyed forward on a first high friction conveyor lane and a second package is conveyed forward and laterally from a second lower friction conveyor lane but not moved a sufficient distance to transfer to a third high friction conveyor lane where it is recirculated. The packages in the first conveying path are conveyed onwards to the receiving conveyor.

The foregoing detailed description is given primarily for clearness of understanding and no unnecessary limitations are to be understood therefrom, for modifications will become obvious to those skilled in the art upon reading this disclosure and may be made without departing from the spirit of the invention and scope of the appended claims. Accordingly, the present invention is not intended to be limited to the specific exemplifications presented hereinabove. Rather, what is intended to be covered is within the spirit and scope of the appended claims.

Claims

1. A multi-channel radio conveyor device comprising:

a first conveyance path, a second conveyance path, and a third conveyance path, each driven and arranged in an adjacent side-by-side configuration;

the first conveying path having a high-friction conveying surface comprising at least one narrow belt for conveying articles forward along a vertical sidewall for receiving articles from an upstream conveyor, the narrow belt having a width less than the articles;

the second conveyor run having a lower friction conveying surface than the first conveyor run, the second conveyor run being disposed alongside and in lateral flow communication with the first conveyor run, the second conveyor run having an inner receiving edge disposed at a lower elevation than an outer edge of the first conveyor run, the second conveyor run being laterally inclined and angled upwardly;

the second conveying path including a series of driven rollers having axes of rotation inclined relative to a forward direction of travel such that the articles are conveyed simultaneously forwardly and laterally outwardly away from the first conveying path and the vertical side walls,

the second conveyor run having a lower friction conveying surface extending from below the first conveyor run at an angle upwardly toward the inner receiving side edge of an adjacent third conveyor run, forming an inclined plane extending above the third conveyor run spaced from the second conveyor run; and

the third conveyor run has a high friction conveying surface comprising at least one narrow strip having an inner receiving side edge at a height above the raised lateral outer edge of the second conveyor run.

2. The multi-channel radio conveyor device of claim 1, wherein the first and third conveyor channels are driven at the same rate.

3. The multi-channel radio conveyor device of claim 2, wherein the first conveyor lane and the third conveyor lane are laterally aligned side-by-side in a selected plane.

4. The multi-channel singler feed channel device of claim 1, wherein the second feed channel is angled upward in a lateral direction from the first feed channel to the third feed channel in a range of 1 to 30 degrees relative to a horizontal plane of the first feed channel.

5. The multi-channel radio conveyor device of claim 1, wherein the first conveyor channel comprises a plurality of spaced apart aligned high friction strips.

6. The multi-channel radio conveyor device of claim 1, wherein the third conveyor channel comprises a plurality of spaced apart aligned high friction belts.

7. The multi-channel radio conveyor device of claim 1, the outer lateral edge of the second conveyor channel being disposed at a lower elevation than the inner lateral edge of the third conveyor channel.

8. The multi-channel radio conveyor device of claim 1, wherein the first, second and third conveyor channels are selected from the group consisting of endless belt conveyor channels, endless roller conveyor channels, and combinations thereof.

9. The multi-channel radio conveyor device of claim 1, wherein the high friction conveying surface comprises plastic, elastomer, rubber, coatings, and combinations thereof.

10. The multi-channel radio conveyor device of claim 1, wherein the lower friction conveying surface comprises a metal, a plastic, a graphite material, or a tetrafluoroethylene material.

11. The multi-lane singler conveyor apparatus of claim 1, wherein the first high-friction conveying surface comprises at least one belt, the second conveying-lane lower-friction conveying surface comprises skewed rollers, and the third conveying-lane high-friction conveying surface comprises at least one belt.

12. The multi-lane singler conveyor apparatus of claim 1 wherein the first high-friction conveying surface comprises at least one belt, the second conveying-lane lower-friction conveying surface comprises skewed rollers, and the third conveying-lane high-friction conveying surface comprises a plurality of spaced-apart narrow belts.

13. The radio conveyor device of claim 1, wherein the first high-friction conveying surface comprises a plurality of spaced-apart, aligned narrow belts, the second conveying path lower-friction conveying surface comprises skewed rollers, and the third conveying path high-friction conveying surface comprises at least one narrow belt.

14. A multi-stage, multi-channel singler conveyor comprising at least two singler conveyors arranged in flow communication in an end-to-end arrangement defining a first stage and a second stage, each stage comprising:

a singler feed channel arrangement including at least three driven feed channels arranged in an adjacent side-by-side configuration;

a first conveying path comprising at least two spaced apart aligned narrow belts having a high friction surface for conveying articles forward along a vertical sidewall along which incoming articles are positioned;

a second conveyor lane with a lower friction conveying surface disposed alongside the first conveyor lane having an inner receiving edge at a lower elevation, the second conveyor lane including a series of driven rollers having axes of rotation inclined relative to a forward direction of travel such that the articles are conveyed simultaneously forward and laterally outward away from the first conveyor lane and the vertical side walls, the second conveyor lane being transversely inclined and angled upward at a selected angle to form a raised outer side edge;

the second conveying path having a low friction conveying surface forming an inclined plane extending at a selected angle above a receiving side edge of an adjacent third conveying path; and

the adjacent third conveying path comprises at least two narrow high friction belts, the third conveying path having inner receiving side edges that are taller than or flush with the raised outer edges of the second conveying path; and

the second transfer passage is angled upwardly in the range of 1 to 30 degrees relative to horizontal.

15. The singulator conveyor apparatus of claim 14, further including an infeed conveyor having a relatively low friction conveying surface and a series of driven rollers having axes of rotation inclined relative to a laterally forward direction of travel for conveying said articles simultaneously laterally forward and laterally inward toward said first conveying path.

16. The radio conveyor device of claim 14, wherein the first high-friction conveying surface comprises a plurality of spaced-apart, aligned narrow belts, the second conveying path lower-friction conveying surface comprises skewed rollers, and the third conveying path high-friction conveying surface comprises at least one narrow belt.

17. The singler conveyor apparatus of claim 14, wherein the first, second, and third conveyance paths are selected from the group consisting of endless belt conveyance paths, endless roller conveyance paths, and combinations thereof.

18. The radio conveyor apparatus of claim 14, wherein the high friction conveying surface comprises plastic, elastomer, rubber, coatings, and combinations thereof.

19. The radio conveyor device according to claim 14, wherein the lower friction conveying surface comprises a metal, a plastic, a graphite material, or a tetrafluoroethylene material.

20. The radio conveyor device of claim 14, wherein the first conveyor lane high friction conveying surface comprises a plurality of narrow bands, the second conveyor lane lower friction conveying surface comprises skewed rollers, and the third conveyor lane high friction conveying surface comprises a plurality of narrow bands.

21. The singler conveyor apparatus of claim 14, the first conveyance lane and the third conveyance lane being the same height.

22. The singler conveyor apparatus of claim 14, wherein the articles on both the first conveyance lane high-friction surface and the third conveyance lane high-friction surface are to be conveyed straight along a main flow.

23. The singler conveyor device of claim 14, wherein the first and third conveyance lanes travel at the same rate so that large parcels resting on the first and third conveyance lanes are conveyed through the singler conveyor device.

24. The singler conveyor apparatus of claim 14, wherein the second conveyor lane is inclined at an obtuse angle relative to the longitudinal direction, and the speed of the second conveyor lane is set so that it has a forward longitudinal component equal to the forward speed of the first conveyor lane, such that parcels resting on both the first conveyor lane and the second conveyor lane will travel forward without rotating.

25. The radio conveyor device according to claim 14, wherein the width of the high friction surface of the first conveyor channel increases and the width of the high surface area of the third conveyor channel decreases on the exit channel side.

26. The radio conveyor device according to claim 25, wherein a width of the low friction second conveyor lane disposed between the first conveyor lane and the third conveyor lane varies in width as a function of the width of the first conveyor lane and the second conveyor lane.

27. The radio conveyor device of claim 25, wherein the width variations of the high friction first and third conveyor channels vary accordingly such that the widths of the first, second and third conveyor surfaces are the same from a feed end of the conveyor to a discharge end of the conveyor.