Description:FIELD OF DISCLOSURE
The present disclosure relates to conveyor systems for parcel handling, and more particularly to conveyor system, method, and conveyor setup for parcel transfer.
BACKGROUND
Conveyor systems play a crucial role in modern logistics and material handling operations across various industries. These systems are designed to efficiently transport goods, packages, and materials from one point to another, streamlining processes and improving productivity in warehouses, distribution centers, and manufacturing facilities.
Conventional conveyor systems typically consist of a series of rollers or belts that move items along a predetermined path. While these systems have been widely adopted and have proven effective in many applications, they often face challenges when transferring items between different conveyor sections, particularly when there are changes in direction or elevation. Common issues include items getting stuck, misaligned, or damaged during the transfer process, leading to system downtime, reduced efficiency, and potential product loss.
Existing transfer mechanisms between conveyors have attempted to address these challenges through various means, such as gravity-assisted chutes, powered transfer belts, or pneumatic systems. However, these solutions often have limitations in terms of adaptability to different parcel sizes and shapes, maintenance requirements, and the ability to handle high-volume transfers without compromising item integrity. Additionally, many current systems lack effective means of detecting and resolving transfer issues in real-time, leading to prolonged disruptions in the conveyor operation.
Therefore, there exists a need for a technical solution that solves the aforementioned problems of conventional systems and methods for conveyor systems and parcel transfer mechanisms.
SUMMARY
This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
In an aspect of the present disclosure, a conveyor setup for transferring parcels is disclosed. The conveyor setup includes a donor conveyor configured to move one or more parcels. The conveyor setup includes a receiving conveyor configured to receive the one or more parcels from the donor conveyor. The conveyor setup includes a funnel disposed downstream of the donor conveyor to guide the one or more parcels onto the receiving conveyor. The conveyor setup includes a transfer mechanism disposed between the donor conveyor and the receiving conveyor. The transfer mechanism includes a transfer plate having an adjustable inclination with respect to a horizontal plane. A first end of the transfer plate is aligned with a center of a roller of the donor conveyor such that the transfer plate maintains a consistent gap from a belt of the donor conveyor. The transfer mechanism includes a sliding plate having an adjustable inclination with respect to the horizontal plane such that the sliding plate is disposed proximate to a second end of the transfer plate with an offset relative to the transfer plate.
In some aspects of the present disclosure, the transfer mechanism includes a sensor array disposed below the gap between the transfer plate and the donor conveyor. The sensor array is configured to sense signals representing one or more stuck parcels of the one or more parcels and enables processing circuitry of an information processing apparatus to control the donor conveyor.
In some aspects of the present disclosure, the adjustable inclination with respect to the horizontal plane of the transfer plate is in a range of 30 degrees to 60 degrees.
In some aspects of the present disclosure, the adjustable inclination with respect to the horizontal plane of the sliding plate is in a range of 30 to 60 degrees.
In some aspects of the present disclosure, the offset between the transfer plate and the sliding plate is adjustable in a range of 10 millimeters (mm) to 40 mm.
In some aspects of the present disclosure, the gap between the donor conveyor and transfer plate is in a range of 0.5 mm to 4mm.
In an aspect of the present disclosure, a conveyor system for parcel handling is disclosed. The conveyor system includes a conveyor setup for transferring parcels. The conveyor setup includes a donor conveyor configured to move one or more parcels. The conveyor setup includes a receiving conveyor configured to receive the one or more parcels from the donor conveyor. The conveyor setup includes a funnel disposed downstream of the donor conveyor to guide the one or more parcels onto the receiving conveyor. The conveyor setup includes a transfer mechanism disposed between the donor conveyor and the receiving conveyor. The transfer mechanism includes a transfer plate having an adjustable inclination with respect to a horizontal plane. A first end of the transfer plate is aligned with a center of a roller of the donor conveyor at one end such that the transfer plate maintains a consistent gap from a belt of the donor conveyor. The transfer mechanism includes a sliding plate having an adjustable inclination with respect to the horizontal plane such that the sliding plate is disposed proximate to a second end of the transfer plate with an offset relative to the transfer plate. The conveyor setup includes a sensor array disposed below the gap between the transfer plate and the donor conveyor. The sensor array is configured to sense signals representing one or more stuck parcels of the one or more parcels. The conveyor system includes an information processing apparatus coupled to the conveyor setup. The information processing apparatus includes processing circuitry configured to control operation of the donor conveyor based on the sensed signals.
In some aspects of the present disclosure, to control the operation of the donor conveyor, the processing circuitry is configured to turn off the donor conveyor when a stuck parcel of the one or more parcels is detected. The processing circuitry is configured to move the donor conveyor in a reverse direction to clear the stuck parcel. The processing circuitry is configured to automatically resume the operation of the donor conveyor when the stuck parcel is cleared.
In some aspects of the present disclosure, the adjustable inclination with respect to the horizontal plane of the transfer plate is in a range of 30 degrees to 60 degrees. The adjustable inclination with respect to the horizontal plane of the sliding plate is in a range of 30 to 60 degrees. The offset between the transfer plate and the sliding plate is adjustable in a range of 10 millimeters (mm) to 40 mm.
In some aspects of the present disclosure, the gap between the donor conveyor and transfer plate is in a range of 0.5 mm to 4mm
In an aspect of the present disclosure, a method for transferring parcels between conveyors is disclosed. The method includes moving one or more parcels on a donor conveyor towards a receiving conveyor. The method includes guiding the one or more parcels from the donor conveyor to the receiving conveyor via a transfer mechanism having a funnel disposed between the donor conveyor and the receiving conveyor. The method includes detecting, using a sensor array disposed below a gap between the transfer plate and the donor conveyor, presence of a stuck parcel. The method includes controlling, by processing circuitry of an information processing apparatus, operation of the donor conveyor based on the detection of the stuck parcel.
In some aspects of the present disclosure, the method includes adjusting an inclination with respect to the horizontal plane of the transfer plate in a range of 30 to 60 degrees. The method includes adjusting an inclination with respect to the horizontal plane of the sliding plate in a range of 30 to 60 degrees. The method includes maintaining an offset between the transfer plate and the sliding plate in a range of 10 millimeters (mm) to 40 mm.
In some aspects of the present disclosure, the gap between the donor conveyor and transfer plate is in a range of 0.5 mm to 4mm.
In some aspects of the present disclosure, controlling the operation of the donor conveyor includes turning off, by way of the processing circuitry, the donor conveyor when a stuck parcel is detected. Controlling the operation of the donor conveyor includes moving, by way of the processing circuitry, the donor conveyor in a reverse direction to clear the stuck parcel. Controlling the operation of the donor conveyor includes automatically resuming operation of the donor conveyor when the stuck parcel is cleared.
The foregoing general description of the illustrative aspects and the following detailed description thereof are merely exemplary aspects of the teachings of this disclosure and are not restrictive.
BRIEF DESCRIPTION OF FIGURES
The following detailed description of the preferred aspects of the present disclosure will be better understood when read in conjunction with the appended drawings. The present disclosure is illustrated by way of example, and not limited by the accompanying figures, in which like references indicate similar elements.
FIG. 1 illustrates a block diagram of a conveyor system for parcel handling and processing, according to aspects of the present disclosure;
FIG. 2A illustrates an isometric view of a conveyor setup for transferring parcels between conveyors, according to aspects of the present disclosure;
FIG. 2B illustrates an enlarged view of a transfer mechanism for conveying parcels between conveyors, according to aspects of the present disclosure;
FIG. 2C illustrates another enlarged view of the transfer mechanism for the conveyor system, according to aspects of the present disclosure;
FIG. 3 illustrates a block diagram of an information processing apparatus of the conveyor system, according to aspects of the present disclosure; and
FIG. 4 illustrates a flowchart of a method for transferring parcels between conveyors, according to aspects of the present disclosure.

DETAILED DESCRIPTION
The following description sets forth exemplary aspects of the present disclosure. It should be recognized, however, that such description is not intended as a limitation on the scope of the present disclosure. Rather, the description also encompasses combinations and modifications to those exemplary aspects described herein.
The present disclosure relates to conveyor systems for parcel handling, and more particularly to a conveyor system, method, and conveyor setup for efficient and damage-free transfer of parcels between conveyors. The conveyor system may include a donor conveyor configured to move parcels, a receiving conveyor configured to receive parcels from the donor conveyor, a funnel disposed downstream of the donor conveyor to guide the one or more parcels onto the receiving conveyor, and a transfer mechanism disposed between the donor and receiving conveyors. The transfer mechanism may include a transfer plate having an adjustable inclination with respect to a horizontal plane. A first end of the transfer plate may be aligned with a center of a roller of the donor conveyor at one end such that the transfer plate maintains a consistent gap from a belt of the donor conveyor. The transfer mechanism may further include a sliding plate having an adjustable inclination with respect to the horizontal plane such that the sliding plate is disposed proximate to a second end of the transfer plate with an offset relative to the transfer plate. A sensor array may be positioned below the gap between the transfer plate and donor conveyor to detect stuck parcels. The system may further include an information processing apparatus with processing circuitry configured to control donor conveyor operation based on signals from the sensor array. Such an configuration may allow for smooth transfer of parcels between conveyors while maintaining zero risk of damage The system may be adaptable to various parcel sizes and shapes, potentially improving efficiency in logistics operations, e-commerce fulfillment centers, and other applications where damage-free parcel handling is critical.
FIG. 1 illustrates a block diagram of a conveyor system 100 for parcel handling and processing. The conveyor system 100 comprises a conveyor setup 102, an information processing apparatus 104, and a communication network 106 interconnecting these components.
The conveyor setup 102 may include a donor conveyor 200 configured to move one or more parcels. The conveyor setup 102 may further include a receiving conveyor 202 configured to receive the one or more parcels from the donor conveyor 200. The conveyor setup 102 may include a transfer mechanism 108 disposed between the donor conveyor 200 and the receiving conveyor 202. The transfer mechanism 108 may be designed to facilitate the movement of parcels between the donor conveyor 200 and the receiving conveyor 202. The conveyor setup 102 may further include a sensor array 110 configured to detect and monitor the parcels during the transfer process.
Although FIG. 1 illustrates that the conveyor system 100 includes a single donor conveyor 200 and a single receiving conveyor 202, it will be apparent to a person skilled in the art that the scope of the present disclosure is not limited to it. In various other aspects, the conveyor system 100 may include multiple donor conveyors and multiple receiving conveyors without deviating from the scope of the present disclosure. In such a scenario, each conveyor may be configured to perform one or more operations in a manner similar to the operations of the donor conveyor 200 and receiving conveyor 202 as described herein.
The information processing apparatus 104 may include processing circuitry 112 and a database 114. The processing circuitry 112 may be responsible for processing data received from the conveyor setup 102, while the database 114 may store relevant information for system operation.
The communication network 106 may serve as the central hub for data exchange between the conveyor setup 102 and the information processing apparatus 104. The communication network 106 may enable bidirectional communication, allowing for real-time data transfer and system control.
The conveyor system 100 may operate by continuously monitoring parcel movement through the sensor array 110 in the conveyor setup 102. The data may be transmitted via the communication network 106 to the information processing apparatus 104, where it may be processed by the processing circuitry 112 and stored in the database 114 if necessary. Based on the processed information, the conveyor system 100 may make decisions to optimize parcel handling and minimize potential damage during transfer.
The sensor array 110 may include various types of sensors such as optical sensors, pressure sensors, or infrared sensors to detect parcel presence and movement. In some aspects, the sensor array 110 may include machine vision systems for more advanced parcel tracking and identification.
Examples of the sensor array 110 may include, but are not limited to, optical sensors, pressure sensors, infrared sensors, machine vision systems, or the like. Aspects of the present disclosure are intended to include and/or otherwise cover any type of the sensor array 110 known to a person having ordinary skill in the art, without deviating from the scope of the present disclosure.
The processing circuitry 112 may include a data collection engine, a data processing engine, and a belt control engine. These engines may work in conjunction to process sensor data, make decisions, and control the conveyor system 100.
The database 114 may store historical data on parcel transfers, system performance metrics, and configuration parameters. The data may be used for system optimization and predictive maintenance.
FIG. 2A illustrates an isometric view of a conveyor setup 102 for transferring parcels between conveyors. The conveyor setup 102 may include a donor conveyor 200 and a receiving conveyor 202. The donor conveyor 200 and the receiving conveyor 202 may be positioned at an angle to each other, forming an L-shaped configuration.
Between the donor conveyor 200 and the receiving conveyor 202, a transfer mechanism 108 may be disposed. The transfer mechanism 108 may include a sliding plate 208 and a transfer plate 206. The sliding plate 208 may be positioned at an angle, bridging the gap between the two conveyors. The transfer plate 206 may be located at the end of the donor conveyor 200, facilitating transition of parcels from the donor conveyor 200 to the sliding plate 208.
At the junction of the two conveyors, a funnel 204 may be positioned, which facilitates in guiding parcels from the sliding plate 208 onto the receiving conveyor 202.
A sensor array 110 may be positioned beneath the gap of the transfer plate 206 and the donor conveyor 200. The sensor array 110 may detect the presence and movement of parcels as the parcels transition between conveyors.
The entire setup may be supported by a series of legs or supports, providing stability to the conveyor system 100. The design of the conveyor setup 102 may allow for the efficient transfer of parcels from one conveyor to another, potentially maintaining zero risk of damage or mishandling during the transfer process.
In some aspects of the present disclosure, the angle between the donor conveyor 200 and the receiving conveyor 202 may be adjustable to accommodate different layout requirements. The transfer mechanism 108 may be designed to adapt to the angle changes automatically.
The sliding plate 208 and transfer plate 206 may have adjustable inclinations with respect to horizontal plane. The inclination of the transfer plate 206 may be adjustable in a range of 30 degrees to 60 degrees. The inclination of the sliding plate 208 with respect to the horizontal plane may be adjustable in a range of 30 to 60 degrees. These adjustments may allow for optimization of parcel transfer for different parcel sizes and weights.
The funnel 204 may be designed to accommodate different parcel sizes.. The sensor array 110 may include multiple sensor types arranged in a grid pattern. Such a configuration may allow for precise tracking of parcel position and movement throughout the transfer process.
FIG. 2B illustrates a perspective view of a transfer mechanism 108 for conveying parcels between conveyors.
The transfer mechanism 108 may comprise several components designed to facilitate smooth parcel transfer. The components of the transfer mechanism 108 may be arranged to work together to facilitate the efficient and controlled movement of parcels from one conveyor to another, potentially maintaining zero damage to parcels.
In some aspects of the present disclosure, a first end of the transfer plate 206 may be aligned with the center of a roller of the donor conveyor 200. The alignment of transfer plate 206 at the center of the roller of the donor conveyor 200 advantageously minimizes the risk of parcels getting stuck during the transfer. The alignment may further ensure that the transfer plate 206 maintains a consistent gap from the belt of the donor conveyor 200. The gap may be adjustable in a range of 0.5 millimeters (mm) to 4 mm to accommodate different parcel sizes and conveyor belt types.
The sliding plate 208 may be disposed proximate to a second end of the transfer plate with an offset relative to the transfer plate 206 such that the second end of the transfer plate may approach towards the sliding plate 208. The offset may be adjustable in a range of 10 millimeters (mm) to 40 mm. The offset may help prevent parcels from getting stuck during the transfer process by creating a slight drop between the two plates. The offset may further allow a tail end of the parcel to lift away from the gap between the transfer plate 206 and the donor conveyor 200. The combined effect of angle of inclination with respect to horizontal plane of sliding plate 208 and the offset relative to the transfer plate 206 may advantageously facilitate in sliding of parcels thereby minimizing the risk of parcels jumping directly to the receiving conveyor. The sliding of parcels thus facilitates in maintaining parcel integrity and continuity in the transfer process and thereby maintaining zero damage to the parcels.
The sensor array 110 may include optical sensors, pressure sensors, or a combination of both. The sensor array 110 may be arranged in a pattern that allows for detection of parcels of various sizes and shapes.
FIG. 2C illustrates a detailed view of a transfer mechanism 108 for the conveyor system 100. As illustrated in FIG. 2C, a close-up, sectional view of the components involved in transferring parcels between conveyors may be depicted. The transfer plate 206 may be positioned at an angle with respect to the horizontal plane, which may be adjustable within a range of 30 to 60 degrees. Such angled configuration may facilitate the smooth transition of parcels.
Adjacent to the transfer plate 206, the sliding plate 208 may be set at an angle with respect to the horizontal plane ranging between 30 to 60 degrees. The sliding plate 208 may be positioned with an offset relative to the transfer plate 206, creating a gap between them. Such an arrangement may be designed to prevent parcels from getting stuck during the transfer process and facilitate in providing adaptability for relative positioning between the transfer plate 206 and the sliding plate 208.
The sensor array 110 positioned below the gap between the transfer plate 206 and the donor conveyor 200. The sensor array 110 may be used to detect any parcels that may become stuck during the transfer process.
Various structural elements including rollers, support brackets, and fasteners, which may contribute to the overall functionality of the transfer mechanism 108. As illustrated in FIG. 2C, a measurement of 0.5 mm to 4 mm gap between the transfer plate 206 and the donor conveyor 200 may be present.
The transfer mechanism 108 may be designed to facilitate the smooth and efficient transfer of parcels between conveyor belts while maintaining zero risk of damage. The angled plates and the sensor array 110 may work together to ensure a controlled and monitored transfer process with zero damage.
In some aspects of the present disclosure, the transfer plate 206 and sliding plate 208 may be made of materials with different coefficients of friction.
The offset between the transfer plate 206 and the sliding plate 208 may be adjustable using precision actuators. These actuators may allow for fine-tuning of the gap to optimize transfer for different parcel types.
In some aspects of the present disclosure, the transfer plate 206 may be aligned with the center of the donor conveyor's roller at one end, ensuring a consistent gap between the donor conveyor 200 belt and the transfer plate 206. Such an alignment may be crucial in maintaining a smooth transition of parcels and maintaining zero risk of damage during transfer.
The sliding plate 208 may be positioned with an offset relative to the transfer plate 206. The offset may be adjustable in a range of 10 millimeters (mm) to 40 mm. The combination of the sliding plate's angle and its offset from the transfer plate 206 may facilitate an easy slide of parcels, effectively preventing the tail ends of parcels from getting stuck during the transfer process. Furthermore, such a configuration may minimize the risk of parcels jumping directly to the receiving conveyor 202, thereby ensuring a controlled and damage-free transfer.
The funnel 204, acting as an end-joint, may be placed downstream of the transfer mechanism 108. The funnel 204 may efficiently guide parcels onto the receiving conveyor 202, further contributing to the system's ability to achieve zero damage to parcels in bulk flow. The design and positioning of the funnel 204 may be optimized to handle various parcel sizes and shapes, ensuring consistent performance across different types of items.
FIG. 3 illustrates a block diagram of an information processing apparatus 104 for a parcel handling system. The apparatus 104 may comprise several interconnected components designed to process data and control conveyor belt operations.
The information processing apparatus 104 may include a network interface 300 and an I/O interface 302, which may facilitate communication with external devices and systems. The network interface 300 and the I/O interface 302 may be connected to the processing circuitry 112 via a first data bus 304.
The processing circuitry 112 may form the core of the apparatus and may contain three main components: a data collection engine 306, a data processing engine 308, and a belt control engine 310. These engines may be interconnected and communicate via a second data bus 312 within the processing circuitry 112.
The data collection engine 306 may be responsible for gathering information from various sources, such as sensors or external inputs. The data processing engine 308 may analyze and interpret the collected data. The belt control engine 310 may use the processed information to manage and control the conveyor belt conveyor system 100.
Connected to the processing circuitry 112 via the first data bus 304 may be a database 114. The database 114 may store relevant information for the system's operation, which may include historical data, operational parameters, or system configurations.
The components within the information processing apparatus 104 may work together to collect, process, and utilize data for efficient parcel handling. The network interface 300 and I/O interface 302 may allow for data input and output, while the processing circuitry 112 may perform the necessary computations and decision-making. The database 114 may provide storage and retrieval capabilities for the system's data.
In some aspects of the present disclosure, the data collection engine 306 may be configured to receive signals from the sensor array 110 in the conveyor setup 102. These signals may represent the presence, position, and movement of parcels on the conveyor system 100. The data collection engine 306 may further receive inputs from external systems, such as warehouse management systems or order processing systems, to coordinate parcel handling with broader logistics operations.
The data processing engine 308 may be configured to analyze the collected data to identify patterns, detect anomalies, and make predictions about parcel flow. It may use machine learning algorithms to continuously improve its understanding of the conveyor system's behavior under different conditions. The data processing engine 308 may further be responsible for identifying stuck parcels based on the signals from the sensor array 110.
The belt control engine 310 may be configured to control the operation of the donor conveyor 200 based on the processed data. When a stuck parcel is detected, the belt control engine 310 may be configured to turn off the donor conveyor 200, move it in a reverse direction to clear the stuck parcel, and automatically resume operation when the parcel is cleared. The belt control engine 310 may further adjust conveyor speeds.
The database 114 may store historical data on parcel transfers, system performance metrics, and configuration parameters. The data may be used by the data processing engine 308 for trend analysis and system optimization. The database 114 may further store predefined rules and thresholds for system operation, which may be updated based on learned patterns and performance data.
FIG. 4 illustrates a flowchart of a method 400 for transferring parcels between conveyors. The method 400 may comprise several steps designed to handle parcel movement and address potential issues during the transfer process.
At step 402, the conveyor system 100 may move one or more parcels on a donor conveyor 200 towards a receiving conveyor 202. The donor conveyor 200 may be configured to transport parcels at a controlled speed towards the transfer mechanism 108.
At step 404, the conveyor system 100 may guide the one or more parcels from the donor conveyor 200 to the receiving conveyor 202 via a transfer mechanism 108 having a funnel 204 disposed between the donor conveyor 200 and the receiving conveyor 202. The transfer mechanism 108 may use the transfer plate 206 and sliding plate 208 to facilitate smooth parcel transition, while the funnel 204 may help align parcels onto the receiving conveyor 202.
At step 406, the conveyor system 100 may detect, using a sensor array 110 disposed below a gap between the transfer plate 206 and the donor conveyor 200, the presence of a stuck parcel. The sensor array 110 may continuously monitor the gap for any obstructions or irregularities in parcel movement.
At step 408, the conveyor system 100 may determine when a parcel is stuck by way of the sensor array 110. When no parcel is stuck, the method 400 may loop back to step 406 to continue monitoring for stuck parcels.
When a parcel is determined to be stuck, the method 400 may proceed to step 410, where the conveyor system 100 may turn off the donor conveyor 200. This immediate stop may prevent further parcels from entering the transfer mechanism 108 and potentially exacerbating the issue.
At step 412, the conveyor system 100 may move the donor conveyor 200 in a reverse direction to clear the stuck parcel. The reverse movement may help dislodge the stuck parcel and return it to the donor conveyor 200.
Once the stuck parcel is cleared, at step 414, the conveyor system 100 may automatically resume the operation of the donor conveyor 200. The conveyor system 100 may verify that the transfer mechanism 108 is clear before restarting the conveyor.
In some aspects of the present disclosure, the method 400 may include additional steps for optimizing the transfer process. For example, the method 400 may include adjusting the inclination of the transfer plate 206 with respect to the horizontal plane in a range of 30 to 60 degrees and adjusting the inclination of the sliding plate 208 with respect to the horizontal plane in a range of 30 to 60 degrees based on parcel characteristics and transfer performance data. The method 400 may further include maintaining the offset between the transfer plate 206 and the sliding plate 208 in a range of 10 millimeters (mm) to 40 mm for smooth transfer of parcels between the plates.
The method 400 may further include steps for data collection and analysis. The conveyor system 100 may continuously collect data on parcel transfers, including successful transfers and instances of stuck parcels. The data may be analyzed to identify patterns and optimize system parameters for improved performance over time.
In operation, the conveyor system 100 may function to achieve zero damage to parcels in bulk flow. The donor conveyor 200 may move parcels towards the transfer mechanism 108, where the transfer plate 206, aligned with the center of the donor conveyor's roller, may maintain a consistent gap from the donor conveyor belt. Such an alignment may be crucial for ensuring a smooth transition of parcels and maintaining zero risk of damage during transfer.
As parcels move from the transfer plate 206 to the sliding plate 208, the offset between the transfer plate 206 and the sliding plate 208 may facilitate an easy slide of parcels. Such a configuration may effectively prevent the tail ends of parcels from getting stuck during the transfer process. Furthermore, the combination of the sliding plate's angle and its offset from the transfer plate 206 may minimize the risk of parcels jumping directly to the receiving conveyor 202, thereby ensuring a controlled and damage-free transfer.
The funnel 204, positioned downstream of the transfer mechanism 108, may act as an end-joint to efficiently guide parcels onto the receiving conveyor 202. The design and positioning of the funnel 204 may be optimized to handle various parcel sizes and shapes, further contributing to the system's ability to achieve zero damage to parcels in bulk flow.
Throughout the transfer process, the sensor array 110 may continuously monitor for any irregularities or stuck parcels. If a stuck parcel is detected, the conveyor system 100 may immediately respond by stopping the donor conveyor 200, reversing its direction to clear the stuck parcel, and then automatically resuming operation once the issue is resolved. Such rapid response mechanism may help prevent cascading issues and maintain the overall efficiency of the parcel handling process.
The information processing apparatus 104 may play a crucial role in optimizing the system's performance. By continuously collecting and analyzing data from the conveyor setup 102, the processing circuitry 112 may make real-time adjustments to conveyor speeds, and other parameters. Such adaptive control may help the conveyor system 100 maintain optimal performance across varying parcel types and volumes, further enhancing its ability to achieve zero damage in bulk parcel flow.
In some aspects of the present disclosure, the conveyor system 100 may be scalable and adaptable to various conveyor configurations and warehouse layouts. The modular nature of the transfer mechanism 108 may allow for easy integration into existing conveyor systems, potentially improving parcel handling efficiency without requiring a complete overhaul of existing infrastructure.
The combination of precisely engineered mechanical components and advanced data processing capabilities may enable the conveyor system 100 to handle a wide range of parcel sizes, shapes, and weights with damage free. Such versatility may make the conveyor system 100 particularly suitable for use in high-volume logistics operations, e-commerce fulfillment centers, and other applications where efficient and damage-free parcel handling is critical.
By achieving zero damage in bulk parcel flow, the conveyor system 100 may offer significant benefits in terms of reduced product losses, decreased customer returns, and improved overall operational efficiency. These improvements may translate into cost savings and enhanced customer satisfaction for businesses utilizing the conveyor system 100.
Thus, the conveyor system 100, the conveyor setup 102, and the method 400 provides several technical advantages. The conveyor system 100 achieves zero damage to parcels in bulk flow through its precisely engineered transfer mechanism 108, reducing product losses and customer returns. The adjustable inclination of the transfer plate 206 and sliding plate 208, along with their optimized offset, ensures smooth parcel transitions and prevents parcels from getting stuck or jumping during transfer. The sensor array 110 enables real-time detection of stuck parcels, allowing for immediate corrective action through automated control of the donor conveyor 200. The modular and scalable nature of the conveyor system 100 allows for easy integration into existing conveyor setups, improving efficiency without requiring complete infrastructure overhauls. Additionally, the system's ability to handle a wide range of parcel sizes, shapes, and weights makes it versatile for various high-volume logistics operations. The combination of mechanical precision and advanced data processing capabilities enables continuous optimization of the system's performance, adapting to varying parcel types and volumes in real-time.
Aspects of the present disclosure are discussed here with reference to flowchart illustrations and block diagrams that depict methods, systems, and apparatus in accordance with various aspects of the present disclosure. Each block within these flowcharts and diagrams, as well as combinations of these blocks, can be executed by computer-readable program instructions. The various logical blocks, modules, circuits, and algorithm steps described in connection with the disclosed aspects may be implemented through electronic hardware, software, or a combination of both. To emphasize the interchangeability of hardware and software, the various components, blocks, modules, circuits, and steps are described generally in terms of their functionality. The decision to implement such functionality in hardware or software is dependent on the specific application and design constraints imposed on the overall system. Person having ordinary skill in the art can implement the described functionality in different ways depending on the particular application, without deviating from the scope of the present disclosure.
The flowcharts and block diagrams presented in the figures depict the architecture, functionality, and operation of potential implementations of systems, methods, and apparatus according to different aspects of the present disclosure. Each block in the flowcharts or diagrams may represent an engine, segment, or portion of instructions comprising one or more executable instructions to perform the specified logical function(s). In some alternative implementations, the order of functions within the blocks may differ from what is depicted. For instance, two blocks shown in sequence may be executed concurrently or in reverse order, depending on the required functionality. Each block, and combinations of blocks, can also be implemented using special-purpose hardware-based systems that perform the specified functions or tasks, or through a combination of specialized hardware and software instructions.
Although the preferred aspects have been detailed here, it should be apparent to those skilled in the relevant field that various modifications, additions, and substitutions can be made without departing from the scope of the disclosure. These variations are thus considered to be within the scope of the disclosure as defined in the following claims.
Features or functionalities described in certain example aspects may be combined and re-combined in or with other example aspects. Additionally, different aspects and elements of the disclosed example aspects may be similarly combined and re-combined. Further, some example aspects, individually or collectively, may form components of a larger system where other processes may take precedence or modify their application. Moreover, certain steps may be required before, after, or concurrently with the example aspects disclosed herein. It should be noted that any and all methods and processes disclosed herein can be performed in whole or in part by one or more entities or actors in any manner.
Although terms like "first," "second," etc., are used to describe various elements, components, regions, layers, and sections, these terms should not necessarily be interpreted as limiting. They are used solely to distinguish one element, component, region, layer, or section from another. For example, a "first" element discussed here could be referred to as a "second" element without departing from the teachings of the present disclosure.
The terminology used here is intended to describe specific example aspects and should not be considered as limiting the disclosure. 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," "includes," "comprising," and "including," as used herein, indicate the presence of stated features, steps, elements, or components, but do not exclude the presence or addition of other features, steps, elements, or components.
As used herein, the term "or" is intended to be inclusive, meaning that "X employs A or B" would be satisfied by X employing A, B, or both A and B. Unless specified otherwise or clearly understood from the context, this inclusive meaning applies to the term "or."
Unless otherwise defined, all terms used herein (including technical and scientific terms) have the same meaning as commonly understood by one of ordinary skill in the relevant art. Terms should be interpreted consistently with their common usage in the context of the relevant art and should not be construed in an idealized or overly formal sense unless expressly defined here.
The terms "about" and "substantially," as used herein, refer to a variation of plus or minus 10% from the nominal value. This variation is always included in any given measure.
The use of examples or exemplary language (such as "for example") is intended to illustrate aspects of the invention and should not be seen as limiting the scope unless otherwise claimed. No language in the specification should be interpreted as implying that any non-claimed element is essential to the practice of the invention.
While many alterations and modifications of the present invention will likely become apparent to those skilled in the art after reading this description, the specific aspects shown and described by way of illustration are not intended to be limiting in any way.
A number of implementations have been described. Nevertheless, it will be understood that various modifications may be made without departing from the scope of the disclosure. Accordingly, other implementations are within the scope of the following claims.
, Claims:1. A conveyor setup (102) for transferring parcels, comprising:
a donor conveyor (200) configured to move one or more parcels;
a receiving conveyor (202) configured to receive the one or more parcels from the donor conveyor (200);
a funnel (204) disposed downstream of the donor conveyor (200) to guide the one or more parcels onto the receiving conveyor (202); and
a transfer mechanism (108) disposed between the donor conveyor (200) and the receiving conveyor (202), the transfer mechanism (108) comprising:
a transfer plate (206) having an adjustable inclination with respect to horizontal plane, wherein a first end of the transfer plate (206) is aligned with a center of a roller of the donor conveyor (200) such that the transfer plate (206) maintains a consistent gap from a belt of the donor conveyor (200);
a sliding plate (208) having an adjustable inclination with respect to the horizontal plane such that the sliding plate (208) is disposed proximate to a second end of the transfer plate (206) with an offset relative to the transfer plate (206).

2. The conveyor setup (102) as claimed in claim 1, wherein the transfer mechanism (108) further comprising a sensor array (110) disposed below the gap between the transfer plate (206) and the donor conveyor (200), wherein the sensor array (110) is configured to sense signals representing one or more stuck parcels of the one or more parcels and enables processing circuitry (112) of an information processing apparatus (104) to control the donor conveyor (200).

3. The conveyor setup (102) as claimed in claim 1, wherein the adjustable inclination with respect to the horizontal plane of the transfer plate (206) is in a range of 30 degrees to 60 degrees.

4. The conveyor setup (102) as claimed in claim 1, wherein the adjustable inclination with respect to the horizontal plane of the sliding plate (208) is in a range of 30 to 60 degrees.

5. The conveyor setup (102) as claimed in claim 1, wherein the offset between the transfer plate (206) and the sliding plate (208) is adjustable in a range of 10 millimeters (mm) to 40 mm.

6. The conveyor setup (102) as claimed in claim 1, wherein the gap between the donor conveyor and transfer plate is in a range of 0.5 mm to 4mm.

7. A conveyor system (100) for parcel handling, comprising:
a conveyor setup (102) for transferring parcels, comprising:
a donor conveyor (200) configured to move one or more parcels;
a receiving conveyor (202) configured to receive the one or more parcels from the donor conveyor (200);
a funnel (204) disposed downstream of the donor conveyor (200), to guide the one or more parcels onto the receiving conveyor (202); and
a transfer mechanism (108) disposed between the donor conveyor (200) and the receiving conveyor (202), the transfer mechanism (108) comprising:
a transfer plate (206) having an adjustable inclination with respect to horizontal plane, wherein a first end of the transfer plate (206) is aligned with a center of a roller of the donor conveyor (200) such that the transfer plate (206) maintains a consistent gap from a belt of the donor conveyor (200);
a sliding plate (208) having an adjustable inclination with respect to the horizontal plane such that the sliding plate is disposed proximate to a second end of the transfer plate (206) with an offset relative to the transfer plate (206); and
a sensor array (110) disposed below the gap between the transfer plate (206) and the donor conveyor (200), wherein the sensor array (110) is configured to sense signals representing one or more stuck parcels of the one or more parcels;
an information processing apparatus (104) coupled to the conveyor setup (102), the information processing apparatus (104) comprising processing circuitry (112) configured to control operation of the donor conveyor (200) based on the sensed signals.

8. The conveyor system (100) as claimed in claim 7, wherein, to control the operation of the donor conveyor (200), the processing circuitry (112) is configured to:
turn off the donor conveyor (200) when a stuck parcel of the one or more parcels is detected;
move the donor conveyor (200) in a reverse direction to clear the stuck parcel;
and
automatically resume the operation of the donor conveyor (200) when the stuck parcel is cleared.

9. The conveyor system (100) as claimed in claim 7, wherein:
the adjustable inclination with respect to the horizontal plane of the transfer plate (206) is in a range of 30 degrees to 60 degrees;
the adjustable inclination with respect to the horizontal plane of the sliding plate (208) is in a range of 30 to 60 degrees; and
the offset between the transfer plate (206) and the sliding plate (208) is adjustable in a range of 10 millimeters (mm) to 40 mm.

10. The conveyor system (100) as claimed in claim 7, wherein the gap between the donor conveyor and transfer plate is in a range of 0.5 mm to 4mm.
11. A method (400) for transferring parcels between conveyors, the method (400) comprising:
moving (402), one or more parcels on a donor conveyor (200) towards a receiving conveyor (202);
guiding (404), the one or more parcels from the donor conveyor (200) to the receiving conveyor (202) via a transfer mechanism (108) having a funnel (204) disposed between the donor conveyor (200) and the receiving conveyor (202);
detecting (406), by way of a sensor array (110) disposed below a gap between a transfer plate (206) and the donor conveyor (200), presence of a stuck parcel; and
controlling (408), by processing circuitry (112) of an information processing apparatus (104), operation of the donor conveyor (200) based on the detection of the stuck parcel.

12. The method (400) as claimed in claim 11, controlling operation of the donor conveyor (200) further comprising:
adjusting an inclination with respect to the horizontal plane of the transfer plate (206) in a range of 30 to 60 degrees; and
adjusting an inclination with respect to the horizontal plane of a sliding plate (208) in a range of 30 to 60 degrees.
maintaining an offset between the transfer plate (206) and the sliding plate (208) in a range of 0.5 millimeters (mm) to 4 mm.

13. The method (400) as claimed in claim 11, the gap between the donor conveyor and transfer plate is in a range of 0.5 mm to 4mm.

14. The method (400) as claimed in claim 11, wherein controlling the operation of the donor conveyor (200) comprises:
turning off (410), by way of the processing circuitry (112), the donor conveyor (200) when a stuck parcel is detected;
moving (412), by way of the processing circuitry (112), the donor conveyor (200) in a reverse direction to clear the stuck parcel; and
automatically resuming (414) operation of the donor conveyor (200), by way of the processing circuitry (112), when the stuck parcel is cleared.