A method of operating a conveyor system includes providing a fixed, non-powered rail defining a conveyor path, the rail supporting first and second consecutive automated conveyor carriers (ACC), each of which includes a motor-powered self-driving trolley. First and second loads are suspended from the first and second ACCs. The first and second ACCs are driven independently along the rail by executing instructions from independent on-board controllers of the first and second ACCs, wherein a first spacing between the first and second ACCs is maintained through a first section of the rail. The first ACC is accelerated away from the second ACC to increase the spacing from the first spacing to a second spacing for navigating a second section of the rail, the second section being a curved section.

An overhead conveyor system with an elongate box girder (9) having a first inner space with rails (12) and a second elongate inner space comprising an endless driven drive element (5, 6) is provided with at least one carrier (14, 14′) adapted to run on said rails (12) wherein said carrier is provided with an elongated body (C) supporting at least one friction driver (15), wherein said at least one friction driver is in the form of a friction arm assembly (19) with an upper end (20), a lower end (21) and an intermediate portion (22) between said upper and lower ends, said upper end comprising a friction shoe (25) adapted to be pressed upwards by the force of gravity towards engagement with the drive element (5) so as to transfer drive to the carrier.

An overhead conveyor system with an elongate box girder (9) having a first inner space with rails (12) and a second elongate inner space comprising an endless driven drive element (5, 6) is provided with at least one carrier (14, 14′) adapted to run on said rails (12) wherein said carrier is provided with an elongated body (C) supporting at least one friction driver (15), wherein said at least one friction driver is in the form of a friction arm assembly (19) with an upper end (20), a lower end (21) and an intermediate portion (22) between said upper and lower ends, said upper end comprising a friction shoe (25) adapted to be pressed upwards by the force of gravity towards engagement with the drive element (5) so as to transfer drive to the carrier.

A conveyor system includes a fixed, non-powered rail defining a conveyor path. An automated conveyor carrier (ACC) is supported by the rail and drivable along the rail by an on-board motor in a self-driving trolley of the ACC, the motor powering a drive wheel. The rail defines a first section and a second section separate from the first section. The conveyor system is adapted to provide a first amount of traction for the ACC on the rail in the first section and a second amount of traction, greater than the first amount of traction, in the second section.

A method of constructing a conveyor system includes decommissioning an existing conveyor system by removing electrification or a powered chain from a conveyor rail. Carriers of the existing conveyor system are removed from the rail. An automated conveyor carrier (ACC) is installed onto the rail so that a drive wheel of a self-driving trolley of the ACC is put into contact with the rail. A battery is installed on the ACC. Electrical connection is established from the battery to the self-driving trolley.

A conveyorized industrial system includes at least one work station including a heated over chamber. A fixed, non-powered rail defines a conveyor path including an oven zone in which the rail extends through or over the heated oven chamber. An automated conveyor carrier (ACC) is suspended from the rail by a self-driving trolley having an on-board motor for driving the ACC along the rail, and by at least one additional free-rolling trolley. The ACC further comprises an enclosure containing one or both of an inverter and a battery, the enclosure having a wall defining an interior space of the enclosure. A heat protection system is provided in addition to the wall, the heat protection system operating to limit an internal temperature of the enclosure during transport along the oven zone.

A method of operating a conveyor system includes providing a fixed, non-powered rail defining a conveyor path, the rail supporting first and second consecutive automated conveyor carriers (ACC), each of which includes a motor-powered self-driving trolley. First and second loads are suspended from the first and second ACCs. The first and second ACCs are driven independently along the rail by executing instructions from independent on-board controllers of the first and second ACCs, wherein a first spacing between the first and second ACCs is maintained through a first section of the rail. The first ACC is accelerated away from the second ACC to increase the spacing from the first spacing to a second spacing for navigating a second section of the rail, the second section being a curved section.

A method of operating a conveyor system includes providing a fixed, non-powered first rail supporting first and second trolleys of a first carrier, at least one of which is self-driving. The first and second trolley are conveyed in line along the first rail with a load bar therebetween. The first carrier defines a length measured along the first rail and a width measured transverse. The first carrier is conveyed to a branch point where a second rail branches from the first rail. The second trolley is conveyed along the second the rail to turn the first carrier so that it is conveyed with the load bar traversing between the first and second rails. The width is substantially less than the length such that the turning of the first carrier reduces an occupancy of the first carrier along the first rail.

A conveyor system including a fixed, non-powered rail defining a conveyor path, and a plurality of automated conveyor carriers supported on the rail. Each carrier includes an on-board motor and electrical power source selectively powering the motor to drive the carrier along the rail. Each of the plurality of ACCs operates to power the on-board motor from the on-board electrical power source under the direction of instructions programmed to a local controller on the respective ACC. Wherein each of the local controllers of the respective ACCs is programmed to carry out independent power level management for its own on-board electrical power source and configured to selectively operate an adaptive low power indicator to communicate a low power status based only in part on the power level of the on-board battery and further based on one or more parameters of a current work cycle.

A conveyor system comprising a fixed, non-powered rail defining a conveyor path and an automated conveyor carrier (ACC) supported on the rail to be movable along the conveyor path. The ACC includes an on-board motor and an on-board electrical power source selectively powering the on-board motor to drive the ACC along the rail. The ACC may include a wireless sleep mode module operable to selectively shut off power to an on-board ACC controller.