A conveyor system includes a conveyor belt having a plurality of article-diverting conveyor belt rollers. An underlying drive roller assembly includes a plurality of pivotable rollers carriers, each having a freely rotatable drive roller that contacts the conveyor belt rollers from below. An actuator engages an orientation device to pivot the carriers and change the orientation of the drive rollers. The drive rollers may also move into and out of engagement with the conveyor belt rollers as their orientation changes. The orientation device is sandwiched between three-dimensional support plates to adjust the orientation of the drive rollers relative to the belt rollers. A top support plate includes corrugated vertical walls forming wearstrip holders. The orientation device may raise or lower the drive rollers during pivoting of the roller carriers. The drive roller assembly may be a modular assembly that can be customized for varying sizes, shapes and configurations.

An order fulfillment system is disclosed in which objects to be collected into orders are provided in output totes. The system includes a primary sortation system that includes a loop conveyance system that moves objects around a closed loop that includes a plurality of primary sortation exits, each of which leads to a location inside the closed loop, and a secondary sortation system that includes a plurality of secondary conveyances, each of which receives an object at one of the plurality of primary sortation exits, and conveys the object to one of a plurality of totes, the plurality of totes being within the closed loop of the primary sortation system.

A workpiece diverter station is disclosed. The workpiece diverter station includes: a base frame; an X-direction workpiece transporter subassembly; a Z-direction lift assembly; and a Y-direction workpiece transporter subassembly. The X-direction workpiece transporter subassembly is axially fixedly supported with respect to the base frame in a Z-direction. The Z-direction lift assembly is supported by the base frame. The Y-direction workpiece transporter subassembly is connected to the Z-direction lift assembly and is axially movably supported with respect to the base frame in the Z-direction. A portion of a workpiece diverter station is also disclosed. A method for operating a workpiece diverter station is also disclosed. A method for servicing a portion of a workpiece diverter station is also disclosed.

A workpiece diverter station is disclosed. The workpiece diverter station includes: a base frame; an X-direction workpiece transporter subassembly; a Z-direction lift assembly; and a Y-direction workpiece transporter subassembly. The X-direction workpiece transporter subassembly is axially fixedly supported with respect to the base frame in a Z-direction. The Z-direction lift assembly is supported by the base frame. The Y-direction workpiece transporter subassembly is connected to the Z-direction lift assembly and is axially movably supported with respect to the base frame in the Z-direction. A portion of a workpiece diverter station is also disclosed. A method for operating a workpiece diverter station is also disclosed. A method for servicing a portion of a workpiece diverter station is also disclosed.

An order fulfillment system is disclosed in which objects to be collected into orders are provided in output totes. The system includes a primary sortation system that includes a loop conveyance system that moves objects around a closed loop that includes a plurality of primary sortation exits, each of which leads to a location inside the closed loop, and a secondary sortation system that includes a plurality of secondary conveyances, each of which receives an object at one of the plurality of primary sortation exits, and conveys the object to one of a plurality of totes, the plurality of totes being within the closed loop of the primary sortation system.

A sorting conveyor system (46) comprising a main conveyor line (48) intersected by cross conveyors (18) having roller-top conveyor belts (20). The roller-top conveyor belts, which can be driven bidirectionally perpendicular to the conveying direction of the main conveyor line, have article-supporting belt rollers (22) that can rotate freely in the main conveying direction (14). Articles (38) fed from the main conveying line onto the cross conveyor can be sorted to the left or the right by the conveyor belt. Articles destined for sorting downstream pass over the stopped roller-top conveyor belt atop the freely rotatable belt rollers and back onto the main conveyor line. A booster (40), such as a motorized roller (40), between the main conveyor line and the cross conveyor applies a force in the main conveying direction against articles destined to cross the cross conveyor.

A sorting conveyor system (46) comprising a main conveyor line (48) intersected by cross conveyors (18) having roller-top conveyor belts (20). The roller-top conveyor belts, which can be driven bidirectionally perpendicular to the conveying direction of the main conveyor line, have article-supporting belt rollers (22) that can rotate freely in the main conveying direction (14). Articles (38) fed from the main conveying line onto the cross conveyor can be sorted to the left or the right by the conveyor belt. Articles destined for sorting downstream pass over the stopped roller-top conveyor belt atop the freely rotatable belt rollers and back onto the main conveyor line. A booster (40), such as a motorized roller (40), between the main conveyor line and the cross conveyor applies a force in the main conveying direction against articles destined to cross the cross conveyor.

A grid sorter for discharging articles received from many inputs to selected discharge destinations. The grid sorter comprises a rectangular grid of parallel conveyor lines. Each line has a series of bidirectional conveyors fed articles by infeed conveyors at each end of the line. Omnidirectional-roller sorters, at the intersections of the conveyor lines, can pass articles received from one line in multiple directions: along that same line; in either direction to an intersecting line; or obliquely to a selected discharge between lines. Omnidirectional rollers in the omnidirectional-roller sorters are controlled by a controller to push articles in selected directions to predetermined discharge destinations.

A grid sorter for discharging articles received from many inputs to selected discharge destinations. The grid sorter comprises a rectangular grid of parallel conveyor lines. Each line has a series of bidirectional conveyors fed articles by infeed conveyors at each end of the line. Omnidirectional-roller sorters, at the intersections of the conveyor lines, can pass articles received from one line in multiple directions: along that same line; in either direction to an intersecting line; or obliquely to a selected discharge between lines. Omnidirectional rollers in the omnidirectional-roller sorters are controlled by a controller to push articles in selected directions to predetermined discharge destinations.

A grouping station for grouping pallets includes an inbound conveyor, which is a gravity conveyor. The grouping station includes a fixed-height pairing conveyor and a grouping conveyor with three height positions for different grouping functions.