SYSTEMS, DEVICES, AND METHODS FOR EXTENDABLE CONVEYORS

Abstract

Systems, devices, methods and computer program products for extendable conveyors are provided. A system includes an extendable conveyor and a separation module. The extendable conveyor is operable to convey items from an upstream side of the extendable conveyor to a downstream side of the extendable conveyor. Further, it is configured to increase the distance from the upstream side to the downstream side. The separation module is operable for conveying items towards the extendable conveyor and configured to decelerate the conveying of the items on the separation module.

Claims

1. A conveying system comprising: an extendable conveyor, operable to convey items from an upstream side of the extendable conveyor to a downstream side of the extendable conveyor, and configured to increase the distance from the upstream side to the downstream side, a separation module, operable for conveying items towards the extendable conveyor and configured to decelerate the conveying of the items on the separation module wherein the separation module is configured to be positioned relative to the extendable conveyor with a level difference between a conveying surface of the separation module and a conveying surface of the extendable conveyor at its upstream side wherein by decreasing the conveying speed, a deceleration of the items is achieved, and an impulse is imparted on the items, such that a pile of items is separated into single pieces, wherein the item which is the top- and front-most item of the pile falls onto the extendable conveyor.

2. The system according to claim 1, wherein the separation module is configured to convey the items at variable speeds.

3. The system according to claim 1, wherein the separation module is configured to decelerate the conveying of the items fully to a halt.

4. The system according to claim 1, wherein the separation module is configured to convey items at least at a first speed and a second speed, the first speed being smaller than the second speed, and the extendable conveyor is configured to convey items at least at essentially the second speed.

5. The system according to claim 1, wherein the system further comprises one or more sensors configured to detect the presence or absence of items at one or more of the following: the separation module, the upstream side of the extendable conveyor, the downstream side of the extendable conveyor.

6. The system according to claim 1, wherein the system further comprises a flexible strip curtain, the curtain having at least three members, wherein a second Member is positioned between the first and third members and has a higher flexibility than the first and third members.

7. The system according to claim 6, wherein the flexible strip curtain is positioned in proximity to the extendable conveyor.

8. The system according to claim 6, wherein the cross-sections of the first and third members are shaped asymmetrically, such as to impart a force on items travelling along the conveying direction through the curtain, the force acting essentially perpendicular to the conveying direction towards the central longitudinal axis of the extendable conveyor.

9. A separation module for use in a conveying system according to claim 1.

10. A method for controlling a conveying system with an extendable conveyor and a separation module, comprising: detecting a presence of a plurality of items at the separation module; and controlling, responsive to the detecting, a conveying speed of the separation module to decelerate the plurality of items.

11. The method according to claim 10, wherein the detecting further comprises detecting the presence or absence of items at the upstream side of the extendable conveyor and/or detecting the presence or absence of items at the downstream side of the extendable conveyor.

12. The method according to claim 11, further comprising controlling a conveying speed of the extendable conveyor based on the outcome of the detecting, in particular the detecting of presence or absence of items at one or more of the following: the separation module; the upstream side of the extendable conveyor; the downstream side of the extendable conveyor.

13. A computer program product, comprising a computer readable hardware storage device having computer readable program code stored therein, said program code executable by a processor of a computer system to implement a method including program code configured to, when executed in a computing device, to carry out the method of claim 10.

Description

BRIEF DESCRIPTION

[0036] Some of the embodiments will be described in detail, with references to the following Figures, wherein like designations denote like members, wherein:

[0037] FIG. 1 is a schematic side view of a system according to the teachings disclosed herein;

[0038] FIG. 2A illustrates a state of the operation of the system according to FIG. 1;

[0039] FIG. 2B illustrates another state of the operation of the system according to FIG. 1;

[0040] FIG. 2C illustrates another state of the operation of the system according to FIG. 1;

[0041] FIG. 3 is a schematic side view of a system according to the teachings disclosed herein;

[0042] FIG. 4 is a schematic top view of a strip curtain according to the teachings disclosed herein;

[0043] FIG. 5 is a high-level flowchart of a method according to the teachings disclosed herein;

[0044] FIG. 6 is a schematic side view of a system according to the teachings disclosed herein;

[0045] FIG. 7 is a high-level flowchart of a further method according to the teachings disclosed herein; and

[0046] FIG. 8 is a perspective view of a system according to the teachings disclosed herein.

DETAILED DESCRIPTION

[0047] As discussed above, in known systems, a plurality of items may be conveyed on a telescopic conveyor. The teaching disclosed herein provides for improved conveyer systems, devices, methods and computer program products, inter alia in terms of reliability, build size, complexity, safety or throughput.

[0048] FIG. 1 is a schematic side view of a conveying system 10. The system 10 comprises an extendable conveyor 12 and a separation module 14.

[0049] The extendable conveyor 12 is operable to convey items P from an upstream side A of the extendable conveyor 12 to a downstream side B of the extendable conveyor 12. Further, the extendable conveyor 12 is configured to increase the distance from the upstream side A to the downstream side B. For this purpose, it has a fixed base portion 12a and multiple movable telescope portions 12b, 12c. The telescope portions 12b, 12c may be retracted beneath or within the base portion 12a to form a retracted state (not shown) of the extendable conveyor. In FIG. 1, an extended state is shown, wherein the telescope portions are distributed along a conveying path of the telescopic conveyor 12. Thus, the extendable conveyor 12 allows to increase or decrease the length of the conveyor.

[0050] The separation module 14 is operable for conveying the items P towards the upstream side A of the extendable conveyor 12 at variable speeds. In particular, it is configured to decelerate the conveying of the items P on the separation module, as will be described with reference to FIG. 2 in detail further below. The deceleration of the separation module 14 imparts an impulse on the items P, thereby allowing to separate the pile of items P into single pieces.

[0051] The separation module 14 is positioned relative to the extendable conveyor 12 with a vertical level difference between a conveying surface 15 of the separation module 14 and a conveying surface 13 of the extendable conveyor 12 at its upstream side A. The conveying surface 15 of the separation module 14 is vertically above the conveying surface 13 of the extendable conveyor 12. In the example shown, the level difference is a vertical step. In other examples, the level difference may be realized with an inclined plane, e.g., in form of a plate. It should be noted that the teachings disclosed herein may also be realized without any or with essentially no level difference between the conveying surface of the separation module 14 and the conveying surface of the extendable conveyor 12.

[0052] When items P reach the end of the separating module 14, they are being conveyed over the downward step formed by the level difference. As a result, the upper items out of the bulk of items P tumble towards the front (in conveying direction), thereby further separating the bulk of items.

[0053] As can be seen from FIG. 1, the separation module 14 may at least partly overlap with the extendable conveyor 12. In this case, the upstream side A may be defined as the region of interface, where items from the separation module 14 are conveyed onto the extendable conveyor 12, even if the extendable conveyor 12 extends further upstream (underneath the separation module 14). In other embodiments, the separation module 14 may fully overlap with the extendable conveyor 12. In still other embodiments (not shown), the separation module 14 may show essentially no overlap with the extendable conveyor 12, in which case the upstream side A of the extendable conveyor 12 corresponds to a front-end face of the extendable conveyor 12.

[0054] FIG. 2A-2C illustrates the operation of the conveying system of FIG. 1. FIGS. 2A-2C illustrate a sequence of three sequential states. FIG. 2A shows a first state, wherein a bulk of items P are loaded into the conveying system. For instance, the bulk of items may stem from a chute leading onto the separating conveyor.

[0055] If the bulk of items P were to be conveyed uniformly starting from the state of FIG. 2A, then a pile of items would be conveyed by the extendable conveyor 12. The pile may or may not be conveyable over the length of the fixed base portion (which is often equipped with side guards, not shown so as not to obstruct the illustration). However, at least at the telescope portions, the pile of items is prone to falling over the edge of the sides of the extendable conveyor.

[0056] Thus, in order to separate the bulk of items P into a line of single items, the conveying system 10 is equipped with a separation module 14. The separation module comprises a conveyor operable to run at at least two speeds, a first speed and a second speed. In this example, the second speed is larger than the first speed. In FIG. 2A, the separation module 14 runs at the second speed, illustrated in FIG. 2A by a double arrow.

[0057] When items P have been conveyed over the length of the separation module and reach the interface with the extendable conveyor 14, the speed of the separation module is decreased to the first speed, illustrated in FIG. 2B by a single arrow. In the example shown, the separation module 14 runs at a finite first speed. In other examples, the state corresponding to FIG. 2B may alternatively be attained by using a velocity of zero, i.e., by halting the separation module 14.

[0058] In any case, by decreasing the conveying speed, a deceleration of the items P is achieved, and an impulse is imparted on the items, such that the pile of items P is separated into single pieces. In FIG. 2B, the item P which is the top- and front-most item of the pile, falls onto the extendable conveyor 12.

[0059] This effect is further strengthened by the additional impulse acting on the upper items in the pile as a result of the level difference between the separation module 14 and the extendable conveyor 12. Since one or very few of the items P tumble onto the extendable conveyor 12 as a result of the deceleration of the separation module 14 and/or the level difference, the extendable conveyor 12 acts to convey these items away at a greater speed than the current speed of the separation module 14. The extendable conveyor thereby creates gaps in conveying direction between the items which have already tumbled onto the extendable conveyor 12 and the items which remain on the separation module 14.

[0060] Turning to FIG. 2C: Once the items on the extendable conveyor 12 have been conveyed onwards, the next items on the separation module 14 are conveyed to the interface between the separation module 14 and the extendable conveyor 12. At this stage, the process described above re-commences anew.

[0061] Thus, the system 10 described with reference to FIGS. 1 and 2 allows create gaps in conveying direction between the various items, even if these items are loaded into the system in a bulk. In embodiments, the system 10 may further be equipped with means to further minimize the risk of the separated items from falling over the sides of the extendable conveyor. An exemplary flexible strip curtain will be described with reference to FIGS. 3 and 4 in the following.

[0062] FIG. 3 is a schematic side view of a system 10, which comprises an extendable conveyor 12 and a separation module 14. These elements and their operation are essentially similar to the corresponding elements of FIGS. 1 and 2 above. The respective description thus applies correspondingly here and is referred to for reasons of conciseness.

[0063] In addition, system 10 of FIG. 3 comprises a flexible strip curtain 20. The curtain 20 may have multiple members in form of flexible strips.

[0064] The curtain 20 is arranged essentially in a plane, which is transverse to the conveying direction of the conveying system and perpendicular to the paper plane of FIG. 3. The flexible strip curtain 20 is positioned over the conveying surface of the extendable conveyor 12. In particular, a frame holds the curtain 20 and extends across the conveying surface of the extendable conveyor 12.

[0065] FIG. 4 is a schematic top view of the strip curtain 20 of FIG. 3 and of the upper conveying surface 13 of a conveyor. The curtain 20 comprises multiple members 20a, 20b, 20c, . . . . The multiple members each extend essentially vertically from a frame towards the conveying surface 13 (e.g., of the extendable conveyor 12) underneath, such that items being conveyed on the conveying surface 13 pass through the flexible strip curtain 20.

[0066] In the example of FIG. 4, two second members 20b are positioned between the first member 20a and the third member 20c. The second members 20b have a higher flexibility than the first member 20a and the third member 20c.

[0067] The first member 20a and the third member 20c are positioned closer to the side of the conveying surface 13 than the second members 20b. As a result, items being conveyed at or close to the sides of the conveying surface 13 come into contact with first member 20a or with the third member 20c.

[0068] The cross-sections of the first member 20a and the third member 20b are shaped asymmetrically.

[0069] In the example shown, they are shaped to have a wedge-like cross-section with a broader portion of the wedge-shape positioned towards the side of the conveying surface 13 and a narrower portion of the wedge-shape positioned towards the central longitudinal axis of the conveying surface 13.

[0070] The relatively low flexibility of the first and third members 20a, 20c allows them to act as “fenders” and to impart a force on those items, which pass through the curtain along the sides of the conveying surface and which are thus prone to the risk of falling over the side edges, in particular in the absence of side guards. The force acts essentially perpendicular to the conveying direction towards the central longitudinal axis of the extendable conveyor 12. For this purpose, the example shown presents a wedge-like cross-section. A wide variety of asymmetric-shaped cross-sections (e.g., triangular, trapezoidal, semi-circular, semi-elliptical, etc.) may be used such as to impart such force towards the central longitudinal axis, as will be apparent to the skilled person.

[0071] The flexible strip curtain of FIG. 4 may also be used in the absence of a system according to FIG. 1 or 3, in order to essentially align items along a longitudinal axis of a conveyor.

[0072] FIG. 5 is a high-level flowchart of a method 30 for controlling a conveying system with an extendable conveyor and a separation module. The method 30 comprises a step 32 of detecting a presence of a plurality of items at the separation module, and a step 34 of controlling, responsive to the detecting, a conveying speed of the separation module to decelerate the plurality of items.

[0073] For instance, the detecting may be performed using one or more sensors at the separation module.

[0074] FIG. 6 is a schematic side view of a system 10, which comprises an extendable conveyor 12 and a separation module 14. These elements and their operation are essentially similar to the corresponding elements of FIGS. 1 to 3 above. The respective description thus applies correspondingly here and is referred to for increased conciseness.

[0075] In addition, system 10 of FIG. 6 comprises multiple sensors 18. The various sensors 18a, 18b, 18c are photodiodes, which are configured to detect the presence (or absence) of items at various locations: First sensor 18a monitors the separation module 14. Second sensor 18b monitors the upstream side A of the extendable conveyor 12. Third sensor 18c monitors the downstream side B of the extendable conveyor 12.

[0076] First sensor 18a may be used to detect whether there are any items (or a bulk of items) on the separation module 14, e.g., at the interface with the upstream side A of the extendable conveyor 12. In the absence of items, the separation module 14 may be operated without deceleration. The separation module 14 may, for instance, be operated at the same speed as the extendable conveyor 12, in order to ensure further in-flow of further items. In the presence of items on the separation module 14, it may further be detected whether it is a single item or a bulk of items. At least in the latter case, the separation module 14 may for instance be operated to execute a deceleration, in order to separate the bulk.

[0077] Second sensor 18b may be used to detect whether there are any items at the upstream side A of the extendable conveyor 12. In the presence of items at the upstream side A of the extendable conveyor 12, the separation module 14 may be operated to stay or be in a halted or slow state, in order to allow the items at the upstream side A of the extendable conveyor 12 to be conveyed onwards. In the absence of items at the upstream side A of the extendable conveyor 12, the separation module 14 may be operated at the same speed as the extendable conveyor 12, in order to ensure further in-flow of further items.

[0078] Third sensor 18c may be used to detect whether there are any items at the downstream side B of the extendable conveyor 12. In the presence of items at the downstream side B of the extendable conveyor 12, the extendable conveyor 12 (and potentially the separation module 14) may be operated to be in a halted (or slow) state, in order to allow the items at the downstream side B of the extendable conveyor 12 to be handled. In the absence of items at the downstream side B of the extendable conveyor 12, the extendable conveyor 12 may be operated at regular speed, in order to ensure further in-flow of further items. The separation module 14 may be operated correspondingly.

[0079] FIG. 7 is a high-level flowchart of a further method 40 for conveying items, e.g., for loading a bulk of items into a truck at a dock. The method 40 may for instance by carried out with a system according to the embodiments described herein, having an extendable conveyor and a separation module.

[0080] At step 41, it is detected, e.g., using a photodiode sensor, whether there are items at the downstream side of the extendable conveyor. The downstream side of the conveyor may for instance extend into the loading volume of the truck, where staff or personnel is in the process of unloading any items arriving via the conveyor into the truck. In the presence of items, both the extendable conveyor and the separation module are halted at step 42, in order for the personnel to discharge the items present at the downstream end. Once the downstream side has been discharged, i.e., the downstream end of the extendable conveyor is “empty”, both the extendable conveyor and the separation module may resume their conveying operation. At step 44, it is detected, e.g., using a sensor at the separation module, whether the items at the separation module arrive in a bulk situation, e.g., as a pile. In the case of items arriving in bulk, then the separation process, in particular using deceleration of the separation module, is started at step 46. This separation is essentially similar to the method described with reference to FIG. 5 above or with the separation operation described with reference to any system described herein. The separated items are conveyed onwards using the extendable conveyor.

[0081] In the absence of a bulk of items (e.g., no items; or items already sparsely separated) at the separation module, then both the extendable conveyor and the separation module run at a same (e.g., regular or continuous) speed, at step 48. In this case, the separation module and the extendable conveyor may essentially operate as a single conveyor.

[0082] FIG. 8 is a perspective view of a system 10. The system 10 comprises an extendable conveyor 12, a separation module 14, and a flexible strip curtain 20. The extendable conveyor 12 is operable to convey items (not shown) from an upstream side A of the extendable conveyor 12 to a downstream side B of the extendable conveyor 12.

[0083] The extendable conveyor 12 has multiple movable telescope portions 12b, which are shown retracted within a base portion 12a to form a retracted state of the extendable conveyor 12. The telescope portions may also be extended so as to be distributed along a conveying path of the telescopic conveyor 12, thereby allowing to increase or decrease the length of the conveyor.

[0084] The separation module 14 is operable for conveying the items towards the upstream side A of the extendable conveyor 12 at variable speeds. In the example of FIG. 8, the separation module 14 fully overlaps with the extendable conveyor 12. In this case, the upstream side A may be defined as the region of interface, where items from the separation module 14 are conveyed onto the extendable conveyor 12, even if the extendable conveyor 12 extends further upstream (underneath the separation module 14).

[0085] As can be seen from FIG. 8, the separation module for use in conveying system may be provided separately from the other system components. In particular, the separation module may be provided in form of an add-on module to existing extendable conveyors 14. In other examples, the system 10 may be provided as an integrated conveying system.

[0086] In any case, the separation module 14 is configured to decelerate the conveying of the items on the separation module, as described in detail further above.

[0087] The separation module 14 is positioned relative to the extendable conveyor 12 with a level difference between conveying surface 15 of the separation module 14 and conveying surface 13 of the extendable conveyor 12 at its upstream side A. The level difference is equipped with an inclined plane in form of a plate 22.

[0088] When items reach the end of the separating module 14, they are being conveyed over the downward slope formed by the level difference and the plate. As a result, the upper items out of the bulk of items tumble towards the front (in conveying direction), thereby further separating the bulk of items.

[0089] The at least partially separated items are then conveyed towards downstream side B, thereby passing through a flexible strip curtain 20, which is essentially similar to the curtain of FIGS. 3 and 4. The curtain 20 has multiple members in form of flexible strips. The curtain 20 is arranged essentially in a plane, which is transverse to the conveying direction of the conveying system.

[0090] The flexible strip curtain 20 is positioned over the conveying surface 13 of the extendable conveyor 12. A frame holds the curtain 20 and extends across the conveying surface 13 of the extendable conveyor 12. The outermost elements of the flexible strip curtain 20 are less flexible (or more massive) than the inner elements, thereby facilitating passage of items closer to the longitudinal central conveying axis and hinder passage of items closer to the side of the conveyor 12.

[0091] As shown in FIG. 8, the separation module 14 is equipped with (relatively high) side guards in order to prevent the upper items out of a bulk of items from falling over the side edges. However, for the extendable conveyor 12, such high side guards are not needed since the separation module 14 and/or the curtain 20 provide for a flow of items which is separated by gaps and centered mostly towards the longitudinal central conveying axis of the extendable conveyor 12.

[0092] In the example shown, the extendable conveyor is equipped with (relatively low) integrated side guides.

[0093] In other embodiments, the extendable conveyor may be equipped partly (e.g., only along the base portion 12a; or from the separation module 14 to the curtain 20) with high side guards.

[0094] Although the present invention has been disclosed in the form of preferred embodiments and variations thereon, it will be understood that numerous additional modifications and variations could be made thereto without departing from the scope of the invention.

[0095] For the sake of clarity, it is to be understood that the use of “a” or “an” throughout this application does not exclude a plurality, and “comprising” does not exclude other steps or elements. The mention of a “unit” or a “module” does not preclude the use of more than one unit or module.