HIGH RATE VOLUMETRIC FLOW CLASSIFICATION

Abstract

A mixed-item sorting system and a method for sorting the volumetric flow of mixed items of various sizes and shapes to separate destinations includes at least two volumetric flow separators configured to receive a volumetric flow of mixed items and arrange the items into respective first and second single-row flows. A first item inlet arranges the first item flow from one of the separators into a first separate item flow, and a first item sensor detects the identity and weight of each item. A second item inlet arranges the single-row item flow from the other separator into a second separate item flow, and a second item sensor detects the identity and weight of each item in the second single-row flow.A combiner combines the first and second single-row streams of items into a third single-row stream. A classifier receives the mixed third single-row stream of items and sorts the items into separate destinations.

Description

HIGH RATE VOLUMETRIC FLOW CLASSIFICATION DESCRIPTION OF THE INVENTION The present invention relates to a method and apparatus for organizing a volumetric flow of mixed articles. Such mixed articles are of various sizes and shapes in separate destinations. Although the invention is illustrated for use with handling parcels or postal boxes, it may find applications in handling other types of articles. Items shipped via parcel and postal services are typically transported in bulk and are usually packaged for consumers with barcode labels printed on each item. These items vary in size and weight, and the label can be applied to any surface. To route each item to its destination, they are unloaded from the transport vehicle at a sorting facility. Each item must be scanned so it can be properly routed and weighed to avoid overloading the transport vehicles and to ensure the user is charged an appropriate rate. Items are then sorted into destinations that can be shipped by air or truck to a specific city, or delivered by a local van. Although in theory any capacity can be achieved by simply multiplying the equipment, there is a cost to doing this, not only in additional capital expenditures, but also in the size of the building that must be constructed to accommodate the space occupied by the equipment. The present invention accomplishes the organization of a volumetric flow of items to separate destinations as quickly as possible while requiring the smallest possible equipment footprint. The present invention provides a method and system for organizing a volumetric flow of items to separate destinations at a rate and in a small footprint that were not previously possible. A mixed articles classification system and a method for classifying the volumetric flow of mixed articles to separate destinations, the mixed articles being of various sizes and shapes, according to one aspect of the invention, includes at least two volumetric flow separators, each configured to receive a volumetric flow of mixed articles that is of various sizes and shapes, and the volumetric flow of articles is arranged in the first and second single-row flows of mixed articles respectively.A first item intake arranges the first single-row flow of mixed items from one of the separators into a first flow of separated and mixed items, separated by spaces, and a first item sensor receives the first single-row flow of separated and mixed items and detects at least the identity and weight of each item in the first single-row flow of separated and mixed items. A second item intake arranges the single-row flow of mixed items from the other separators into a second flow of separated and mixed items, separated by spaces; and a second item sensor receives the second single-row flow of separated and mixed items and detects at least the identity and weight of each item in the second single-row flow of separated items. A combiner combines the first and second single-row streams of separated and mixed items from the first and second item sensors into a third single-row stream of mixed items. A positive-displacement classifier receives the third single-row stream of mixed items from the combiner and sorts the items for their respective destinations. The items from the first and second separate item streams can reach the combiner in a relatively controlled manner, where the items are combined into a third, single-row item stream by the lateral displacement of some of the items. Each of the separators can be a recirculating separator, each having a volumetric flow inlet configured to receive a volumetric flow of items, a separation conveying surface extending from the inlet to an outlet configured to arrange juxtaposed items in a single-row item stream, and a recirculating conveying surface configured to return at least one of the juxtaposed items from the separation conveying surface at the outlet to the separation conveying surface at the inlet.Volumetric flow separators can share a common recirculation transport surface or each can have a recirculation transport surface. A third item inlet can be provided between the combiner and the classifier to adjust the spacing between items in the third single-row flow of mixed items. A fourth item inlet can be provided between the first item sensor and the combiner to adjust the spacing between items exiting the first item sensor. A fifth item inlet can be provided between the second item sensor and the combiner to adjust the spacing between items exiting the second item sensor. A first dynamic accumulator may be provided between the first volumetric flow separator and the first inlet to eliminate gaps in the first single-row flow of mixed articles. A second dynamic accumulator may be provided between the second volumetric flow separator and the second inlet to eliminate gaps in the second single-row flow of mixed articles. A control system responsive to item sensors can be provided to track the identity of items downstream of the sensors, where the identity of each item supplied to the sorter is known to be independent of the additional detection of items in the third stream of a single row of mixed items. The sorter may be capable of sorting at least 10,000 items per hour. The combiner may include a conveying surface defined by the upper surfaces of top slats that interconnect in a longitudinally moving network, and push shoes that move along at least one of the slats to laterally displace items on the conveying surface from the second single-row flow of separated and mixed items to the first single-row flow of separated and mixed items to create the third flow of mixed items. The combiner may edge-align supplied items in the third single-row flow of mixed items. The combiner may include a first conveyor that receives items from the first single-row flow of separated and mixed items, and a second conveyor that is generally parallel to and adjacent to the first conveyor. The second conveyor receives items from the second single-row flow of separated and mixed items. A control monitors the first and second single-row flows of separated and mixed items to establish a relative position between the items in the first and second single-row flows, and diverts an item from the second conveyor to laterally displace that item on the first conveyor into a gap between the items on the first conveyor. In this way, the items exit the first conveyor in a merged stream of items as the third single-row flow of mixed items. The second conveyor may consist of a plurality of parallel slats interconnected in a network that moves longitudinally, and a plurality of push shoes that move laterally along at least one of the slats. The control deflects the push shoes adjacent to the item being deflected toward the first conveyor from a non-deflected state, in which the push shoes do not move laterally, to a deflected state, in which the push shoes move laterally.The first single-row flow can supply items that are edge-aligned items on the first conveyor in alignment with the push shoe transfer extension when in the divert state where the diverted items are edge-aligned with the items of the first single-row flow of separated and mixed items when the items come off the first conveyor as the third single-row flow of items. The control can regulate the relative speeds of at least the first and second inlets to establish controlled relative positions between items in the first and second controllers. The offset thrust shoes can be moved together in a longitudinal line to laterally displace an item without substantial rotation of that item. The push shoes may have extensions that at least partially overlap the first conveyor when they are diverted to ensure that an item travels completely over the first conveyor. A return rail may be provided, which laterally returns the push shoes to a position where the extensions do not overlap the first conveyor before the push shoes are moved to one end of the network. A combiner of mixed articles and a method for combining the first and second single-row flows of separated and mixed articles into a third single-row flow of mixed articles, the mixed articles having different sizes and shapes, according to one aspect of the invention, includes a first conveyor that receives the first single-row flow of separated and mixed articles. A second conveyor is generally parallel to and adjacent to the first conveyor. The second conveyor receives the second single-row flow of separated and mixed articles. A control monitors the articles to establish relative positions between the articles of the first and second single-row flows of separated and mixed articles, and diverts articles from the second conveyor to laterally displace the articles to the first conveyor into a space between the articles on the first conveyor.In this way, the mixed items exit the first conveyor in a fused stream of edge-aligned items as the third single-row flow. These and other objects, advantages, and features of this invention will become apparent after reviewing the following specification together with the drawings. BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a block diagram of a high-rate volumetric flow classification system, according to one embodiment of the invention; Figure 2 is a top plan view of the physical scheme of the classification system component in β / ρ / ηη / ζζηζ / E / γ claim 1; Figure 3 is a detailed view of the components of an alternative modality of a high-rate volumetric flow classification system; Figure 4 is a top plan view of a warehouse material handling system that includes multiple sorting systems; Figure 5 is a top plan view of a combiner according to one embodiment of the invention; Figure 6 is a cross-sectional view taken along line VI-VI in Figure 5; Figure 7 is a top plan view of a portion of the combiner shown in Figure 6; Figure 8 is a top plan view of the second conveyor illustrating a diverter return rail; Figure 9 is an enlarged side elevation view schematically illustrating a diagram of a diverter assembly; and Figure 10 is a diagram illustrating the operation of the diverter switches in Figure 9 to divert various lengths of items. Now, with reference to the drawings and illustrative configurations depicted therein, a System 110 mixed-item routing system is adapted to organize a volumetric flow of mixed items, which are illustrated as cartons, but could be distribution boxes, trays, receptacles, and unpackaged items to separate destinations (Figure 1). The mixed items are of a variety of different shapes and sizes. It should be understood that System 110 can be duplicated to increase system throughput, as illustrated in Figure 4. In the illustrated configuration, System 110 is capable of routing 10,000, or potentially 15,000 items up to 50.8 cm (20 inches) in diameter per hour. Therefore, up to 20,000 and 30,000 items per hour can be achieved by duplicating System 110, as shown in Figure 4. System 110 receives mixed items by volume, such as those unloaded from transport vehicles (not shown). The items are of various sizes and shapes and are in various orientations, with an indicator, such as a barcode or QR code, that can be oriented in any direction. The volumetric flow of items is supplied to two volumetric flow separators: a first volumetric flow separator 112 and a second volumetric flow separator 114. The volumetric flow separator 112 is configured to receive a volumetric flow of mixed items of various sizes and shapes and to arrange the volumetric flow of items into a first single-row flow of items, which is then separated by an inlet 126.The β / ρ / ηη / ζζηζ / E / γ volumetric flow separator 114 is configured to receive a volumetric flow of articles of various sizes and shapes, and to arrange the volumetric flow of articles into a second single-row flow of articles that are then separated into a second single-row flow of articles by a second admission 128. The inlet 127, outlet 127, supplies the first single-row flow of separated items to an item sensor 130, where the barcode label on the item is scanned regardless of its location on the item. This is accomplished by scanners facing the top, bottom, and all four sides of the item. The item sensor 130 includes a scale that measures the item's weight. The item sensor 130 is commercially available from multiple sources. The item's identity and weight are stored in a computer system 136, which may be a programmable logic controller, a microcomputer, or another type of industrial computer.Similarly, the second single-row flow of items provided from output 129 of inlet 128 is supplied to a cardboard box sensor 132 where the barcode label on the item is scanned regardless of the item's surface on which the label is located. Also, the items are weighed, and the identity and weight of each item are stored by the computer system 136. Downstream of the item sensors 130 and 132, the items will already be checked for relative positions on both lines 140 and 142 when they reach a combiner 134, so that it will be possible to combine the first and second single-row flows of separated items without further spacing adjustment. However, if desired, an additional induction unit can be provided on lines 140 and 142 between the item sensor 130 and the combiner 134 to adjust the item spacing and relative positions of items in the first single-row flow of separated items relative to the items in the second single-row flow for proper combination with the second single-row flow of separated items.Similarly, an additional induction unit can be provided between the item sensor 132 and the combiner 134 to adjust the item spacing in the second single-line flow of separated items and their relative position with the items in the first single line from the separated items. In this way, the inlets 126 and 128 are coordinated so that the downstream from the item sensors 130 and 132, the first and second separate item flows reach the combiner 134 in a staggered manner to combine into the third single-line flow of β / ρ / ηη / ζζηζ / E / γ β / ρ / ηη / ζζηζ / E / γ items 121, such as by lateral displacement of the items. The combiner 134 combines the first and second single-line flows of separate items into a third single-line flow of items 121, which are then fed to a classifier 124 for sorting. In the illustrated configuration, a minimum space of 15 is required.A 2 cm (6 inch) gap between items supplied to sorter 124 will allow the sorter to sort the items to their respective destinations. Because computer system 136 tracks the identity of each item, it is able to instruct sorter 124 about the destination for each item. An optional item identifier, such as a barcode scanner or REID reader (not shown), can be deployed in front of sorter 124 to confirm the identity of each item. In this way, each item supplied to sorter 124 will be identified either by the optional item identifier or tracked by computer system 136, or a combination of both. Although the combiner 134 can take several known forms, such as converging vertical surfaces or rotating guide belts, in the illustrated embodiment, the combiner 134 includes a conveying surface defined by the upper surfaces of top slats that interconnect in a longitudinally moving network, and push shoes that move along at least one of the slats to laterally displace the items on the conveying surface. The combiner 134 is capable of edge-aligning the items supplied in the third flow 121 in a single row. Although this could be achieved with multiple push shoes on at least some of the slats in the illustrated embodiment, only one push shoe is provided on each slat. The separators 112 and 114 can be any of the various types of devices known in the art. In the embodiment illustrated in more detail in Figures 2 and 3, the separators are recirculating separators marketed by Cinetics that have a volumetric flow separation capacity of up to 7,500 items per hour. Each separator has a volumetric flow inlet 144 configured to receive a volumetric flow of items and a separation conveying surface 146 extending from the inlet 144 to an outlet 148 configured to arrange juxtaposed items in a single-row flow. The separators 112 and 114 include a recirculating conveying surface 150 configured to return at least one of the juxtaposed items from the separation conveying surface 146 at the outlet 148 to the separation conveying surface at the inlet 144.Only the roller actuators comprising the conveying surface 146 are shown for clarity. In the illustrated configuration β / ρ / ηη / ζζηζ / E / γ β / ρ / ηη / ζζηζ / E / γ, the volumetric flow separators 112 and 114 share a common recirculating conveying surface 150. However, the volumetric flow separators 112 and 114 can have separate recirculating conveying surfaces 150, thereby increasing the recirculating flow capacity for system 110. The item routing system 110 can also include a third item intake 138 between the combiner 134 and the classifier 136. The third item intake 138 is configured to adjust the spacing between items in the third single-row item flow, if necessary. System 110 can also include a fourth item intake on line 140 between the first item sensor 130 and the combiner 134 to adjust the spacing between items exiting the first item sensor, and a fifth item intake 142 on the line between the second item sensor 132 and the combiner 134 to adjust the spacing between items exiting the second item sensor. The fourth and fifth item intakes are controlled to adjust the relative positions of items between lines 140 and 142, as previously described.Although various configurations may be used, all the admissions mentioned above may be of the type described in U.S. Patent No. 8,408,380 commonly assigned for a CONVEYOR ADMISSION, the description of which is incorporated herein for reference. Classifier 136 is a high-capacity positive displacement classifier capable of sorting at least 10,000 mixed items per hour. Such a classifier may be a high-speed parallel deviation classifier of the type described in U.S. Patents Nos. 5,927,465; 6,041,909; 6,513,642; 6,814,216; 6,860,383; and 6,866,136. 6,923,308; 7,086,519; 7,117,988; 7,128,197; 7,513,356 and 8,469,177 commonly assigned, whose descriptions are collectively incorporated herein for reference. However, any classifier capable of classifying at this rate may be used. Thus, it can be observed that with volumetric flow separators capable of separating up to 7,500 items per hour and with classifier 136 capable of classifying at least 10,000 items per hour, system 110 is capable of classifying at least 10,000 to 15,000 items per hour to destinations according to the item identities. Classifier 136 is capable of classifying items to a large number of separate destinations D, which are illustrated in Figure 4 as trucks at loading docks. Conventional chutes and conveyors are used to route the items from each conveyor 136 to the appropriate destination D. A mixed-item routing system 210 is generally the same as 110, except that it includes a first dynamic accumulator 252 in a first single-row flow of items 216 to eliminate gaps between items downstream of a first volumetric-flow separator 212. A second dynamic accumulator 254 is located in a second single-row flow of items 218 to eliminate gaps between items downstream of a second volumetric-flow separator 214. The dynamic accumulators 252 and 254, which are well-known in the material handling industry, are low-pressure, pneumatically actuated, belt-driven, motorized roller conveyors that provide light-pressure coupling between items and do not include photosensors or other item sensors for item detection. Admissions on lines 226 and 228 are the same as admissions 126, 128.Item sensors 230 and 232 are the same as sensors 130 and 132. Admissions on lines 240 and 242 are the same as admissions on lines 140 and 142. Combiner 234 is the same as combiner 134. A classifier (not shown) is the same as classifier 124. Systems 110 and 210 include a control system that incorporates computer system 136. This control system tracks the identity of items downstream of item sensors 130, 132, 230, and 232, where the identity of items supplied to a respective sorter is known to be independent of any additional item detection in the third single-row item stream. This allows the respective sorter to sort items independently of, or in addition to, any item scanner at the sorter inlet. A combiner, or merging assembly 134, 234, merges multiple streams of mixed articles of various sizes and shapes from a first feed 140 and a second feed 142 (Figure 5). The first feed 140 supplies a stream of mixed articles to a first conveyor 16, which, in the illustrated embodiment, is a belt conveyor having a carrying surface 17 that is a transfer conveyor belt 40. The second feed 142 supplies a stream of mixed articles to a second conveyor 18, which is usually parallel to and adjacent to the first conveyor 16, as best seen in Figure 5. Each conveyor 16, 18 has a separate carrying surface. Although they may share certain structural components, they have separate frames.The conveying surfaces of conveyors 16 and 18 are as close together as possible and may have a sliding plate between them to prevent gaps that could trap a stray item. The second conveyor 18 is a shunt conveyor having a conveying surface 19 formed from a plurality of parallel slats 30 that interconnect in a network that moves in a longitudinal direction. The second conveyor 18 has a plurality of thrust shoes 32 that move laterally along at least one of the slats 30.The selected push shoes 32 are deflected from a non-deflected state, in which the shoe does not move laterally on the conveying surface 19, to a deflected state, in which the shoe moves laterally across the conveying surface 19, by a deflector change 34 that deflects the push shoe to a deflection rail 35 below the conveying surface 19. The second conveyor 18 is similar in operation to a positive displacement classifier of the type described in U.S. Patent No. 6,814,216, commonly assigned, a description of which is incorporated herein for reference. As noted above, in the illustrated embodiment, the first conveyor 16 is a belt conveyor of the type well known in the art, although a variety of materials and conveying surface designs may be used. Control unit 136 receives input from a first item sensor, such as a photosensor 22, to monitor items entering the first conveyor 16, and from a second item sensor, such as a photosensor 24, to monitor items entering a second conveyor to ensure appropriate relative spacing for a lateral combination of items. Control unit 136 monitors the relative positions of items arriving from inlets 140 and 142 and controls inlets 140 and 142 in a manner that provides controlled placement of items supplied to conveyors 16 and 18, ensuring sufficient spacing between items to merge them. Although relative item positions can be controlled by the control unit at inlets 140 and 142, relative positions can also be controlled upstream, such as at inlets 126 and 128.In fact, the inlets 140, 142 may be replaced with conveyors if the relative positions of the articles are controlled by the inlets 126, 128. The inlets 126, 128, 138, 140 and 142 may be any type known in the art, such as those described in United States Patents Nos. 5,267,638; 6,918,484 and 8,408,380 commonly assigned, the descriptions of which are incorporated herein in full for reference. Control 136 monitors the location of items on the second conveyor 18 and is aware of the location of the push shoes 32 using the technology described in patent '216 mentioned above. Therefore, control 20 identifies which push shoes are adjacent to an item on the second conveyor. The push shoes adjacent to an item are deflected by some or all of the diverter switches 34 to laterally push the item on the first conveyor 16 into a space between the items on the first conveyor 16, as illustrated by imaginary lines in Figure 5.In this way, a third separate stream of mixed articles from the article mixer from the second flow of separated mixed articles arriving on conveyor 18 with the articles from the first flow of separated mixed articles arriving on conveyor 16 exits the first conveyor 16 in a fused stream of separated articles on an outlet conveyor 121 extending from the first conveyor 16. An optional recirculation conveyor 28 can extend from a discharge end of the second conveyor 18 to return, to a feed end of the second conveyor 18 or another area, any article that is unable to merge with the articles on the first conveyor 16 detected by a sensor 25. The thrust shoes 32 move in a longitudinal line, as illustrated, to laterally push an item without substantial rotation of that item. This is known as parallel sorting. This can be achieved by all the diverter switches 34 that divert the thrust shoes to divert a particular item β / ρ / ηη / ζζηζ / E / γ that is driven at approximately the same time. Each diverter switch 34 diverts a thrust shoe 32 on a diverter rail 35 under the transport surface 19, thereby causing the lateral displacement of the thrust shoe. Each thrust shoe 32 has a lower portion 37 that lies below the transport surface 19 to engage the diverter rail and a cap 36 that extends over the transport surface to engage the item.The pusher shoe cap 36 has an extension 38 that overlaps a portion of the first conveyor's carrying surface 17 when the pusher shoe is fully deflected to ensure that an item is fully pushed onto the first conveyor's carrying surface 16, as best seen in Figures 3 and 4. A return rail 42 is provided below the carrying surface 19 that laterally returns the deflected pusher shoes to a position where the extensions 38 do not overlap the first conveyor 16 before the pusher shoes 32 move to one end of the second conveyor's network 18, as shown in Figure 8. This prevents mechanical interference between the pusher shoe cap extensions 38 and the first conveyor when the pusher shoes unfold as they move around the end of the second conveyor.The return rails 42 can partially return the deflected thrust shoes β / ρ / ηη / ζζηζ / E / γ to a location that clears the first conveyor 16, or can return them to the fully undeflected position of the thrust shoes at the loading end of the second conveyor 18 adjacent to the second feed 14. The first stream of separated and mixed items can reach the edge-aligned conveyor 16 toward the portion of conveyor 16 closest to conveyor 18, as shown in Figure 5. This can be achieved using conventional edge-alignment techniques (not shown) that edge-align the items upstream of conveyor 16, such as at inlet 140, 240, or upstream of the inlets. Because the items are a mixture of various sizes and shapes, they can only be edge-aligned. Such edge-aligned items on the first conveyor are aligned along an imaginary line reached by the deflection surface 39 at the farthest lateral extension where the pusher shoe extension 38 travels in the deflection state.In this way, the items deflected by the push shoes 32 are edge-aligned with the items fed from the first feed 12, and all items are edge-aligned as they exit the first conveyor in a fused stream on conveyor 26. This allows the fused mixed items of a variety of shapes and sizes to be sorted by classifier 124 without additional alignment. This enables the mixed items to reach classifier 124 with minimal separation achieved without rotating the items during merging or edge-aligning the fused items. Control 136 regulates the relative speeds of conveyors 16 and 18 to synchronize their speeds. This can be achieved by pulse position monitors 21 that monitor the movement of conveyors 16 and 18, respectively. Control 136 also monitors the items at one feed end of the conveyors using photosensors 22 and 24. Control 136 responds to sensors 22 and 24, and possibly additional upstream sensors, to control the relative speeds of lines 140 and 142 to establish controlled spacing between items on conveyors 16 and 18, using, for example, the techniques described in patents '638 and '484 mentioned above.As described above, control 136 monitors the relative positions of the items and the push shoes on the second conveyor to determine which push shoes align with an item and which diverter change 34 should be actuated to divert an item. Although conveyors 16, 18 are illustrated as separate synchronized conveying surfaces, it can be understood that these could be incorporated into a single conveying surface. The plurality of diverter switches 34 that can be operated to drive a thrust shoe 32 to travel along the second conveyor 18 are arranged as shown in Figures 9 and 10. The diverter switches 34 are spaced at intervals equal to integral values ​​of the slat pitch because, in the illustrated embodiment, the thrust shoes travel along one slat and are therefore also spaced at integral values ​​of the slat pitch. At least one pair of adjacent diverter switches, designated #1 and #2, are separated by one slat pitch. The remaining adjacent diverter switches #3 through #6 can be separated by two slat pitches, as shown in Figure 9. This configuration allows a wide range of item lengths to be diverted without requiring many diverter switches. Figure 10 illustrates the identity of deflector changes that are changed for various item lengths.It should be understood that not all diverter switches need to be operated for the length of the item; it is only necessary to operate the diverter switches to divert the push shoes on the front and rear portions of the item with intermediate diverter switches not operated. It should also be understood that, although only one set of diverter switches #1 to #6 is shown to divert an item over the first conveyor 16, it is possible to have two or more sets of diverters to divert more than one item at a time and to divert items to different longitudinal positions along the conveying surface 19. Although the foregoing description outlines various embodiments of the present invention, it shall be understood by those skilled in the art that variations and modifications to these embodiments may be made without departing from the spirit and scope of the invention, as defined in the following claims. The present invention encompasses all combinations of the various embodiments or aspects of the invention described herein. It is understood that any and all embodiments of the present invention may be taken together with any other embodiment to describe further embodiments of the present invention. Furthermore, any element of one embodiment may be combined with any and all other elements of any other embodiment to describe further embodiments.

Claims

CLAIMS 1. A mixed articles combiner that combines the first and second single-row flows of separated and mixed articles into a third single-row flow of mixed articles, the mixed articles being of various sizes and shapes, CHARACTERIZED IN THAT said combiner comprises: a first conveyor receiving the first single-row flow of separated and mixed articles that are edge-aligned on said first conveyor along an imaginary line; a second conveyor generally parallel to and adjacent to said first conveyor, said second conveyor receiving the second single-row flow of separated and mixed articles and having push shoes reaching said imaginary line at the farthest lateral extension of said push shoes when in a deflected state;and a control, said control monitors the articles to establish relative positions between articles of the first and second single-row flow of mixed separated articles and diverts at least one of said push shoes, thereby diverting an article on said second conveyor to laterally displace that article to said first conveyor in a space between articles on said first conveyor, wherein the articles exit said first conveyor in a fused stream of edge-aligned articles along said imaginary line as the third single-row flow.

2. The mixed article combiner according to claim 1, CHARACTERIZED IN THAT said second conveyor comprises a transport surface defined by upper surfaces of upper slats that are interconnected in a longitudinally moving network, each of said push shoes moving along at least one of said slat to laterally displace an article on said transport surface from the second single-row flow of separated and mixed articles to create the third single-row flow of mixed articles.

3. Combiner of mixed articles according to claim 1, CHARACTERIZED IN THAT the deflected thrust shoes are moved together in a longitudinal line to laterally displace an article without substantial rotation of that article.

4. Combiner of mixed articles according to claim 1, CHARACTERIZED IN THAT said push shoes have extensions that overlap at least partially on said first conveyor when they are deflected to ensure that an article is completely displaced on said first conveyor.

5. The mixed article combiner according to claim 4, CHARACTERIZED IN THAT it includes a return rail that laterally returns said push shoes to a position where said extensions do not overlap said first conveyor before said push shoes are moved to one end of said network.

6. A method for combining the first and second single-row flows of separated and mixed articles into a third single-row flow of articles, the mixed articles being of various sizes and shapes, CHARACTERIZED IN THAT said method comprises: receiving the first single-row flow of separated and mixed articles with a first conveyor that is edge-aligned on said first conveyor along an imaginary line; receiving the second single-row flow of separated and mixed articles with a second conveyor that is generally parallel to and adjacent to said first conveyor and having push shoes that reach said imaginary line at a lateral extension further than said push shoes when in a deflected state;and monitor the articles to establish a relative separation between the articles of said first and second single-row flow of separated and mixed articles and divert at least one of said push shoes, thereby diverting an article on said second conveyor to laterally displace that article on said first conveyor in a space between the articles on said first conveyor, wherein the articles exit said first conveyor in a fused stream of edge-aligned articles along said imaginary line as the third single-row flow.

7. A mixed articles combiner that combines the first and second single-row flows of separated and mixed articles into a third single-row flow of mixed articles, the mixed articles being of various sizes and shapes, CHARACTERIZED IN THAT said combiner comprises: a conveying surface defined by upper surfaces of upper slats that are interconnected in a longitudinally moving network and push shoes that each move along at least one of said slats to laterally displace an article on said conveying surface from the second single-row flow of separated and mixed articles to the first single-row flow of separated and mixed articles to create the third single-row flow of mixed articles, wherein the articles in the first single-row flow of separated and mixed articles are edge-aligned along an imaginary line,wherein said push shoes reach said imaginary line at a more distant lateral extension of said push shoes when in a deflected state; 5 a control, said control monitors the articles to establish relative positions between the articles of the first and second flow of a single row of separated and mixed articles and deflects at least one of said push shoes, thereby deflecting an article from the second flow of a 10 single row of separated and mixed articles to displace the article to a space between articles in the first flow of a single row of separated and mixed articles, wherein said combiner edge-aligns the articles along the imaginary line supplied in the third single-row flow.

Images