System, apparatus, and method for detecting pusher block failures of pusher block sortation conveyors

Abstract

Systems, apparatuses, and methods for detecting pusher failure of a pusher sorter conveyor are presented. A pusher sorter is described. The pusher sorter can include a switch plate that supports movement of a pusher pin, a finger, and an actuation arm of a pusher. In some examples, the finger can be configured to move in a first direction in response to a portion of the pusher pin contacting a portion of the finger. The actuation arm can be pivotably engaged to the finger such that movement of the finger in the first direction can cause movement of the actuation arm in a second direction. In this regard, the actuation arm in the second direction can cause a change in a signal output by a photoelectric sensor coupled to the pusher sorter. A processor can use this change in the signal to determine that the pusher pin is misaligned.

Description

[0001] This application is a divisional application of the invention patent application filed on January 4, 2021, with application number 202110003583.3 and invention title "System, Apparatus and Method for Detecting Push Block Faults in Push Block Sorting Conveyors". Technical Field

[0002] The exemplary embodiments described herein relate generally to push-block sorting conveyors including push blocks with push pins, and more specifically, to techniques for detecting faults in the push blocks of push-block sorting conveyors. Background Technology

[0003] Generally speaking, in material handling environments such as, but not limited to, distribution centers, warehouses, storage or shipping centers, material handling systems can convey, handle, sort and organize various types of products (e.g., items, cartons, boxes, containers, shipping containers, bags, packaging, etc.) at high speeds on conveyors. Summary of the Invention

[0004] A brief summary of the invention is provided below to offer a basic understanding of some aspects of the disclosed material transport system. This summary is not an exhaustive overview and is neither intended to identify key or critical elements nor to describe the scope of such elements. Its purpose is to serve as an introduction to the detailed embodiments provided below, to present some concepts of the described features in a simplified form.

[0005] The various exemplary embodiments described herein relate to push-block sorting machines. A push-block sorting machine may include a switch plate configured to define a travel path for push-block pins of the push-block sorting machine. Additionally, the push-block sorting machine may include fingers mechanically coupled to the switch plate. According to the exemplary embodiments, the fingers may be configured to move in a first direction in response to a first portion of the push-block pin contacting a top portion of the fingers. Furthermore, the push-block sorting machine may include an actuator arm. This actuator arm may be pivotally engaged with the fingers such that movement of the fingers in the first direction causes movement of the actuator arm in a second direction. In this regard, in some examples, the actuator arm in the second direction causes a change in a signal output by a photoelectric sensor. Additionally, in response to the change in the signal output by the photoelectric sensor, a processor coupled to the push-block sorting machine may determine misalignment of the push-block pin.

[0006] According to some exemplary embodiments described herein, in response to the distal end of the actuator arm being in a first position due to movement of the actuator arm in a second direction, the photoelectric sensor begins to receive light previously blocked by the actuator arm.

[0007] According to some exemplary embodiments, the finger portion can be positioned along a movement path defined by the switch plate such that, in response to movement of the push pin in the movement path, the curved portion of the push pin contacts the top portion of the finger portion. Additionally, in some exemplary embodiments, the finger portion can be positioned along the movement path defined by the switch plate such that, as the second push pin moves in the movement path, the non-curved portion of the second push pin passes along the finger portion through the movement path without contacting the top portion of the finger portion.

[0008] According to some exemplary embodiments described herein, a processor coupled to a pusher-type sorter can generate an alarm indicating that the pusher pin is misaligned.

[0009] In some exemplary embodiments, the processor coupled to the pusher sorter may be a processor that generates a command to stop the operation of the pusher sorter based on determining that the pusher pin is misaligned.

[0010] According to some exemplary embodiments, the top portion of the finger may taper so that, in response to the first portion of the push pin contacting the top portion of the finger, the finger and the actuator arm pivot about the pivot pin.

[0011] According to some exemplary embodiments, a switch plate may be configured to define a first movement path for moving a first set of pusher pins for turning a first group of items on a pusher sorter. Additionally, the switch plate of the pusher sorter may also define a second movement path for moving a second set of pusher pins for preventing a second group of items on the pusher sorter from turning. To this end, according to the exemplary embodiments, the pusher sorter may further include a first finger and a first actuating arm. Additionally, the pusher sorter may include a second finger and a second actuating arm. In this regard, the first finger may be configured to mechanically engage with the switch plate along the first movement path. Furthermore, the first finger may be pivotally engaged with the first actuating arm such that movement of the finger in a first direction causes movement of the actuating arm in a second direction. Furthermore, the second finger may be configured to mechanically engage with the switch plate along the second movement path. Furthermore, the second finger may be pivotally engaged with the second actuating arm such that movement of the second finger in a third direction causes movement of the second actuating arm in a fourth direction.

[0012] In some exemplary embodiments, the processor may be configured to detect misaligned push pins from the first set of push pins and the second set of push pins by recognizing changes in signals output by photoelectric sensors due to movement of at least one of the first actuating arm and the second actuating arm, respectively.

[0013] Some exemplary embodiments described herein relate to a fault detection unit configured to detect faults in pusher pins of a pusher sorter. The fault detection unit may include a photoelectric sensor, a finger, and an actuator arm. The finger may be mechanically coupled to a portion of a switch plate of the pusher sorter. Additionally, the finger may be configured to move in a first direction in response to a portion of the pusher pin contacting the top portion of the finger. Furthermore, the actuator arm may be pivotally engaged with the finger. In this respect, movement of the finger in the first direction may cause movement of the actuator arm in a second direction. Furthermore, in some exemplary embodiments, the actuator arm in the second direction may cause a change in the amount of light received by the photoelectric sensor of the fault detection unit.

[0014] According to some exemplary embodiments, a change in the light received by the photoelectric sensor of the fault detection unit can cause a change in the signal output by the photoelectric sensor. In this respect, the change in signal can indicate misalignment of the push pin. According to some exemplary embodiments, in response to the distal end of the actuator arm being in a first position due to movement of the actuator arm in a second direction, the path of the light received at the photoelectric sensor may not be blocked by the actuator arm, thereby causing a change in the signal output by the photoelectric sensor.

[0015] According to some exemplary embodiments, the finger portion can be positioned along a movement path defined by the switch plate such that when the first push pin moves in the movement path, the curved portion of the first push pin can contact the top portion of the finger portion.

[0016] In some exemplary embodiments, the fingers of the fault detection unit may be positioned along a movement path defined by the switch plate. The fingers may be positioned such that, as the second push pin moves in the movement path, the non-bent portion of the second push pin passes along the fingers through the movement path without contacting the top portion of the fingers.

[0017] According to some exemplary embodiments, the top portion of the finger can be tapered such that a portion of the finger contacts the top portion of the finger in response to the push pin, and the finger and the actuator arm pivot about the pivot pin.

[0018] In some exemplary embodiments, the fault detection unit may further include a spring pin. The spring pin may be mechanically engaged with the actuating arm. The spring pin may be configured to retract the actuating arm in a direction opposite to the second direction when the actuating arm moves in the second direction.

[0019] Some exemplary embodiments described herein relate to a method for detecting a fault in a pusher pin of a pusher sorter. The method may include initializing a photoelectric sensor of the pusher sorter. Additionally, the method may include initializing movement of the pusher pin along a movement path defined by a switch plate of the pusher sorter. The method may also include having a processor recognize a change in the signal value output by the photoelectric sensor. In this respect, a change in the signal value may be attributed to unobstructed light received at the photoelectric sensor. This unobstructed light is caused by the movement of the actuation component of the pusher sorter in response to contact between the pusher pin and a portion of the actuation component.

[0020] In some exemplary embodiments, the actuation assembly may include fingers mechanically coupled to a portion of the switch plate of a pusher-type sorter. The fingers may be configured to move in a first direction in response to a pusher pin contacting a portion of the fingers. Furthermore, the actuation assembly may include an actuating arm pivotally engaged with the fingers, such that movement of the fingers in the first direction causes movement of the actuating arm in a second direction. In this respect, movement of the actuating arm in the second direction may prevent light received at the photoelectric sensor from being blocked.

[0021] According to some exemplary embodiments, the method may also include generating a warning in response to the recognition of a change in the signal value. In this regard, the warning may indicate misalignment of the push pin.

[0022] In some exemplary embodiments, the method may also include generating a command to stop the operation of the pusher sorter based on the determination of misalignment of the pusher pin.

[0023] The above description of the invention is provided merely to outline some exemplary embodiments to provide a basic understanding of some aspects of this disclosure. Therefore, it should be understood that the above embodiments are merely examples and should not be construed as limiting the scope or substance of this disclosure in any way. It should be understood that, in addition to those summarized herein, the scope of this disclosure covers many possible embodiments, some of which will be further described below. Attached Figure Description

[0024] The description of the exemplary embodiments can be read in conjunction with the accompanying drawings. It should be understood that, for simplicity and clarity of illustration, the elements shown in the drawings are not necessarily drawn to scale. For example, the dimensions of some elements are exaggerated relative to others. Embodiments incorporating the teachings of this disclosure are shown and described with reference to the accompanying drawings, in which:

[0025] Figure 1 A top perspective view of a switchboard of a sorting conveyor including a fault detection unit, according to some exemplary embodiments described herein, is shown.

[0026] Figure 2A bottom perspective view of a switchboard of a sorting conveyor including a fault detection unit according to some exemplary embodiments described herein is shown.

[0027] Figure 3 A perspective view of a section of a sorting conveyor according to some exemplary embodiments described herein is shown. The sorting conveyor includes a fault detection unit for detecting misalignment of at least one of the pusher bearings and / or pusher pins of the pusher blocks of the sorting conveyor.

[0028] Figure 4 A perspective view depicting a first state of a fault detection unit according to some exemplary embodiments described herein is shown, wherein the pusher pin and bearing of the pusher block move along a movement path defined by the switch plate without contacting a portion of at least one finger of the fault detection unit.

[0029] Figure 5 Another perspective view depicting a second state of a fault detection unit according to some exemplary embodiments described herein is shown, wherein the misaligned push pin and misaligned push bearing of another push block move through a movement path, thereby contacting a portion of at least one finger of the fault detection unit.

[0030] Figure 6 An exemplary flowchart illustrating the operation of a method for detecting a fault in a pusher block of a sorting conveyor, according to various exemplary embodiments described herein, is shown.

[0031] Figure 7 A first perspective view of a first state of a fault detection component according to an alternative exemplary embodiment described herein is shown.

[0032] Figure 8 A second perspective view of a second state of a fault detection component according to an alternative exemplary embodiment described herein is shown.

[0033] Figure 9 and Figure 10 A fourth and fifth perspective view of a fault detection component according to an alternative exemplary embodiment described herein is shown. Detailed Implementation

[0034] Some embodiments of this disclosure will be described more fully below with reference to the accompanying drawings, which illustrate some, but not all, embodiments of this disclosure. In fact, this disclosure may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided to enable this disclosure to meet applicable legal requirements. Unless otherwise specified, the terms “or” and “optionally” are used herein in the sense of alternatives and combinations. The terms “illustrative” and “exemplary” are used for examples without an indication of quality level. Throughout the document, similar reference numerals refer to similar elements.

[0035] The components shown in the accompanying drawings represent components that may or may not be present in the various embodiments of this disclosure described herein, such that the embodiments may include fewer or more components than those shown in the drawings without departing from the scope of this disclosure.

[0036] The various exemplary embodiments described herein relate to sorting conveyors (e.g., pusher sorters) including one or more pushers that can travel laterally (i.e., laterally to the longitudinal direction of travel of the conveyor surface of the sorting conveyor) to deflect articles carried by the conveyor surface of the sorting conveyor to a deflection position (or deflection channel) associated with the sorting conveyor. In this regard, in some examples, the pushers may be guided along a deflection guide path to gently engage the conveyed articles laterally and gradually accelerate them to a deflection unit that can be mechanically coupled to the sorting conveyor.

[0037] In some examples, the sorting conveyor and the switching assembly including the switchboard mentioned in several instances throughout the specification may correspond to the sorting conveyor described in U.S. Patent Application No. US16 / 672979, filed November 4, 2019, entitled “Conveyor with Guide Rails to support a Divert Unit,” the details of which are incorporated herein by reference.

[0038] Typically, a sorting conveyor includes a switching assembly and a deflection guide path mounted on a portion of the conveyor frame. In this respect, the switching assembly may be mounted upstream of the deflection guide path along the length of the sorting conveyor. The switching assembly includes one or more plates defining at least one movement path for movement of pusher pins. In some examples, these plates may define a deflection movement path and a home path, wherein the deflection movement path further connects to the deflection guide path. In this respect, the deflection movement path is defined for moving the pusher pin of a pusher in a lateral direction and along the length of the sorting conveyor to deflect an item. Additionally, the home path is defined for moving another pusher pin of another pusher when the item is not deflected. Thus, in operation, the pusher pin moves into the deflection movement path defined by the one or more plates and further along the length of the sorting conveyor into the deflection guide path to deflect the article for sorting. The deflection guide path referred to herein represents an arcuate section that connects a first side frame of the sorting conveyor to a second side frame across the length of the sorting conveyor. Therefore, as the pusher pin moves into these paths, the pusher face (also known as the head) of the pusher gently contacts the articles being conveyed on the sorting conveyor, thereby guiding the articles on the turning guide path and further toward the turning channel.

[0039] Typically, for the push pin to move smoothly and unimpeded along these paths, it is desirable that one or more plates of the switch assembly be properly aligned with each other and further with the deflection guide path. Therefore, in some cases, misalignment of the plates often causes the push pin to move obstructedly into the movement path. The push pin may even move into the movement path of a improperly installed plate, causing the push pin to become misaligned (or bent).

[0040] Furthermore, in some examples, the pusher pins are "misaligned" or "bent" due to foreign debris in their path or problems with the products being conveyed on the sorting conveyor, thus hindering the pusher from traveling on its standard turning path. Additionally, in some cases, the pusher pins are misaligned or bent from their original position, also due to wear and tear, which can even damage any parts of the switching assembly and / or other parts of the sorting conveyor. In other words, if a bent pusher pin or anomalies in the pusher are used in operation for an extended period, it can often lead to incorrect item turning and extensive damage to the entire sorting conveyor. Therefore, it is desirable to identify misalignment of the pusher pins from their original position and to take repair and / or maintenance measures. In other words, it is desirable to identify misalignment of the pusher pins in a timely manner so as to reduce the production time of the pusher sorter by taking preventative measures rather than corrective measures after the pusher pins are misaligned. Existing technologies for detecting misalignment of pusher pins in pusher sorters are costly and / or have associated challenges.

[0041] The various exemplary embodiments described herein relate to techniques for detecting the fit or misalignment of pusher pins in pusher-type sorting machines. By implementing the various exemplary embodiments described below, potential damage to the assembly of the sorting conveyor that may be caused by bent pusher pins can be prevented, thereby extending customer uptime.

[0042] Turning now to the accompanying drawings, the specific embodiments illustrated below, taken in conjunction with the drawings, are intended to describe various configurations and are not intended to represent the only configuration in which the concepts described herein can be practiced. The specific embodiments include detailed descriptions intended to provide a comprehensive understanding of the various concepts, wherein similar reference numerals are used throughout several views. However, it will be apparent to those skilled in the art that these concepts can be practiced without these specific details.

[0043] Figure 1 A top perspective view 100 of a switching assembly 102 of a sorting conveyor according to some exemplary embodiments described herein is shown. In some exemplary embodiments, the sorting conveyor may correspond to a pusher-type sorter comprising a plurality of pushers that can travel laterally across the conveying surface of the sorting conveyor to deflect articles. In this regard, in some exemplary embodiments, each of such pushers may include a pusher head (i.e., a head portion) and a pusher bearing, as well as a pusher pin disposed below the pusher head.

[0044] See Figure 1 According to the various exemplary embodiments described herein, the switch assembly 102 may include a fault detection unit 104. In some exemplary embodiments, the fault detection unit 104 may be configured to detect misalignment of at least the pusher pin and / or the pusher bearing of the sorting conveyor pusher.

[0045] According to the various exemplary embodiments described herein, the term "push block pin" as used throughout may correspond to any portion of the push block defined below the head portion of the push block, and includes a component capable of traveling along a path beneath the conveyor bed of a sorting conveyor. In this regard, the push block described in the various exemplary embodiments may include a head portion and a tail portion below the head portion. The head portion of the push block may generally correspond to portions of the push block that impact articles on the conveyor bed of the sorting conveyor. Furthermore, the tail portion of the push block may correspond to a portion capable of traveling along a path defined beneath the conveyor bed of the sorting conveyor. For example, in some exemplary embodiments, the tail portion of the push block may include a push block bearing and a push block pin. According to some exemplary embodiments, the push block pin may correspond to a portion of the push block that is below the push block head (i.e., including the push block bearing and the push block pin below the push block bearing). Alternatively, in some exemplary embodiments, the push block pin may correspond to a pin portion of the push block below the push block bearing.

[0046] Examplely, the switch assembly 102 may include a switch plate 106. The switch plate 106, along with other components of the switch assembly 102, may be mounted on a portion of the conveyor frame of a sorting conveyor, such as, but not limited to, a spreader. In some exemplary embodiments, the switch plate 106 may include one or more members 103, such as, but not limited to, structures defined by machined plastic or metal casting molds or molding elements, which project outward from the top surface of the switch plate to define at least one path of movement, i.e., a path that enables movement of the pusher bearing and pusher pin of the pusher block. For example, as shown, the switch plate 106 may be configured to define a path 108 that enables movement of the pusher pin of the pusher block. In other words, the path 108 defines a channel through which the pusher bearing and pusher pin move, thereby moving the pusher block across the length of the sorting conveyor.

[0047] In some exemplary embodiments, the movement path 108 may be further connected to a turning path (e.g., an arcuate path) to enable the pusher to move laterally from one side (e.g., the left side) of the sorting conveyor to the other side (e.g., the right side). In some exemplary embodiments, the switch plate 106 may define more than one movement path 108. For example, in some examples, the switch plate 106 may define two movement paths, such as a turning path and a home path. In some exemplary embodiments, the switch plate 106 may also include a switch (not shown) that can be mounted on a portion of the switch plate 106. For this purpose, the switch may be actuated by a processing unit (e.g., a controller of the sorting conveyor) and movable between two positions (e.g., a first position or a second position), thereby enabling the pusher pin to move in one of the two movement paths (i.e., the turning path and the home path). In other words, in some examples, the switch may be actuated to move to a first position that closes the home path defined by the switch plate 106 and allows the pusher pin to move into the turning path, thereby causing lateral movement of the pusher on the sorting conveyor to facilitate the turning of the item. Therefore, the switch can be used to selectively turn a pusher from its in-situ path to a steering guide path based on the movement of pusher pins of one or more pushers along these paths, for the purpose of turning or not turning the item.

[0048] According to the various exemplary embodiments described herein, the fault detection unit 104 may be configured to detect misalignment (e.g., fault, bending, torsion, etc.) of the pusher pin of the pusher block, details of which will be referred to Figures 1 to 6 This will be described later.

[0049] According to some exemplary embodiments, the fault detection unit 104 may include at least one finger, such as a first finger 110-1 and a second finger 110-2 (hereinafter referred to interchangeably as at least one finger 110 for brevity), a photoelectric sensor 112, and a corresponding actuating arm (not shown) mechanically coupled to the finger (110-1 and 110-2). As shown, at least one finger 110 may be positioned along the switch plate 106 or mounted on a portion of the switch assembly 102. For example, in some examples, at least one finger 110 of the fault detection unit 104 may be positioned at the distal end of the switch plate 106 along a movement path 108 defined by the switch plate 106, i.e., adjacent to the member 103 defined by the switch plate 106. In this regard, in some exemplary embodiments, the fingers 110-1 and 110-2 may be positioned (a) adjacent to a member 103 defining a movement path 108 toward the distal end of the switch plate 106, and (b) through a hole 105 defined in the switch assembly 102.

[0050] In other words, according to the various exemplary embodiments described herein, at least one finger 110 (i.e., fingers 110-1 and 110-2) can be positioned on the switch plate 106 in the direction of movement of the push pin along the movement path 108 defined by the switch plate 106. This positioning of the fingers 110-1 and 110-2 defines a channel (gate-like structure) such that, in response to the movement of the first push pin (not shown) in the movement path 108 and further through the channel, the curved portion of the first push pin contacts the top portion of at least one finger 110. Furthermore, by this positioning, a second push pin without a curved portion passes through the movement path 108 and further reaches a turning path (not shown) without contacting any portion of at least one finger 110.

[0051] According to the various exemplary embodiments described herein, at least one finger 110 undergoes movement based on contact between the pusher pin and at least one finger 110. In this regard, according to the various exemplary embodiments, at least one finger 110 may be mechanically coupled to an actuating arm (not shown) in such a way that the movement experienced by at least one finger 110 can further cause movement of the actuating arm of the fault detection unit 104. Additionally, the actuating arm, in a direction toward the photoelectric sensor 112 and reaching a defined position, unblocks light previously obstructed by the actuating arm and not received by the photoelectric sensor 112, thereby causing a change in the signal output by the photoelectric sensor 112. The controller of the sorting conveyor uses this change in signal to determine misalignment of the first pusher pin of the pusher. In an alternative embodiment, the photoelectric sensor 112 may be mounted on the switching assembly 102 such that movement of a bent or misaligned pusher pin blocks an unobstructed or unobstructed path of light received at the photoelectric sensor 112, while movement of a non-bent pusher pin maintains an unobstructed or unobstructed light path toward the photoelectric sensor 112. Further details about the fault detection unit 104 will be provided below. Figures 2 to 6 Describe it.

[0052] Figure 2 A bottom perspective view 200 of a switching assembly 102 of a sorting conveyor including a fault detection unit 104 according to some exemplary embodiments described herein is shown. Illustratively, the switching plate 106 of the switching assembly 102 includes a member 103 (e.g., a member in the form of a structural mold) defined on the top surface of the switching plate 106. The member 103 defines a travel path 108 for movement of one or more pusher pins of a respective pusher of the sorting conveyor. Figure 2 The bottom perspective view 200 also shows a switch plate 106 mounted on a portion of the switch assembly 102 via engagement members 204 (e.g., a nut and bolt assembly).

[0053] As previously referenced Figure 1 The fault detection unit 104 may include at least one finger 110, a photoelectric sensor 112, and an actuating arm 210. According to some exemplary embodiments, the fault detection unit 104 may be a separate unit (i.e., separate from the switch assembly 102) that can be mounted on a portion of the switch assembly 102 (i.e., the switch assembly of an existing sorting conveyor) and may be further configured to identify misaligned push pins that may pass through the switch assembly 102. Alternatively, in some exemplary embodiments, the fault detection unit 104 and its components may be part of the switch assembly 102 itself, i.e., manufactured and supplied by an original equipment manufacturer (OEM).

[0054] According to the various exemplary embodiments described herein, at least one finger 110 of the fault detection unit 104 may have any shape, such as, but not limited to, a rod, a crossbar, or a piece of metal. At least one finger 110 may be defined between two ends, such as a first end 208 and a second end 209, and may engage with a portion of the switch assembly 102. For example, at least one finger 110 may pass through a hole 215 defined in the switch assembly 102. According to various exemplary embodiments, at least one finger 110 may be constituted from a metal plate, or an aluminum spike, or a portion of any kind of engineering plastic. In this regard, in some exemplary embodiments, movement of the actuator arm 210 may be based on the physical contact of a misaligned bearing / pin with at least one finger 110.

[0055] Furthermore, according to some exemplary embodiments, the actuating arm 210 may have any shape and structure (e.g., but not limited to, a shape and structure similar to at least one finger 110) and may be defined between a third end 212 and a fourth end 214. According to the various exemplary embodiments described herein, the actuating arm 210 and at least one finger 110 are pivotally engaged about a pivot point P, for example, with each other or via a pivot assembly 216. In some examples, the pivot assembly 216 may include at least one pivot pin 218 that passes through a hole defined in the pivot assembly 216 and further through a corresponding portion of at least one finger 110 and the actuating arm 210, thereby enabling pivotal engagement of at least one finger 110 with the actuating arm 210.

[0056] In an alternative exemplary embodiment, at least one finger 110 and an actuating arm 210 may correspond to two parts (e.g., a vertical part and a horizontal part) of the same unit (e.g., an L-shaped member). In this respect, the vertical part of the L-shaped member may correspond to the finger 110, and the horizontal base of the L-shaped member may correspond to the actuating arm 210. In this respect, the L-shaped member may be pivotally engaged to a pivot assembly 216, such that the respective parts may be pivotally moved about a pivot point P. In other words, the L-shaped member may be pivotally engaged to the pivot assembly 216 such that after movement of the vertical part of the L-shaped member along a first direction X, movement of the horizontal part of the L-shaped member along a second direction Z (e.g., but not limited to a direction substantially perpendicular to the first direction).

[0057] According to the various exemplary embodiments described herein, the actuating arm 210 may be pivotally engaged to at least one finger 110 such that movement of at least one finger 110 causes movement of the actuating arm 210, and vice versa. In this respect, both the actuating arm 210 and the at least one finger 110 may be engaged to a pivot pin 218 such that pivotal movement of either the at least one finger 110 or the actuating arm 210 causes a resulting movement to the other. In other words, in some exemplary embodiments, the actuating arm 210 may be pivotally engaged to at least one finger 110 in such a manner that movement of at least one finger 110 in a first direction causes movement of the actuating arm 210 in a second direction.

[0058] Additionally, referring to an alternative exemplary embodiment, in which at least one finger 110 and the actuating arm 210 are portions of an L-shaped member, the movement of the vertical portion of the L-shaped member along a first direction X (which may be caused by contact with the pusher pin) may further cause the horizontal portion of the L-shaped member to move along a second direction Z. Figure 5 Exemplary movement of at least one finger 110 and an actuating arm 210 is depicted. In some exemplary embodiments, a spring pin (not shown) may be mechanically coupled to the actuating arm 210 and a portion of the switching assembly 102. The spring pin may be configured to retract the actuating arm in a direction opposite to the second direction when the actuating arm 210 moves in the second direction.

[0059] According to the various exemplary embodiments described herein, the actuator arm 210 along the second direction Z can cause a previously blocked optical path toward the photoelectric sensor 112 to be unobstructed, as detailed below. Figures 3 to 6 The following description is provided. In an alternative embodiment, the actuating arm 210 along the second direction Z can cause the light path toward the photoelectric sensor 112 to be blocked, thereby producing a change in the signal output by the photoelectric sensor 112. Furthermore, this blocking or unblocking of the light path can cause a change in the signal value output by the photoelectric sensor 112. Moreover, according to the various exemplary embodiments described herein, the change in signal value can be used to determine the misalignment of the pusher pin of the pusher block, the details of which will be described below.

[0060] Figure 3A perspective view 300 of a section of a sorting conveyor according to some exemplary embodiments described herein is shown. The sorting conveyor includes a fault detection unit 104 for detecting misalignment of at least one of the pusher bearings and / or pusher pins of the pusher blocks of the sorting conveyor. In some exemplary embodiments, the sorting conveyor may correspond to a slat pusher sorting machine having a plurality of slats 302-1...302-n forming an annular conveyor bed that is looped around a portion of a conveyor frame and can support the transport of one or more items by the sorting conveyor. In some exemplary embodiments, the slats 302-1...302-n may be in the form of components that can support the transport of articles on the sorting conveyor, such as, but not limited to, aluminum components. In some exemplary embodiments, the sorting conveyor may also include a pair of annular chains positioned adjacent to two side conveyor frames of the sorting conveyor, wherein the plurality of slats 302-1...302-n may be connected to the respective chains at their opposite ends to provide a moving conveyor surface.

[0061] Figure 3 A portion of the conveyor frame 306 of the sorting conveyor is also shown. Exemplarily, slats (304-1...304-n) may be mounted between two side frames of the conveyor frame 306. Furthermore, in some exemplary embodiments, the conveyor frame 306 may include one or more spreaders 308-1, 308-2,...308-n that may be mounted between the two side frames. The spreaders 308-1...308-n may be configured to support the mounting of one or more components, such as, but not limited to, switch assembly 102, switch plate 106, one or more guide rails (not shown), etc. Exemplarily, a fault detection unit 104 may be positioned below the plurality of slats 302-1...302-n and may be supported on the switch plate 106 mounted on the spreader 308-1.

[0062] According to some exemplary embodiments, as shown in the figures, each slat (302-1, 302-2, ..., 302-n) may be fitted with a corresponding push block (304-1, 304-2, ..., 304-n). In this respect, each push block (304-1...304-n) may include a push block head, a push block bearing, and a push block pin. The push block bearing and push block pin may be located below the push block head. For example, as shown in the figures, push block 304-5 includes a push block head 310, a push block bearing 311, and a push block pin 312, wherein the push block bearing 311 and push block pin 312 are located below the push block head 310.

[0063] As previously described, in some examples, the sorting conveyor may correspond to a slat sorter with multiple slats, wherein each pusher travels laterally across the length of the sorting conveyor between the multiple slats. That is, in exemplary operation of the sorting conveyor, each pusher (304-1...304-n) may be configured to slide and travel laterally (e.g., along direction P) across the corresponding slat (302-1...302-n) based on the movement of the pusher pin (e.g., pusher pin 312) and pusher bearing (e.g., pusher bearing 311) of the corresponding pusher (304-1...304-n). For this purpose, the pusher bearing and the corresponding pusher pin (e.g., pusher bearing 311 and pusher pin 312) may travel in a movement path (e.g., movement path 108) defined by the switch plate 106 and the steering guide path (not shown) of the steering rail. Therefore, by implementing the various exemplary embodiments described herein, the movement of one or more push blocks (304-1...304-n) of the sorting conveyor can be guided by a guide rail below the conveying surface of the sorting conveyor, the guide rail being formed by a movement path defined by the switch plate 106 and a steering guide rail connected to the switch plate 106.

[0064] Figure 4 A perspective view 400 depicting a first state of the fault detection unit 104 is shown, wherein the pusher pin and bearing of the pusher block move along a movement path 108 defined by the switch plate 106 without contacting a portion of at least one finger 110 of the fault detection unit 104. In this respect, the pusher pin and pusher bearing of the pusher block are not misaligned with their original shape and alignment.

[0065] also, Figure 5 Another perspective view 500 depicting a second state of the fault detection unit 104 is shown, in which the misaligned push pin and misaligned push bearing of another push block move through the movement path 108, thereby contacting a portion of at least one finger 110 of the fault detection unit 104.

[0066] According to some exemplary implementations, such as Figure 4As shown, the first pusher 401 may include a first pusher head 402, a first pusher bearing 404, and a first pusher pin 406. In this respect, according to the exemplary embodiment described herein, both the first pusher bearing 404 and / or the first pusher pin 406 are not aligned with their original shapes. In other words, the first pusher bearing 404 and the first pusher pin 406 are fault-free and have the correct shape and are correctly aligned relative to their pusher head 402. Additionally, according to some exemplary embodiments, in the operation of laterally sliding the first pusher 401 across a slat between two ends of the sorting conveyor, the pusher pin and the pusher bearing travel through a movement path 108 defined by a switch plate 106. Exemplarily, the switch plate 106 may include two ends, for example, a primary end 407 and a distal end 408. The movement path 108 may be defined between the two ends 407 and 408. In this respect, the movement path 108 referred to herein may be configured for the movement of the pusher bearing and pusher pin of the respective pusher. According to some exemplary embodiments, pusher 401 can initially be installed / accommodated in its original position, i.e., at the primary end 407 on switch plate 106. Therefore, movement of the first pusher pin 406 and the first pusher bearing 404 can begin from the primary end 407 of switch plate 106 and can continue further toward the distal end 408 of switch plate 106.

[0067] As shown in the figure, according to various exemplary embodiments, at least one finger 110 of the fault detection unit 104 may be mounted on a portion of the switch assembly 102 including the switch plate 106. In this regard, at least one finger 110 may be positioned along a guide rail adjacent to or near the distal end 408 of the switch plate 106 for movement of push pins and push bearings below the strips (302-1...302-n).

[0068] In some exemplary embodiments, the fault detection unit 104 may include two fingers, namely a first finger 110-1 and a second finger 110-2, wherein each finger 110-1 and 110-2 may be pivotally engaged with a corresponding actuating arm. In such embodiments, each of the fingers 110-1 and 110-2 may be mounted on a portion of the switch assembly 102 such that each finger may be positioned adjacent to or near the distal end 408 of the switch plate 106 along opposite sides of the switch plate 106. In this respect, the two fingers 110-1 and 110-2 may be positioned to form a defined gap between each other along the movement path 108 of the switch plate 106. For this purpose, the fingers 110-1 and 110-2 may be positioned to form a gate-like structure for the passage of the bearings and push pins of the corresponding push blocks. In this respect, the finger portions 110-1 and 110-2 are mounted on the switch assembly 102 in such a position that the gate-like structure allows the passage of non-bent push pins and push bearings and blocks the passage of bent push pins and bent push bearings.

[0069] In other words, the gate-like structure defined by the finger-like portions 110-1 and 110-2 defines a channel such that the first pusher bearing 404 and the first pusher pin 406 (i.e., the non-bent / misaligned pusher pin and bearing) move along the movement path 108 and pass through the gate formed by the finger-like portions 110-1 and 110-2, without any part of the first pusher bearing 404 and the first pusher pin 406 making any contact with any part of the finger-like portions 110-1 and 110-2. Therefore, Figure 4 This is an exemplary illustration of a state in which pusher pin 406 and / or pusher bearing 404 pass through at least one finger 110 without making any contact with the finger 110.

[0070] However, conversely, the gate-like structure defined by the finger-like portions 110-1 and 110-2 blocks the passage of the misaligned pusher bearing and the misaligned pusher pin. In other words, the bending of the pusher bearing and the bending of the pusher pin through the gate causes at least some portions of the pusher bearing and / or the pusher pin to contact at least some portions (e.g., the top portions) of the finger-like portions 110-1 and / or 110-2. For this purpose, Figure 5 This exemplary state of the fault detection unit 104 is shown.

[0071] Figure 5 Another perspective view 500 depicting a second state of the fault detection unit 104 is shown. In the second state, as... Figure 5As shown, the second pusher bearing 504 (e.g., misaligned / bent pusher bearing) and the second pusher pin 506 (e.g., misaligned / bent pusher pin) of the second pusher 501, including the second pusher head 502, contact the T portion 508 (e.g., top portion) of at least one finger 110 of the fault detection unit 104 when moving through the movement path 108.

[0072] As shown, at least one finger 110 may be mechanically coupled to or mounted on a portion of the switch plate 106 along a movement path 108. In this regard, at least one finger 110 may be configured to move in a first direction X in response to a portion of the second pusher bearing 504 and / or the second pusher pin 506 contacting a top portion (i.e., portion 508 of at least one finger 110). In some exemplary embodiments, the top portion (i.e., portion 508) may taper such that, in response to a portion of the second pusher bearing 504 and / or the second pusher pin 506 contacting portion 508 of at least one finger 110, at least one finger 110 and the actuating arm 210 pivot about a pivot pin 218. Furthermore, according to some exemplary embodiments, the movement of at least one finger 110 in the first direction X depends on the contact and / or force of the second pusher bearing 504 and / or the second pusher pin 506 contacting portion 508 of at least one finger 110. In this regard, in some exemplary embodiments, at least one finger 110 may be designed to withstand impacts from at least one of the pusher bearing 504 and / or pusher pin 506. According to some exemplary embodiments, an impact on at least one finger 110 may cause it to move the actuator arm 210, thereby causing a change in the signal output by the photoelectric sensor 112 (e.g., a photoelectric monitor), and returning to the initial value before the next pusher arrives (so that it is possible to detect whether two pushers, one after the other, include a bent pusher pin and / or pusher bearing).

[0073] Additionally, in some exemplary embodiments, at least one finger 110 may be designed such that if the pusher pin is misaligned, the passage of the misaligned pusher pin (e.g., the second pusher pin 506) may cause damage to internal components of the pusher sorter due to its movement. During movement along the channel, the misaligned pusher pin may contact at least some portions of at least one finger 110, which may cause detectable movement of the actuator arm 210 in a second direction.

[0074] Examplely, at least one finger 110 can be pivotally connected to the actuator arm 210 via a pivot assembly 216 including a pivot pin 218, such as Figure 2Therefore, according to some exemplary embodiments described herein, when the actuator arm 210 is pivotally engaged with at least one finger 110, movement of the at least one finger 110 in a first direction X causes movement of the actuator arm 210 in a second direction Y.

[0075] Alternatively, as previously described, in some exemplary alternative embodiments, wherein at least one finger portion 110 and the actuating arm 210 are part of the same unit (i.e., L-shaped member), and the horizontal portion (i.e., the actuating arm 210 of the L-shaped member) moves along the second direction Y after the vertical portion (i.e., the finger portion 110) moves along the first direction X.

[0076] According to various exemplary embodiments, the actuating arm 210 along the second direction Y causes the signal of the photoelectric sensor 112 to be interrupted. In some examples, the actuating arm 210 along the second direction Y can cause the signal of the photoelectric sensor 112 to be interrupted when a portion 510 of the actuating arm 210 reaches a defined position Z in its movement path. Therefore, in some exemplary embodiments, the actuating arm 210 along the second direction Y does not obstruct a light path toward the photoelectric sensor 112 that could previously be blocked by the actuating arm 210, thereby causing a change in the signal output by the photoelectric sensor 112. Thus, in such exemplary embodiments, the actuating arm 210 along the second direction Y can cause a sudden change in the light received at the photoelectric sensor 112, i.e., at the moment when portion 510 reaches position Z and light is received by the photoelectric sensor 112. According to the various exemplary embodiments described herein, the sorting conveyor may include a processor that can be coupled to the photoelectric sensor 112. In some examples, the change in the signal output by the photoelectric sensor 112 may be accessed by the processor to identify misalignment of the second pusher bearing 504 and / or the second pusher pin 506, details of which will be referred to Figure 6 Further description is required.

[0077] Figure 6 An exemplary flowchart illustrating the operation of a method for detecting a fault in a pusher block of a sorting conveyor, according to various exemplary embodiments described herein, is shown.

[0078] It should be understood that each block in the flowchart, and combinations of blocks in the flowchart, can be implemented by various means, such as hardware, firmware, one or more processors, circuitry, and / or other devices associated with the execution of software including one or more computer program instructions. For example, one or more of the processes described above can be embodied by computer program instructions. In this regard, computer program instructions embodying the processes described above can be stored in the memory of a device employing an embodiment of the present invention and executed by a processor in the device. It is understood that any such computer program instructions can be loaded onto a computer or other programmable device (e.g., hardware) to produce a machine such that the resulting computer or other programmable device provides an implementation of the functions specified in one or more flowchart blocks. These computer program instructions can also be stored in a non-transitory computer-readable storage memory that can instruct the computer or other programmable device to operate in a particular manner, such that the instructions stored in the computer-readable storage memory produce an article of writing whose execution can implement the functions specified in one or more flowchart blocks. The computer program instructions can also be loaded onto a computer or other programmable device to cause a series of operations to be performed on the computer or other programmable device, thereby producing a computer-implemented method such that the instructions executing on the computer or other programmable device provide operations for implementing the functions specified in one or more flowchart blocks. Therefore, Figure 6 When executed, the operation transforms the computer or processing circuitry into a specific machine configured to perform exemplary embodiments of the present invention. Therefore, Figure 6 The operation can define algorithms used to configure a computer or processor to execute exemplary implementation schemes. In some cases, an instance of a processor can be provided for a general-purpose computer that executes... Figure 6 The algorithm transforms a general-purpose computer into a specific machine configured to execute an exemplary implementation.

[0079] Therefore, the boxes in a flowchart support combinations of devices for performing a specified function and combinations of operations for performing the specified function. It will also be understood that one or more boxes in a flowchart, as well as combinations of boxes in a flowchart, can be implemented by a hardware-based dedicated computer system or a combination of dedicated hardware and computer instructions to perform the specified function.

[0080] See Figure 6The flowchart illustrates a method 600 for detecting a failure of at least one of the pusher bearing 504 and pusher pin 506 of a pusher 501 of a sorting conveyor. According to some exemplary embodiments, the sorting conveyor may correspond to a pusher-type sorting machine including components operable based on technologies such as U.S. Patent Application No. US12 / 014922, filed January 16, 2008, entitled “Sortation Conveyor,” and / or U.S. Patent Application No. US15 / 147475, filed May 5, 2016, entitled “High-speed, dual-sided shoe sorter with offset induct,” details of which are incorporated herein by reference.

[0081] The method begins at step 602. At step 604, the sorting conveyor may include means for initializing the photoelectric sensor 112 of the sorting conveyor, such as a processor. In some examples, the photoelectric sensor 112 may be initialized in response to the initialization of the article conveying operation of the sorting conveyor.

[0082] Moving to step 606, the sorting conveyor may include means for initiating movement of push block 501, such as a processor. In this regard, movement of the push block may include movement of push block bearing 504 and push block pin 506 along a movement path 108 defined by the switch plate 106 of the sorting conveyor, thereby causing the push block 501 to move laterally across the slats of the sorting conveyor.

[0083] According to various exemplary embodiments, pusher 501 can be moved on the top surface of switch plate 106 into an in-situ path or a deflection path defined by member 103. Therefore, in some examples, when it is necessary to deflect items on the surface of a sorting conveyor, pusher bearing 504 and pusher pin 506 of pusher 501 can move through the deflection path based on actuation of the switch of switch plate 106. The deflection path may correspond to movement path 108, such as... Figures 1 to 5 As shown and described.

[0084] Moving to step 608, the sorting conveyor may include means, such as a processor, for identifying changes in the signal value output by the photoelectric sensor 112. In this regard, in some exemplary embodiments, the change in signal value may be attributed to the unblocking of light emitted toward the photoelectric sensor 112. In other words, the change in signal value may be attributed to the unblocking of the path of light previously blocked by the actuating arm 210. For this purpose, in some exemplary embodiments, the light may be unblocked because the actuating components (i.e., at least one finger 110 and some portion of the actuating arm 210) move in response to at least one of the pusher bearing 504 and pusher pin 506 of the pusher 501 contacting the top portion 510 of at least one finger 110 mechanically coupled to the actuating arm 210. The method stops at step 610.

[0085] In some exemplary embodiments, method 600 may further include generating a warning in response to the identification of a change in a signal value. In this regard, in an exemplary embodiment, the warning may indicate misalignment of the pusher pin. Furthermore, in another exemplary embodiment, a warning may be generated to notify a worker of a malfunction in pusher 501. In this regard, in some examples, a malfunction in pusher 501 may correspond to bending or misalignment of pusher bearing 504 and / or pusher pin 506. In another exemplary embodiment, method 600 may further include generating a command to stop the operation of the sorting conveyor based on the determination of misalignment of pusher bearing 504 and / or pusher pin 506.

[0086] By implementing the various exemplary embodiments described herein, an undamaged pusher (i.e., any bent or misaligned pusher without a pusher pin and / or pusher bearing) will pass through a specially designed door formed by fingers 110-1 and 110-2 without contacting any portion of fingers 110-1 and 110-2. However, a damaged pusher (i.e., any bent or misaligned pusher with a pusher pin and / or pusher bearing) will contact some portions of fingers 110-1 and / or 110-2 as it passes through the door, thereby also moving the actuator arm 210, which will cause the alarm signal of the photoelectric sensor 112 to be interrupted. This will indicate an abnormal or malfunctioning condition that may represent a bent pin or misaligned pusher pin or pusher bearing. Furthermore, in some exemplary embodiments, if such an abnormality is detected, the positional information of the misaligned pusher pin can be determined, and one or more commands can be generated, such as, but not limited to, shutting down the sorting machine, sending a warning, or formulating some other type of programming result, such as automatically turning the abnormal pusher and marking it for detection.

[0087] Figure 7A first perspective view 700 of a fault detection assembly 702 of a sorting conveyor (not shown) according to an alternative exemplary embodiment described herein is shown in a first state. In some exemplary embodiments, the fault detection assembly 702 may include a gate-like structure that defines a channel for movement of one or more pusher pins of a corresponding pusher for the sorting system. In some exemplary embodiments, the gate-like structure may be formed by a pair of elements positioned at the defined gap. For example, in some examples, the gate-like structure may include a first tab 704 and a second tab 706. In some examples, the first tab 704 and the second tab 706 may correspond to contactor springs that can be compressed or stretched about a rest position. In this respect, the contactor spring may be of any material, such as a metallic contactor spring or a non-metallic contactor spring, which can be compressed or stretched from a rest position in response to external contact formed on the contactor spring.

[0088] According to the exemplary embodiment, the first tab 704 and the second tab 706 of the fault detection component 702 may form an incomplete circuit. In this regard, in some examples, the first tab 704 may be connected to a power source (i.e., the +V signal terminal), and the second tab 706 may be connected to a slot of a power unit (i.e., the 0-volt terminal). Furthermore, the power unit may be connected to a processor.

[0089] According to some exemplary embodiments, the first tab 704 and the second tab 706 forming the gate-like structure can be positioned on the switch plate 102 of the switch assembly 106 in a similar manner, as referenced by [reference needed]. Figures 1 to 5The gate-like structure is formed by at least one finger portion 110. According to some exemplary embodiments, the first tab 704 and the second tab 706 forming the gate-like structure can be positioned on the switch plate 102 such that, in response to the movement of the first push pin (i.e., a push pin having a curved portion or associated with a push pin bearing having a curved portion) through the channel, the curved portion of the first push pin and / or the push pin bearing associated with the first push pin contacts the first tab 704 and the second tab 706 respectively, thereby completing the circuit. Alternatively, the gate-like structure formed by the first tab 704 and the second tab 706 allows a second push pin without a curved portion (i.e., a push pin and / or the curved portion of the bearing associated with the push pin) to pass through the channel defined by the gate-like structure, while any portion of the second push pin or the bearing associated with the second push pin does not form any contact with either the first tab 704 or the second tab 706 respectively, thereby decompiling the circuit. In other words, in one example, when a standard (non-misaligned) bearing / pin passes through the channel defined by the first tab 704 and the second tab 706, it does not contact portions on either side of the gate-like structure (i.e., any portion of the first tab 704 and / or the second tab 706), and the circuit remains incomplete or unclosed, thus not sending a signal to the processor. However, in one example, when a misaligned bearing / pin enters the channel, a portion of the bearing and / or pusher pin completes the circuit and sends a signal to the processor. In some exemplary embodiments, the signal may indicate misalignment of the pusher pin. Figure 7 The fault detection assembly 702 is shown in a first state, wherein the first push pin 406 passes through a channel defined by the first tab 704 and the second tab 706. Illustratively, since neither the first push pin 404 nor any portion of the first push bearing 404 is bent or misaligned, the first push pin 404 and / or the first push bearing 404 pass through the channel without forming any contact with either the first tab 704 or the second tab 706.

[0090] Figure 8A second perspective view 800 is shown of a second state of a fault detection component 702 according to an alternative exemplary embodiment described herein. In this second state of the fault detection component 702, as shown, a second pusher bearing 504 associated with a second pusher pin 506 is bent or misaligned. Therefore, when the second pusher pin 506 passes through the channel defined between the first tab 704 and the second tab 706, a portion of the second pusher bearing 504 contacts the first tab 704 and the second tab 706. In this respect, in one example, when the second pusher bearing 504 contacts the first tab 704 and the second tab 706, circuitry is performed by the second pusher bearing 504, the first tab 704, and the second tab 706 to send a signal to the processor regarding the misalignment or fault condition of the second pusher pin 506 and / or the pusher bearing 504. In some exemplary embodiments, the processor may generate a command to stop the operation of the sorting conveyor upon receiving the signal. Furthermore, in some examples, the processor may also generate an alarm indicating a misaligned position including the second pusher 501. In addition, the processor can generate commands to move the second pusher 501 to a maintenance position for servicing the second pusher pin 506 and the second pusher bearing 504.

[0091] Figure 9 and Figure 10 A third perspective view 900 and a fourth perspective view 1000 are shown of a fault detection component 702 according to an alternative exemplary embodiment described herein. The second perspective view 1000 shows a second state of the fault detection component 702, as shown in reference... Figure 8 As stated above.

[0092] Throughout this specification, the term "processor" as used herein may refer to, for example, but not limited to, processors in conveyor systems, industrial computers, distributed networks of computing devices, cloud computing platforms, external computers, stand-alone computing devices, etc. In some exemplary embodiments, a processor may correspond to a specially configured field-programmable gate array (FPGA) or an application-specific interface circuit (ASIC). As used herein, the term "processor" may refer to virtually any computing processing unit or device, including but not limited to: single-core processors; single-core processors with software multithreading capabilities; multi-core processors; multi-core processors with software multithreading capabilities; multi-core processors with hardware multithreading technology; parallel platforms; and parallel platforms with distributed shared memory. Additionally, a processor may refer to an integrated circuit, application-specific integrated circuit (ASIC), digital signal processor (DSP), field-programmable gate array (FPGA), programmable logic controller (PLC), complex programmable logic device (CPLD), discrete gate or transistor logic, discrete hardware components, or any combination thereof designed to perform the functions described herein. Processors may utilize nanoscale architectures, such as, but not limited to, molecular and quantum dot-based transistors, switches, and gates, to optimize space utilization or enhance the performance of user equipment. A processor can also be implemented as a combination of computing units.

[0093] It should be noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the” include plural indicators, unless otherwise expressly stated.

[0094] References to “one embodiment,” “implementation,” “multiple embodiments,” or “one or more embodiments” in this specification are intended to indicate that a particular feature, structure, or characteristic described in connection with an embodiment is included in at least one embodiment of this disclosure. The appearance of such phrases in various places in the specification does not necessarily refer to the same embodiment, nor is it a single or alternative embodiment mutually exclusive with other embodiments. Furthermore, various features that may be presented by some embodiments but not by others are described.

[0095] It should be noted that, when used in this disclosure, the terms “comprising,” “including,” and other derivatives of the root term “comprising” are intended to be open-ended terms that specify the presence of any of the said features, elements, integers, steps, or components, and are not intended to exclude the presence or addition of one or more other features, elements, integers, steps, components, or groups thereof.

[0096] This document discloses detailed implementation schemes; however, it should be understood that the disclosed implementation schemes are merely exemplary and can be embodied in various forms. Therefore, the specific structural and functional details disclosed herein should not be construed as restrictive, but merely form the basis of the claims.

[0097] While it will be apparent that the exemplary embodiments described herein achieve the aforementioned objectives, it should be understood that many modifications and other embodiments can be devised by those skilled in the art. Therefore, it should be understood that the appended claims are intended to cover all such modifications and embodiments that fall within the substance and scope of this disclosure.

Claims

1. A push-block sorting machine, the push-block sorting machine comprising: A switchboard, configured to limit the movement path of the pusher pin of the pusher block of the pusher block sorting machine; A first tab, the first tab being mechanically connected to the switch plate; A power unit electrically connected to the first tab, such that movement of the push pin in contact with a portion of the first tab establishes a complete circuit, wherein in response to the establishment of the complete circuit, the power unit sends a signal to the processor to determine that the push pin is misaligned; and A second tab, mechanically coupled to the switch plate, such that the first tab and the second tab form a gap-like structure defining the movement path of the push pin, wherein the complete circuit is established in response to the push pin moving through the gap and contacting at least the top portion of the first tab or the second tab.

2. The pusher-type sorting machine of claim 1, wherein the processor is configured to generate an alarm indicating that the pusher pin is misaligned.

3. The push-block sorting machine according to claim 1, wherein the first tab and the second tab correspond to a contactor spring made of metal or non-metal.

4. The push-block sorting machine according to claim 1, wherein the processor is configured to perform at least one of the following: Generate an alarm indicating the position of the pusher; and Generate a command to move the pusher block to the maintenance position.

5. The push-block sorting machine according to claim 1, wherein the first tab is connected to the source terminal of the power unit and the second tab is connected to the slot terminal of the power unit.

6. The push-block sorting machine of claim 1, wherein the first tab and the second tab are positioned such that, as another push-block pin moves in the travel path, the non-bent portion of the other push-block pin passes through the travel path without contacting the top portions of the first tab and the second tab.

7. The pusher-type sorting machine of claim 6, wherein the non-bent portion of the other pusher pin passing through the movement path renders the circuit incomplete.

8. A method for detecting a fault in the pusher pin of a pusher-type sorting machine, comprising: The pusher pin begins to move along a movement path defined by the switch plate of the pusher sorter, wherein the pusher sorter further includes a first tab connected to the switch plate and a second tab connected to the switch plate, such that the first tab and the second tab form a gap-like structure that defines the movement path of the pusher pin. and A signal is sent to the processor to determine that the push pin is misaligned, wherein the signal is sent by the power unit in response to the establishment of a complete circuit, wherein the complete circuit is established in response to movement of the push pin into contact with a portion of the first tab. The complete circuit is established in response to the pusher pin moving through the gap and contacting at least the top portion of the first tab or the second tab.

9. The method of claim 8, further comprising generating an alarm indicating that the pusher pin is misaligned.

10. The method of claim 9, further comprising generating a command to stop the operation of the pusher sorter based on determining that the pusher pin is misaligned.

11. The method of claim 8, wherein the first tab and the second tab are positioned such that, in response to movement of the push pin in the movement path, a curved portion of the push pin contacts the top portions of the first tab and the second tab.

12. A fault detection unit for detecting faults in the pusher pins of a pusher-type sorting machine, comprising: Photoelectric sensors; A finger-like portion, the finger-like portion being configured to be mechanically connected to a portion of the switch plate of the pusher-type sorter, wherein the finger-like portion is configured to move in a first direction in response to a portion of the pusher pin contacting the top portion of the finger-like portion; An actuator arm is pivotally engaged with the finger portion such that movement of the finger portion in the first direction causes movement of the actuator arm in the second direction, wherein the actuator arm in the second direction causes a change in the signal output by the photoelectric sensor. and A spring pin, which is mechanically engaged with the actuating arm and configured to retract the actuating arm in a direction opposite to the second direction when the actuating arm moves in the second direction.

13. The fault detection unit of claim 12, wherein the movement of the actuator arm along the second direction does not obstruct the path of light toward the photoelectric sensor, thereby causing a change in the signal, and wherein the change in the signal indicates misalignment of the push pin.

14. The fault detection unit according to claim 12, wherein, In response to the distal end of the actuator arm being in a first position due to the movement of the actuator arm along the second direction, the path of the light received at the photoelectric sensor is not blocked by the actuator arm, thereby causing a change in the signal output by the photoelectric sensor.

15. The fault detection unit of claim 12, wherein the finger is positioned along a movement path defined by the switch plate such that, as the first push pin moves in the movement path, the curved portion of the first push pin contacts the top portion of the finger.

16. The fault detection unit of claim 12, wherein the finger is positioned along a movement path defined by the switch plate such that, as the second push pin moves in the movement path, the non-bent portion of the second push pin passes along the finger through the movement path without contacting the top portion of the finger.

17. The fault detection unit of claim 12, wherein the top portion of the finger tapers such that the portion responding to the push pin contacts the top portion of the finger, the finger and the actuating arm pivoting about the pivot pin.

18. A method for detecting a fault in the pusher pin of a pusher-type sorting machine, comprising: Initialize the photoelectric sensors of the pusher-type sorting machine; Initialize the movement of the pusher pin along the movement path defined by the switch plate of the pusher sorter; and The processor identifies changes in the signal value output by the photoelectric sensor, wherein the changes in the signal value are attributed to unobstructed light received at the photoelectric sensor, caused by the actuation component moving in response to contact between the push pin and a portion of the actuation component, resulting in unobstructed light at the photoelectric sensor. The actuation component includes: A finger-like portion mechanically coupled to a portion of the switch plate of the pusher-type sorter, wherein the finger-like portion is configured to move in a first direction in response to contact of the pusher pin with a portion of the finger-like portion; and An actuator arm is pivotally engaged with the finger, such that movement of the finger in the first direction causes movement of the actuator arm in the second direction, wherein the movement of the actuator arm in the second direction causes the light received at the photoelectric sensor to be unblocked.

19. The method of claim 18, further comprising generating an alarm in response to the recognition of a change in the signal value, wherein the alarm indicates misalignment of the push pin.

20. The method of claim 19, further comprising generating a command to stop the operation of the pusher sorter based on the determination of misalignment of the pusher pin.

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