Telescopic conveyor

Abstract

An extendable conveyor system (30) and a method of operating the same. An extensible conveyor system includes a plurality of conveyor segments (138a), a conveyor extension / retraction system, and a control system. The plurality of conveyor sections are interlocked in a telescopic configuration, wherein each conveyor section at least partially overlaps one another. A conveyor extension / retraction system is operably coupled to at least one of the conveyor sections and is configured to control extension and retraction of the extensible conveyor system by controlling movement of the conveyor sections relative to each other. The control system is in electrical communication with the conveyor extension / retraction system and is configured to perform operations including adjusting a position of one or more conveyor segments in response to data received from a parcel handling robot in electrical communication with the control system.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to U.S. Provisional Application No. 63 / 448,038, filed on February 24, 2023, and U.S. Application No. 18 / 444,442, filed on February 16, 2024. The contents of U.S. Application Nos. 63 / 448,038 and 18 / 444,442 are incorporated herein by reference in their entirety. Background Art

[0003] Conveyor systems are used in many different industries to efficiently move objects through a facility. For example, conveyor systems are used in manufacturing to move individual parts around a manufacturing facility. Conveyor systems are also used in distribution facilities to move packages throughout the facility. Conveyor systems are used in shipping and receiving facilities to route packages through sorting facilities and to shipping containers or vehicles. Improvements to such transportation systems are sought to continually improve the efficient routing of objects within such industries. Summary of the invention

[0004] The present specification relates to an extendable conveyor system and the operation of such a system.

[0005] In general, the innovative aspects of the subject matter described in this specification can be embodied in a method, which includes an operation of obtaining a first distance between a front end of a conveyor system and at least one object located in front of the conveyor system from a sensor system. The operation includes determining that the first distance is less than a first predetermined distance. And, the operation includes controlling the conveyor system to move to increase the distance from at least one object in response to the first distance being less than the first predetermined distance. Other embodiments of this aspect include corresponding systems, devices, and computer programs, which are configured to perform the actions of the method encoded on a computer storage device. These and other embodiments can each optionally include one or more of the following features.

[0006] In some implementations, determining that the first distance is less than a first predetermined distance includes comparing a measurement of the first distance to the first predetermined distance.

[0007] In some implementations, the first predetermined distance comprises a user-selected value.

[0008] In some embodiments, controlling the conveyor system includes sending instructions to one or more motor controllers that cause the conveyor system to retract until the first distance is equal to or greater than the first predetermined distance.

[0009] In some embodiments, the conveyor system is an extendable conveyor system comprising a first conveyor section and a second conveyor section, the second conveyor section being configured to nest beneath the first conveyor section, and wherein one or more motor controllers control relative movement between the first conveyor section and the second conveyor section.

[0010] In some embodiments, the first distance is the shortest distance between a front end of the conveyor system and the plurality of objects.

[0011] In some embodiments, operation includes controlling a front end of the conveyor system to move laterally relative to a length of the conveyor system.

[0012] In some embodiments, controlling lateral movement of the front end of the conveyor system includes moving the front end in response to measurement data from a sensor system.

[0013] In some embodiments, controlling lateral movement of the front end of the conveyor system includes sending instructions to one or more motor controllers that control lateral movement of the conveyor system in response to measurement data from the sensor system.

[0014] In some embodiments, the operation includes: obtaining a second distance between a first side of the conveyor system and a second object from a sensor mounted on at least a first side of the sensor system; obtaining a third distance between a second side of the conveyor system and a third object from a sensor mounted on a second side of the sensor system; determining that a difference between the second distance and the third distance exceeds a threshold difference; and in response, controlling the conveyor system to move so that the difference is within the threshold difference.

[0015] In some embodiments, the conveyor system includes an interface for connecting the robot to the conveyor system, and the operation of obtaining the first distance includes obtaining the first distance to the robot through the interface.

[0016] In some embodiments, the operations include acquiring parcel flow data indicating a rate of parcel flow along the conveyor system; and controlling operation of the independent indexing sections of the conveyor system based on the parcel flow data.

[0017] In some embodiments, controlling the operation of the independent indexing sections includes controlling at least one of the independent indexing sections to adjust a buffer distance between packages by varying a speed of the at least one independent indexing section.

[0018] Another general aspect can be embodied in an extendable conveyor system comprising a plurality of conveyor segments, a conveyor extension / retraction system, and a control system. The plurality of conveyor segments are interlocked in a telescopic configuration, wherein the individual conveyor segments at least partially overlap one another. The conveyor extension / retraction system is operably coupled to at least one of the conveyor segments and is configured to control extension and retraction of the extendable conveyor system by controlling movement of the conveyor segments relative to one another. The control system is in electrical communication with the conveyor extension / retraction system and is configured to perform operations including adjusting the position of one or more conveyor segments in response to data received from a package handling robot in electrical communication with the control system. In some embodiments, the control system can be configured to perform any one or more of the operations discussed above.

[0019] In some embodiments, each conveyor segment includes one or more indexing sections, and operation of the control system includes controlling a speed of one indexing section independently of the other indexing sections in response to second data received from the package handling robot.

[0020] In some embodiments, a forward-most conveyor segment of the plurality of conveyor segments includes an articulated end portion configured to pivot relative to the forward-most conveyor segment.

[0021] In some embodiments, a base conveyor segment of the plurality of conveyor segments includes a wrap stop configured to be raised and lowered in response to a control signal from a control system.

[0022] In some embodiments, the plurality of conveyor sections include a base conveyor section, an end conveyor section, and one or more intermediate conveyor sections, wherein the base conveyor section is configured to receive packages from a gravity chute, and the one or more intermediate conveyor sections are arranged between the base conveyor section and the end conveyor section.

[0023] In some embodiments, a base conveyor segment of the plurality of conveyor segments includes a wrap stop configured to be raised and lowered in response to a control signal from a control system.

[0024] In some embodiments, one or more intermediate conveyor sections each include an independently controllable conveyor belt.

[0025] In some embodiments, the forward-most conveyor section includes a plurality of rollers including at least a first set of powered rollers and a second set of powered rollers, wherein the first set of powered rollers is separated from the second set of powered rollers by a set of unpowered rollers.

[0026] In some embodiments, the front-most conveyor segment includes an articulated end portion configured to pivot relative to a front end of the end conveyor segment.

[0027] Another general aspect can be embodied in an extendable conveyor system, the extendable conveyor system comprising a plurality of conveyor segments, a conveyor extension / retraction system, a sensor system, and a control system. The plurality of conveyor segments are interlocked in a telescopic configuration, wherein the individual conveyor segments at least partially overlap one another. The conveyor extension / retraction system is operably coupled to at least one of the conveyor segments and is configured to control extension and retraction of the extendable conveyor system by controlling movement of the conveyor segments relative to one another. The control system is in electrical communication with the conveyor extension / retraction system and the sensor system, the control system being configured to perform operations including: obtaining a first distance between a front end of the conveyor system and at least one object located in front of the conveyor system from the sensor system; determining that the first distance is less than a first predetermined distance; and in response to the first distance being less than the first predetermined distance, controlling the conveyor extension / retraction system to move the conveyor segment to increase the distance from the at least one object. In some embodiments, the control system can be configured to perform any one or more of the operations discussed above.

[0028] In some embodiments, the plurality of conveyor sections include a base conveyor section, an end conveyor section, and one or more intermediate conveyor sections, wherein the base conveyor section is configured to receive packages from a gravity chute, and the one or more intermediate conveyor sections are arranged between the base conveyor section and the end conveyor section.

[0029] In some embodiments, a base conveyor segment of the plurality of conveyor segments includes a wrap stop configured to be raised and lowered in response to a control signal from a control system.

[0030] In some embodiments, one or more intermediate conveyor sections each include an independently controllable conveyor belt.

[0031] In some embodiments, the forward-most conveyor section includes a plurality of rollers including at least a first set of powered rollers and a second set of powered rollers, wherein the first set of powered rollers is separated from the second set of powered rollers by a set of unpowered rollers.

[0032] In some embodiments, the front-most conveyor segment includes an articulated end portion configured to pivot relative to a front end of the end conveyor segment.

[0033] Certain embodiments of the subject matter described in this specification can be implemented to achieve one or more of the following advantages. Embodiments can improve the efficiency of performing package loading operations. Embodiments can reduce worker fatigue by maintaining an appropriate distance between the end of the conveyor and the package loading location.

[0034] The details of one or more implementations of the subject matter described in this specification are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the subject matter will become apparent from the description, drawings, and claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0035] 1 is a front view of an exemplary extendable conveyor system in a transport configuration for transporting vehicles according to an embodiment of the present disclosure;

[0036] 2 is a front view of the extendable conveyor system of FIG. 1 in an extended configuration according to an embodiment of the present disclosure;

[0037] 3-6 are elevation views of various configurations of adjustable heights at the delivery end of the extendable conveyor system of FIG. 1 ;

[0038] 7 is a perspective view of an exemplary embodiment of an extendable conveyor system in a retracted configuration and configured to interface with a package handling robot;

[0039] 8 is a front view of an exemplary embodiment of an extendable conveyor system in a retracted configuration and docked with a package handling robot;

[0040] FIG9 is a detailed view of a side edge of an embodiment of an extendable conveyor system;

[0041] FIG10 is a block diagram of an exemplary control system for an extendable conveyor system;

[0042] FIG. 11 depicts a flow chart of an alignment process for the extendable conveyor system that may be performed by the control system of FIG. 10 ;

[0043] 12A-12D depict a series of diagrams illustrating alignment operations of an extendable conveyor system within a transport vehicle;

[0044] FIG13A is a perspective view of another embodiment of an extendable conveyor system in an extended configuration;

[0045] 13B and 13C are perspective views of the extendable conveyor system embodiment of FIG. 13A in a retracted configuration; and

[0046] 14 is a detailed view of the articulated end of the extendable conveyor system embodiment of FIG. 13A.

[0047] Like reference numbers and designations in the various drawings indicate like elements. DETAILED DESCRIPTION

[0048] Embodiments of the present disclosure generally relate to an extendable conveyor system. The conveyor system can be configured to extend and retract automatically under user control or by interacting with a robot. The extendable conveyor system will be described in the context of an exemplary use of loading a transport trailer. However, such a system can be used in a variety of other contexts and / or industries, for example, for warehousing operations, manufacturing operations, agricultural operations, etc.

[0049] Referring to FIGS. 1 and 2 , an extendable conveyor system 30 according to an embodiment of the present disclosure is depicted. As shown, the extendable conveyor system 30 is configured for loading a transport vehicle such as a flatbed trailer. The extendable conveyor system 30 includes an assembly of conveyor segments 32 supported by a frame 34. The frame 34 forms a support structure from which the conveyor segments 32 extend and into which they retract. The assembly of conveyor segments 32 may include a base conveyor segment 36 and one or more extension conveyor segments 38 nested below the base conveyor segment 36. The conveyor segments 36, 38 of the conveyor segment assembly 32 are slidingly coupled to each other for arrangement in a transport or stowed configuration 42 ( FIG. 1 ) or an operating or extended configuration 44 ( FIG. 2 ). The base conveyor section 36 and each extension conveyor section 38 may include a transfer ramp 46 extending from the respective conveyor section 38 in a distal (forward) direction 48 to provide an inclined transition between consecutive conveyor sections 36, 38. The assembly of conveyor sections 32 may be laterally dimensioned to extend onto a flatbed trailer 50 or other transport vehicle. In some embodiments, the conveyor system 30 is configured to extend the entire length of a 53-foot trailer from a truck dock to allow the robot to enter and exit a door, and retract to create a small footprint inside a building. For example, the number of conveyor sections 32 and / or the length of each section 32 can be configured to achieve a small retracted footprint, but extend to more than 53 feet.

[0050] In some embodiments, the frame 34 can be configured to move a transport cart. In such embodiments, the frame 34 can include casters 62. In some embodiments, each of the extended conveyor segments 38 is supported at a distal end by a support frame 66 mounted to the casters 68. In some embodiments, the extendable conveyor system 30 includes one or more stabilizers 72 that can be selectively extended from the frame 34. In some embodiments, the extendable conveyor system 30 includes a drive unit 74 mounted to the support frame 66 of the leading (forward) conveyor segment 76 of the conveyor segment assembly 32. The drive unit 74 includes a drive wheel 78 that contacts the flatbed trailer 50 and is driven, for example, by a motor (not depicted). The drive unit 74 can rotate about a vertical steering axis 80. In some embodiments, the frame 34 is a fixed frame.

[0051] Functionally, the extendable conveyor system 30 facilitates loading packages onto a transport vehicle, such as a flatbed trailer 50. The nested arrangement of the components of the conveyor segments 32 enables the extension conveyor segment 38 to extend in a distal direction 48 relative to the base conveyor segment 36. For embodiments where the components of the conveyor segments 32 are appropriately sized, the extension conveyor segment 38, along with the base conveyor segment 36 and frame 34, can be positioned at the rear end 92 of the flatbed trailer 50.

[0052] The stabilizer 72 is used to selectively anchor the frame 34. The drive unit 74 is used to actuate the guide conveyor segment 76 in the distal direction 48, thereby extending the extension conveyor segment 38 as the guide conveyor segment 76 advances distally. In some embodiments, the drive unit 74 rotates about the vertical steering axis 80 to steer the front end 94 of the guide conveyor segment 76 relative to the frame 34. In some embodiments, the drive unit 74 can also actuate the guide conveyor segment 76 in the proximal direction 96 to reposition the front end 94 as loading of the flatbed trailer 50 proceeds.

[0053] In operation, in the transport configuration 42, the extendable conveyor system 30 is positioned proximate the rear end 92 of the flatbed trailer 50. In some embodiments, one of the stabilizers 72 is placed on the ground so that the frame 34 can pivot thereabout as the drive unit 74 extends and turns the assembly of the conveyor segment 32 onto the flatbed trailer 50. Upon reaching the desired extension of the assembly of the conveyor segment 32, any stabilizer 72 not placed on the ground can be placed on the ground to secure the extendable conveyor system 30 proximate the rear end 92 of the flatbed trailer 50.

[0054] Referring to FIGS. 3-6 , configurations for vertically positioning the front end 94 of the leading conveyor segment 76 to a desired height 112 are depicted in accordance with embodiments of the present disclosure. In some embodiments, when in the extended configuration 44, all of the conveyor segments 36, 38 of the assembly 32 rotate vertically about a pivot 114 located on or near a rear upright 116 of the frame 34 to achieve the desired height 112 ( FIG. 3 ). In some embodiments, only the conveyor segments 36, 38 of the assembly 32 rotate vertically about a pivot 114 located at or near a front upright 118 of the frame 34 ( FIG. 4 ). In some embodiments, the pivot 114 is disposed at or near the support frame 66 of one of the extended conveyor segments 38 so that any extended conveyor segment 38 away therefrom can be tilted to achieve the desired height 112 ( FIG. 5 ). In some embodiments, the pivot 114 is disposed along the leading conveyor segment 76 for articulating the leading conveyor segment 76 to the desired height 112 ( FIG. 6 ).

[0055] In some embodiments, the front end 94 of the leading conveyor segment 76 is vertically positioned using jacks (not shown) mounted to the support frame 66 of the leading conveyor segment 76. The jacks may be manual or power driven. In some embodiments, the support frame 66, as well as the front uprights 118 of the frame 34, are configured to adjust vertically as needed to accommodate the varying heights of the respective conveyor segments 36, 38 during adjustment of the desired height 112 of the front end 94. The height adjustment of the support frame 66 may be passive, where support is provided by pneumatic or hydraulic cylinders.

[0056] In some embodiments, the extendable conveyor system 30 is configured to automatically align the front end 94 within a confined area, such as within a flatbed trailer 50. For example, a trailer may be misaligned with a loading dock due to parking changes, and such embodiments allow the conveyor system 30 to adjust for such changes while maintaining alignment with the trailer wall as the conveyor system 30 is extended into the trailer. In such embodiments, the extendable conveyor system 30 can automatically adjust its alignment within the trailer 50 as the package 122 is loaded into the trailer 50. For example, the extendable conveyor system 30 may include a system of alignment sensors 124 disposed at the front end 94. The alignment sensors 124 may include distance measurement sensors, such as laser sensors, IR sensors, ultrasonic sensors, imaging sensors, stereo sensors, or combinations thereof. The alignment sensor system 124 is configured to measure a distance 128 between the front end 94 of the extendable conveyor system 30 and an object in front of the extendable conveyor system 30 (e.g., a package wall 120 formed within the flatbed trailer 50, a rear wall of the trailer 50, or a package handling robot). In the manual loading configuration, the extendable conveyor system 30 can be configured to adjust the position within the flatbed trailer 50 in response to measurements from the alignment sensor system 124. For example, as the distance 128 decreases while a worker adds packages 122 from the extendable conveyor system 30 onto the package wall 120, the extendable conveyor system 30 can automatically retract to provide the worker with additional space between the front end 94 and the package wall 120. Additionally, as discussed in more detail below, some embodiments are also configured to use measurements from the alignment sensor system 124 to align the front end 94 of the extendable conveyor system 30 laterally within the trailer 50.

[0057] In some embodiments, the extendable conveyor system 30 is configured to automatically buffer the packages 122 as the packages 122 are conveyed along the conveyor. For example, the extendable conveyor system 30 may include a package sensor system c. In an exemplary embodiment, the package sensor system 126 may be configured with a set of sensors 126 arranged along the extendable conveyor system 30. The package sensor system 126 may include a gate sensor and / or a visual sensor. For example, the gate sensor may include a line-break, such as an optical sensor arranged along the extendable conveyor system 30, which detects the passage of packages moving along the extendable conveyor system 30. The control system (discussed below) can calculate the package flow rate and adjust the speed of the independently controlled conveyors along the extendable conveyor system 30 to maintain a manageable spacing between packages so that workers or robots can stack packages 122 at the front end 94. As another example, the package sensor system 126 can be configured with a visual sensor and employ an object recognition process, such as a machine learning network, to detect the package spacing and flow rate along the extendable conveyor system 30. Package buffering can be used to slow the rate at which packages flow or increase the rate at which packages are removed from the conveyor system 30, depending on the rate at which package stacking robots or workers are removing packages from the conveyor system 30. In some cases, the conveyor system can shut down one or more conveyors to save energy, for example, if the flow rate of packages from elsewhere in the distribution system is slow or sporadic due to the arrival frequency of incoming deliveries.

[0058] FIG. 7 is a perspective view of an exemplary embodiment of an extendable conveyor system 30 in a retracted configuration, and FIG. 8 is a front view of the extendable conveyor system 30 in a retracted configuration. The extendable conveyor system 30 is shown having a base conveyor section 36 that is aligned, for example, below a gravity feeder 134 in a sorting facility. The gravity feeder 134 can be, for example, a sheet metal chute, a chute with a package stopper, or a chute with a powered conveyor and / or a package stopper. Each conveyor section 32 of the extendable conveyor system 30 can include an impact surface 140 and one or more independently controlled conveyor indexing sections 138. For example, in the depicted embodiment, the base section 36 includes an impact surface 140 and two conveyor indexing sections 138. Other extension sections 38 can be configured similarly to the base conveyor section 36. The impact surface 140 is configured with a set of freely rotating rollers. In some embodiments, the rollers may be mounted on bearings supported by rubber or another type of shock absorber to absorb the shock of packages falling onto the impact surface 140. The conveyor indexing sections 138 are independently controllable sections of the motorized conveyor. For example, each conveyor indexing section 138 may be a separate conveyor belt driven by a motor, which may be configured to operate independently of the other conveyor indexing sections 138. In some embodiments, the conveyor indexing sections 138 may be motorized rollers, which may be configured to operate independently of the other conveyor indexing sections 138. In some embodiments, the conveyor indexing sections may be configured with a combination of motorized rollers and free-spinning rollers. The motorized rollers may be configured to operate independently of the other conveyor indexing sections 138.

[0059] The front end 94 is configured as a cantilever end 132 to allow access underneath the front end 94. For example, the cantilever end 132 may be configured to allow a package handling robot 130 to fit underneath. For example, the cantilever end 132 may allow a package loading platform of the robot 130 to fit underneath the front end 94 so that packages are dropped from the extendable conveyor system 30 onto the robot's platform. The robot 130 may be programmed to remove packages from the conveyor, or the robot 130 may have a presentation conveyor or platform onto which packages are dropped before they are stacked by the robot 130.

[0060] In some embodiments, the extendable conveyor system 30 is configured to dock with the package handling robot 130. For example, in some embodiments, the extendable conveyor system 30 may include an interface that couples the robot 130 to the extendable conveyor system 30. The interface may be configured for communication between the control system of the extendable conveyor system 30 and the robot 130 (e.g., a wired or wireless communication interface), or may include a mechanical connection that allows the robot 130 to manipulate the front end 94 of the extendable conveyor system 30. When used with the robot 130, the robot sends operating commands to the extendable conveyor system 30 to control the movement of the conveyor system 30, and, for example, maintains a spaced docking between the robot 130 and the end of the conveyor system 30 as both are traversed into / out of a trailer.

[0061] In some embodiments, the extendable conveyor system 30 is configured to interface with the gravity feed 134 in a manner that creates a smooth transition between the gravity feed 134 and the base conveyor section 36 of the extendable conveyor system 30. For example, the base conveyor section 36, the gravity feed 134, or both may be oriented at an angle relative to each other that creates a smooth transition between the two.

[0062] 9 depicts a detailed view of the side edges of the extendable conveyor system 30. Each segment 32 of the extendable conveyor system 30 may include an edge 202 that extends upward from a top surface of a conveyor belt 204 and / or rollers 200 at an angle.

[0063] 10 shows a block diagram of an exemplary control system 300 for an extendable conveyor system 30. The control system 300 includes a controller 302 that communicates with various input and output systems. The controller 302 includes one or more processors 304 and computer memory 306. The computer memory may store instructions that are executed by the processor 304 to perform the control system operations described below.

[0064] Each of the input and output systems can be configured as one or more computer executable software modules, hardware modules, or a combination thereof. For example, one or more of the input and output systems can be implemented as a software code block having instructions that cause one or more processors of the control system 300 to perform the operations described herein. Additionally or alternatively, one or more of the input and output systems can be implemented in an electronic circuit, such as, for example, a programmable logic circuit, a field programmable logic array (FPGA), or an application specific integrated circuit (ASIC). The input system can include a conveyor alignment sensor system 308, a package flow sensor system 310, a user control interface 312, and optionally a robot communication interface 314. The output system can include a conveyor extension / retraction system 31, a conveyor alignment system 318, and a package buffer system 320.

[0065] The conveyor alignment sensor system 308 may include the conveyor alignment sensor 124 discussed above. In addition, the conveyor alignment sensor system 308 may include sensors directed outward from the sides of the front end 94 of the extendable conveyor system 30 and arranged to obtain measurement data indicating the distance between the sides of the extendable conveyor system 30 and the side walls of the trailer 50 (see Figures 12A-12D). The conveyor alignment sensor system 308 sensors may be arranged to help maintain lateral alignment of the front end 94 within the confined space and manage the distance from the wrapping wall 120.

[0066] The parcel flow sensor system 310 may include the parcel sensor system 126 described above. In some embodiments, where the parcel sensor system 126 includes an imaging sensor, the parcel flow sensor system 310 may perform an image processing algorithm to identify parcels within an image and pre-process the image before sending parcel flow data to the controller 302. For example, the parcel flow sensor system 310 may employ an image processing algorithm to determine the parcel flow rate and parcel spacing along the extendable conveyor system 30. The parcel flow sensor system 310 may send the parcel flow rate and parcel spacing data to the controller 302. In some embodiments, the parcel flow sensor system 310 includes a machine learning model that is trained to receive image data (e.g., a series of images or videos) along the extendable conveyor system 30 as input and output parcel flow and spacing data. In some embodiments, the parcel flow sensor system 310 may be configured to determine parcel flow and spacing using a series of line break sensors. For example, the parcel flow sensor system 310 can determine the parcel flow rate and spacing based on the operating speed of each conveyor indexing section 138 adjacent to the corresponding sensor and the timing between the detected line breaks. Likewise, the package flow sensor system 310 is able to determine the size of each package based on the operating speed of each conveyor index 138 adjacent to the corresponding sensor and the duration of a line break, such as a blockage of an optical signal between two sensors located on opposite sides of the extendable conveyor system 30.

[0067] In response, the controller 302 can use the package flow rate and spacing data to adjust the speed of each conveyor indexing section 138 to manage the appropriate package spacing. For example, the appropriate package spacing is the spacing between packages that conforms to the rate at which workers or robots remove packages from the extendable conveyor system 30 and stack them in the trailer 50. The control system 300 can be configured to adjust the appropriate package spacing to accommodate changes in the rate at which workers or robots work. For example, the package flow sensor system 310 can include a sensor at the front end 94 that measures the time between workers or robots removing packages from the extendable conveyor system 30. The controller 300 can determine the speed at which the conveyor indexing section 138 is operated so that the packages arrive at approximately the same rate as the workers or robots stack them.

[0068] The user control interface 312 allows a user to manually control the operation of the control system 300 and calibrate the system operation. For example, the user control interface 312 may allow a user to manipulate the extendable conveyor system 30 to manually extend / retract and / or align the front end 94. In some embodiments, the user control interface 312 may allow a user to calibrate the automated operation of the extendable conveyor system 30 by, for example, adding or adjusting default values ​​for the distance maintained between the front end 94 and the package wall 120, the lateral position of the extendable conveyor system 30 within the trailer 50, the package flow rate maintained, etc. The user control interface 312 may be hardwired to the extendable conveyor system 30 or configured to wirelessly interface with the control system 300. For example, the user control interface 312 may be a touch screen display or a mobile computing device (e.g., a tablet computer or laptop computer). In some embodiments, the user control interface 312 may include a joystick to manipulate the extendable conveyor system 30.

[0069] The robot communication interface 314 is an electrical communication interface that allows the package handling robot 130 to communicate with the controller 302. For example, in some embodiments, the operation of the extendable conveyor system 30 may be controlled or directed by the robot 130. For example, the controller 302 may receive commands from the robot 130 via the robot communication interface 314 and operate the extendable conveyor system 30 in response to such commands.

[0070] The conveyor extension / retraction system 316 is configured to control the extension and retraction operation of the extendable conveyor system 30. For example, the conveyor extension / retraction system 316 includes one or more motors 324, which are connected to one or more conveyor sections 36 and are arranged to extend and retract the conveyor sections 36 of the extendable conveyor system 30. In addition, the conveyor extension / retraction system 316 includes one or more motor controllers 322 to control the operation of the motors 324. For example, the motor controller 322 can be configured to receive digital commands from the controller 302 and operate the motors 324 according to the commands. The conveyor extension / retraction system 316 can include two independent drive motors connected to the above-mentioned drive wheels 78. In some embodiments, the motors are connected to the drive wheels through a set of reduction gears. The extendable conveyor system 30 can be extended or retracted by controlling the drive motors. In some embodiments, the conveyor extension / retraction system 316 can include a drive wheel 78 and a drive motor on each extension segment 36 so that each extension segment 36 can be independently extended or retracted relative to adjacent segments. Typically, the conveyor extension / retraction system 316 receives commands from the controller 302 and operates the drive wheel 78 in accordance with such commands to manipulate the extension and retraction of the extendable conveyor system 30.

[0071] In some embodiments, the conveyor extend / retract system 316 may include other mechanisms to extend and retract the extendable conveyor system 30. For example, the conveyor extend / retract system 316 may employ a motor-driven worm gear or a gear and rack configuration mounted between adjacent conveyor segments 36 to extend and retract the segments relative to each other.

[0072] The conveyor alignment system 318 is configured to control the lateral movement of the front end 94 of the extendable conveyor system 30. The conveyor alignment system 318 includes one or more motors 328 that are coupled to the extendable conveyor system so as to move the front end 94 laterally (or in an arc if the extendable conveyor system 30 is mounted on a pivot point at the rear end). In addition, the conveyor alignment system 318 includes one or more motor controllers 326 to control the operation of the motors 328. As described above, the motor controller 326 can be configured to receive digital commands from the controller 302 and operate the motors 328 according to the commands. The conveyor alignment system 318 can also operate the drive wheel 78. For example, the conveyor alignment system 318 can include a motor (e.g., a servo motor) coupled to a support of the drive motor to pivot the drive wheel 78 ninety degrees so that the front end 94 can be manipulated from one side to the other. In some embodiments, the conveyor alignment system 318 can be included in the conveyor extension / retraction system 316 or can be a subsystem of the conveyor extension / retraction system 316. Generally speaking, the conveyor alignment system 318 receives commands from the controller 302 and operates the drive wheels 78 to steer the front end 94 of the extendable conveyor system 30 in accordance with such commands.

[0073] The parcel buffer system 320 is configured to control the operation of the conveyor indexing sections 138 to maintain a buffer distance between parcels conveyed along the extendable conveyor system 30. The buffer system 320 includes a motor 332 coupled to a drive unit of each indexing section 138. The drive unit may include one or more drive rollers in a belt conveyor or one or more drive rollers in a group of rollers in each indexing section 138. As described above, the motor controller 330 may be configured to receive digital commands from the controller 302 and operate the motor 332 according to the command. The individual indexing sections 138 can be independently controlled by the controller 302 in response to input from a parcel flow sensor system 310 (e.g., a vision system), or independently controlled by the robot 130 in communication with the controller 302. The controller 302 can independently control the speed of the indexing section 138 to maintain a parcel spacing and flow rate commensurate with the rate at which the parcels are removed from the front end of the conveyor system. Each indexing section 132 can be stopped or reversed independently of the other indexing sections to maintain the desired parcel flow. In some examples, when no packages are present on indexing portion 138 , indexing portion 138 may be stopped, for example, to reduce power usage.

[0074] Parcel buffer system 320 may also control a series of one or more parcel stops 602 along the length of conveyor system 30. Parcel stops 602 may be controlled to allow parcels to enter the conveyor system (e.g., from gravity feed 134) automatically and at a controlled rate. For example, controller 302 may raise and lower parcel stops 602 as a gate for parcel flow while controlling the speed at which parcels travel along indexing section 138. Controller 302 may control the operation of parcel stops 602 based on input from parcel flow sensor system 310 (e.g., a vision system) or based on input commands from robot 130 having a vision system.

[0075] Typically, the package buffer system 320 receives commands from the controller 302 and adjusts the individual speeds of the appropriate indexing sections 138 in response to the commands. For example, the controller 302 receives package flow and spacing data from the package flow sensor system 310 and / or from the robot 130. The controller 302 can then determine whether the package flow rate is too fast or too slow compared to the rate at which a worker or robot removes packages from the front end 94. For example, using data from the package flow sensor system 310, the controller 302 can determine the package dwell time to track how long a package stays at the front end 94 before a worker removes the package and stacks it in the trailer 50. For example, the package dwell time can be determined from an imaging sensor at the front end that detects package arrival and tracks how long a package stays at the front end 94 before a worker or robot removes the package. As another example, the package dwell time can be determined based on the duration of the package triggering the line interruption sensor at the front end 94. If the package dwell time is too long, such as it exceeds a threshold time, the controller 302 can operate the indexing section 138 to slow down the package flow rate. Alternatively, if the parcel dwell time is too short (eg, indicating that parcels are removed immediately upon their arrival), the controller 302 may operate the indexing portion 138 to increase the parcel flow rate.

[0076] In some cases, packages may arrive at different spacings. The controller may control the upstream indexing section 138 to adjust the package spacing. For example, if data from the package flow sensor system 310 indicates that two packages are arriving one after the other, the controller 302 may be able to temporarily slow down or stop the first indexing section 138 once the first package passes from the first indexing section to the next subsequent indexing section on the extendable conveyor system 30. In this way, the two packages may be appropriately spaced apart. In an embodiment employing an imaging sensor (e.g., computer vision), the controller 302 may monitor the spacing between all packages along the extendable conveyor system 30 and independently adjust each conveyor indexing section 138 to maintain appropriate package spacing using real-time feedback provided by the imaging sensor.

[0077] In some embodiments, parcel buffering system 320 includes parcel stops (e.g., parcel stops 604 discussed below). Control system 300 can control the operation of parcel stops to help buffer parcels. For example, control system 300 can operate motors and / or hydraulic actuators to raise and lower parcel stops 604 to ease the flow of parcels onto extendable conveyor system 30.

[0078] Figures 13A to 13C depict another embodiment of the extendable conveyor system 30. The embodiment shown in Figures 13A to 13C is generally similar to the above-described embodiment, with some optional variations. The extendable conveyor system 30 is configured to be installed below the gravity feeder 134. For example, the base conveyor section 36 is shortened, which allows the frame to be positioned below the gravity feeder 134. The base conveyor section 35 also includes a package stop 602. The control system 300 can control the operation of the package stop 602 to help buffer packages passing through the extendable conveyor system 30. For example, the package stop 602 can be controlled to selectively raise and lower to control the flow of packages 122 to the extendable conveyor system 30. For example, the control system 300 can operate the package stop 602 to allow packages 122 to pass individually or in groups.

[0079] The base conveyor section 36 and each extension conveyor section 38 have a transition ramp 606 between sections. The transition ramp 606 can be a flat low friction surface, or can have free-wheeling rollers. In some embodiments, the transition ramp 606 can have powered rollers, for example, to help move packages up the extendable conveyor system 30 in the opposite direction to help unload a trailer.

[0080] As shown, the base conveyor section 36 and each extension conveyor section 38 each have only one conveyor index 138a implemented as a conveyor belt. The final extension section 638 has a different configuration than the three intermediate sections 38. The extension section 638 employs rollers with all three conveyor indexes 138b using powered rollers, for example, to assist in package buffering at the ends of the extendable conveyor system 30. As described above, the control system 300 can independently control the direction and speed of each index 138b to buffer packages.

[0081] As shown in FIG. 13C , the extension section 638 may have an interface for attaching a removal cart 610. The removal cart 610 may be used to sort packages 122 that cannot be handled by the robot 130, such as damaged or oddly shaped packages 122. The removal cart 610 may be releasably coupled to the extension section 638 using a latch assembly and / or a pair of magnets. For example, the removal cart interface may be coupled to a side wall or frame of the extension section 638. The removal cart connection interface allows the removal cart 610 to move side by side with the extendable conveyor system 30 as the extendable conveyor system 30 is extended and retracted. In some examples, the removal cart is below the hinged end 604 so that unpickable packages can be pushed in.

[0082] 13C, a power source 612 is mounted to the frame 34. A flexible wire channel 614 is used to supply power to the conveyor segments 32.

[0083] The front end of the extension section 638 includes an articulated end 604. The articulated end can be manually controlled or controlled by the control system 300 for height adjustment and / or lateral adjustment. FIG. 14 is a detailed view of the extension section 638 of the articulated end 604. As shown in FIG. 14, the articulated end 604 can be configured to be vertically articulated to adjust the height of the extendable conveyor system 30 at the front end 94. For example, the articulated end 604 can be mounted to the extension section 638 at the articulated joint 616, thereby allowing the articulated end 604 to pivot automatically (via the control system 300) or manually. The articulated end 604 is shown in three positions. Position A is substantially horizontal and extends at the same height as the extension section 638. This position can be used to dock with the package handling robot 130. In position B, the articulated end 604 pivots downward. This position can be used to manually unload packages from the extendable conveyor system 30 / manually load packages into the extendable conveyor system 30. Position C is a storage position. In some embodiments, the articulated end 604 can be mounted on a vertical pivot that allows the articulated end 604 to pivot laterally. The articulated end 604 can include a motor or hydraulic device controlled by the control system 300, which is arranged to allow the articulated end 604 to automatically move relative to the rest of the extension section 638.

[0084] The articulated end 604 includes a wrap stop 622, for example to prevent wraps from falling off the end. The wrap stop 622 can be fixed. In some embodiments, the wrap stop 622 is movable and can be raised / lowered, similar to the wrap stop 602. The articulated end 604 can have a wrap indexing portion 138 (e.g., a powered conveyor belt or powered rollers) similar to other conveyor segments 32.

[0085] The articulated end 604 may include a bumper 618 on the end. In some embodiments, the bumper has a pressure sensor to detect if / when the articulated end 604 hits an object. The pressure sensor can be used to alert the control system 300, which in turn can retract or stop the movement of the extendable conveyor system 30 when a collision is sensed. In some examples, the articulated end 604 includes lights and / or reflectors on the front end 94 and / or sides.

[0086] The operation of the articulated end 604 can be controlled by the controller 302 independently or by commands from the robot 130. That is, the controller 302, operating independently or by commands from the robot 130, can control the pivoting of the articulated end 604 (e.g., up / down or from side to side), the operation of the conveyor or powered rollers on the indexing portion 138 of the articulated end, and the operation of the package stop 602. In some embodiments, the articulated end 604 serves as a package picking area for the robot 130 or a worker. For example, when operating with the robot 130, multiple packages can be present on the articulated end 604 at one time (e.g., three packages in a row). If the robot 130 picks a package that is not in the middle or rear of the articulated end 604 (e.g., the second package in a row), it can command the controller 302 to advance the indexing portion 138. This will move the packages at the rear of the articulated end 604 forward while preventing the front-most package from falling off the edge by the package stop 602. In some embodiments, the controller 302 can automatically sense the location of a parcel on the articulated end 604 and advance the indexing portion 138 appropriately without control from the robot 130. For example, the controller 302 can control the operation of the indexing portion 138 on the articulated end 604 in a manner similar to that described, but in response to input from the parcel flow sensor system 310 (e.g., a vision system) or from a pressure sensor array beneath the indexing portion 138 indicating the location of a parcel on the indexing portion 138.

[0087] FIG. 11 depicts a flow chart of alignment processes 400, 420 for operating an extendable conveyor system. Processes 400 and 420 may be performed by one or more computing systems, including but not limited to the control system 300 described above, to control the extendable conveyor system 30. Processes 400 and 420 will be described with reference to FIGS. 11 and 12A-12D. FIGS. 12A-12D depict a series of bird's-eye views illustrating the operation of processes 400 and 420.

[0088] Process 400 is a process for automatically controlling the retraction of the extendable conveyor system 30 when a package is loaded into the trailer 50. The control system 300 obtains a first distance measurement between the front end of the conveyor system and at least one object located in front of the conveyor system (402). For example, the control system can obtain one or more distance measurements (e.g., d1 and d2) from the alignment sensor 124. In some embodiments, the robot 130 can perform the measurements and transmit them to the control system 300. The object can be, for example, a package wall 120, a front wall of the trailer 50, or a package handling robot 130. For example, when the extendable conveyor system 30 is used with the package handling robot 130, the control system 300 can maintain a desired distance to the robot 130 so that the end of the extendable conveyor system 30 is within reach of the robot 130. In such an embodiment, the control system 300 can store different distance settings. For example, the desired distance from the package wall under manual operation may be different from the desired distance from the robot 130 (e.g., because the front end 94 may overhang above a portion of the robot, the desired distance from the robot may be less than the desired distance from the package wall in manual operation).

[0089] The control system 300 determines that the first distance is less than a first predetermined distance (404). For example, the control system 300 may compare the measured distance to a predetermined spacing (e.g., a working distance) between the front end 94 and the rear of the trailer or the wrapping wall 120. If the measured spacing is less than the predetermined spacing, the control system 300 may retract the extendable conveyor system 30 (406). If the measured distance is greater than the predetermined spacing, the control system 300 may extend the extendable conveyor system 30. In some embodiments, a variation distance may be used to avoid excessive movement of the extendable conveyor system 30. For example, the variation distance may define an allowable variation from a predetermined spacing (e.g., 6 inches). If the difference between the measured distance and the predetermined distance is within the variation, the control system 300 does not extend or retract the extendable conveyor system 30. The control system 300 may control the retraction / extension of the extendable conveyor system 30 by sending instructions to one or more motor controllers, which retract / extend the conveyor system until the measured distance is equal to or greater than the predetermined spacing.

[0090] The predetermined spacing may be a user set value, for example, in the case of a manual trailer loading process. In some embodiments, the user may adjust the predetermined spacing value during operation.

[0091] In some embodiments, the control system 300 may employ a time delay to account for a loading operation's temporary obstruction of one or more alignment sensors 124. For example, the control system 300 may require that any change in measured distance persist for a period of time (e.g., 1 to 2 seconds) before taking any action to retract the extendable conveyor system 30.

[0092] In some embodiments, the control system 300 may use multiple distance measurements, as shown in FIGS. 12A-12C . For example, the control system may require multiple distance measurements to be less than a predetermined spacing before initiating the action of retracting the extendable conveyor system 30. As depicted in FIG. 12A , the distance d1 is less than the predetermined spacing because the package has been placed in front of the leftmost sensor. However, the distance d2 is still within the predetermined spacing, so the control system 300 will not retract the extendable conveyor system 30. When the package is placed in front of the rightmost sensor (as shown in FIG. 12B ), both d1 and d2 are less than the predetermined spacing, so the control system 300 retracts the extendable conveyor system 30 ( FIG. 12C ) until the average or mean of all forward distance measurements (d1 and d2) is within the allowed variation of the predetermined spacing. The control system may wait to retract the extendable conveyor system until all distance measurements are less than the predetermined distance, or it may use a majority rule process and retract when the majority of the forward sensors measure a distance less than the predetermined spacing.

[0093] The control system 300 may control the retraction of the extendable conveyor system 30 by sending instructions to one or more motor controllers that cause the conveyor system to retract until the measured distance is equal to or greater than a predetermined spacing.

[0094] In some embodiments, the package handling robot 130 can perform the process 400. In such embodiments, the robot 130 can control the operation of the extendable conveyor system 30 by sending commands to the control system 300. For example, the robot 130 can use its own sensors and determine when to extend or retract the extendable conveyor system 30, and then send the appropriate commands to the control system 300, which causes the control system 300 to operate the extendable conveyor system 30 accordingly.

[0095] 11 and 12D, process 420 is a process for automatically aligning an extendable conveyor system 30 within a confined space (e.g., a trailer 50). The control system 300 obtains a first distance measurement and a second distance measurement from either side of the conveyor at the front end 95 (422). One measurement is the distance between the right side of the conveyor and the right side wall 550 of the trailer (e.g., d4), and the other measurement is the distance between the left side of the conveyor and the left side wall 552 of the trailer (e.g., d3). For example, the measurements may be obtained from an alignment sensor 124 positioned to take distance measurements from the side of the extendable conveyor system 30.

[0096] The control system determines a difference between the first distance measurement and the second distance measurement (424). If the measurements are different, the extendable conveyor system 30 is misaligned within the trailer. The control system 300 may compare the difference to a threshold value (e.g., 6 inches). If the difference is greater than the threshold value, the control system 300 may control the extendable conveyor system 30 to adjust its lateral position within the trailer (426). For example, the control system 300 may control the extendable conveyor system 30 to move in the direction of the sensor that measured the greater distance in order to reduce the difference between the two measurements. For example, the control system 300 may send instructions to one or more motor controllers to pivot the drive wheels and move the front end 94 to the left (as shown in FIG. 12D ).

[0097] Although the extendable conveyor system 30 has been described as performing a trailer loading operation, it can also be used in an unloading configuration. For example, the conveyor can be operated in the opposite direction, and the process 400 can be performed in a similar manner to extend the extendable conveyor system 30 incrementally into the trailer as packages are removed from the trailer. As the measured distance becomes greater than the predetermined spacing, the extendable conveyor system 30 is incrementally extended to maintain the spacing. In addition, in embodiments capable of performing both loading and unloading operations, the transition ramp 606 can be designed to have a low profile and / or can include powered rollers to help move packages up the conveyor.

[0098] The subject matter and implementation of the functional operations described in this specification may be implemented in digital electronic circuits, in tangibly implemented computer software or firmware, in computer hardware, including the structures disclosed in this specification and their structural equivalents, or a combination of one or more of them. The implementation of the subject matter described in this specification may be implemented as one or more computer programs, i.e., one or more modules of computer program instructions encoded on a tangible, non-transitory program carrier for execution by a data processing apparatus or for controlling the operation of a data processing apparatus. The computer storage medium may be a machine-readable storage device, a machine-readable storage substrate, a random or serial access memory device, or a combination of one or more of them.

[0099] The term "controller" refers to data processing hardware and covers all kinds of devices, equipment and machines for processing data, including, for example, a programmable processor, a computer or multiple processors or computers. The device may also be or further include special-purpose logic circuits, such as a central processing unit (CPU), an FPGA (field programmable gate array) or an ASIC (application-specific integrated circuit). In some embodiments, the data processing device and / or the special-purpose logic circuit may be hardware-based and / or software-based. The device may optionally include code that creates an execution environment for a computer program, for example, code that constitutes processor firmware, a protocol stack, a database management system, an operating system, or a combination of one or more of them. The present disclosure contemplates the use of data processing devices with or without conventional operating systems, such as Linux, UNIX, Windows, Mac OS, Android, iOS, or any other suitable conventional operating system

[0100] A computer program, which may also be referred to or described as a program, software, software application, module, software module, script or code, may be written in any form of programming language, including compiled or interpreted languages, or declarative or procedural languages, and may be deployed in any form, including as a standalone program or as a module, component, subroutine or other unit suitable for use in a computing environment. A computer program may but need not correspond to a file in a file system. A program may be stored in a portion of a file that stores other programs or data, such as one or more scripts stored in a markup language document, in a single file dedicated to the program in question, or in a plurality of coordinated files, such as files storing one or more modules, subroutines or code portions. A computer program may be deployed to execute on a computer or on multiple computers located at a site or distributed across multiple sites and interconnected by a communication network. Although portions of the program shown in the various figures are shown as separate modules that implement various features and functions through various objects, methods or other processes, the program may alternatively include multiple submodules, third-party services, components, libraries, etc., as appropriate. On the contrary, the features and functions of various components may be appropriately combined into a single component.

[0101] The processes and logic flows described in this specification can be performed by one or more programmable computers executing one or more computer programs to perform functions by operating on input data and generating output. The processes and logic flows can also be performed by special purpose logic circuits, and the apparatus can also be implemented as special purpose logic circuits, such as a central processing unit (CPU), an FPGA (field programmable gate array), or an ASIC (application specific integrated circuit).

[0102] Computers suitable for executing computer programs include, for example, central processing units that can be based on general or special purpose microprocessors or both, or any other kind of central processing unit. Typically, the central processing unit will receive instructions and data from a read-only memory or a random access memory or both. The basic elements of a computer are a central processing unit for executing or performing instructions and one or more memory devices for storing instructions and data. Typically, a computer will also include one or more mass storage devices (such as magnetic disks, magneto-optical disks, or optical disks) for storing data, or be operably coupled to receive data from or transfer data to or to one or more mass storage devices, or both. However, a computer need not have such a device. In addition, a computer can be embedded in another device, such as a mobile phone, a personal digital assistant (PDA), a mobile audio or video player, a game console, a global positioning system (GPS) receiver, or a portable storage device, such as a universal serial bus (USB) flash drive, to name a few.

[0103] Computer-readable media suitable for storing computer program instructions and data (transitory or non-transitory, as the case may be) include all forms of non-volatile memory, media and memory devices, including, for example, semiconductor memory devices, such as EPROM, EEPROM and flash memory devices; magnetic disks, such as internal hard disks or removable disks; magneto-optical disks; and CD ROM and DVD-ROM disks. The memory may store a variety of objects or data, including caches, classes, frameworks, applications, backup data, jobs, web pages, web page templates, database tables, repositories for storing business and / or dynamic information, and any other appropriate information including any parameters, variables, algorithms, instructions, rules, constraints or references thereto. In addition, the memory may include any other appropriate data, such as logs, policies, security or access data, report files, and others. The processor and memory may be supplemented by or incorporated into special purpose logic circuitry.

[0104] To provide interaction with a user, embodiments of the subject matter described in this specification may be implemented on a computer having a display device (e.g., a CRT (cathode ray tube), LCD (liquid crystal display), or plasma monitor) for displaying information to the user, and a keyboard and pointing device (e.g., a mouse or trackball) through which the user can provide input to the computer. Other kinds of devices may also be used to provide interaction with the user; for example, the feedback provided to the user may be any form of sensory feedback, such as visual feedback, auditory feedback, or tactile feedback; and input from the user may be received in any form, including acoustic, voice, or tactile input. In addition, a computer may interact with a user by sending documents to and receiving documents from a device used by the user; for example, by sending a web page to a web browser on a user's client device in response to a request received from the web browser.

[0105] Implementations of the subject matter described in this specification may be implemented in a computing system that includes a back-end component (e.g., as a data server), or includes a middleware component (e.g., an application server), or includes a front-end component (e.g., a client computer with a graphical user interface or a web browser through which a user can interact with implementations of the subject matter described in this specification), or includes any combination of one or more such back-end, middleware, or front-end components. The components of the system may be interconnected by any form or medium of digital data communication (e.g., a communication network). Examples of communication networks include local area networks (LANs), wide area networks (WANs) (e.g., the Internet), and wireless local area networks (WLANs).

[0106] A computing system may include clients and servers. Clients and servers are generally remote from each other and typically interact through a communication network. The relationship of client and server arises by virtue of computer programs running on the respective computers and having a client-server relationship to each other.

[0107] Although this specification contains many specific implementation details, these should not be interpreted as limitations on the scope of any invention or the scope that may be claimed, but rather as descriptions of features that may be specific to a particular implementation of a particular invention. Certain features described in this specification in the context of separate implementations may also be implemented in combination in a single implementation. Conversely, the various features described in the context of a single implementation may also be implemented in multiple implementations separately or in any suitable sub-combination. In addition, although features may be described above as working in certain combinations and even initially claimed as such, one or more features from the claimed combination may be deleted from the combination in some cases, and the claimed combination may be directed to a sub-combination or a variation of the sub-combination.

[0108] Similarly, although operations are depicted in a particular order in the accompanying drawings, this should not be understood as requiring that the operations be performed in the particular order shown or in sequence, or that all of the operations shown be performed, to achieve the desired results. In some cases, multitasking and parallel processing may be helpful. In addition, the separation of various system modules and components in the above-described embodiments should not be understood as requiring such separation in all embodiments, and it should be understood that the described program components and systems can generally be integrated together in a single software product or packaged into multiple software products.

[0109] Although this document contains many specific implementation details, these should not be interpreted as limitations on the scope that can be claimed, but rather as descriptions of features that can be specific to a particular implementation or embodiment. Certain features described in the context of separate embodiments in this specification may also be implemented in combination in a single embodiment. On the contrary, the various features described in the context of a single embodiment may also be implemented in multiple embodiments separately or in any suitable sub-combination. In addition, although features may be described above as working in certain combinations and even initially claimed as such, in some cases, one or more features from the claimed combination may be deleted from the combination, and the claimed combination may be directed to a sub-combination or a variation of the sub-combination.

Claims

1. A method for operating a conveyor system executed by one or more processors, the method comprising: obtaining, from a sensor system of the conveyor system, a first distance between a front end of the conveyor system and at least one object located in front of the conveyor system; determining that the first distance is less than a first predetermined distance; and In response to the first distance being less than the first predetermined distance, the conveyor system is controlled to move to increase the distance from the at least one object.

2. The method according to claim 1, wherein: Determining that the first distance is less than the first predetermined distance includes comparing a measurement of the first distance with the first predetermined distance.

3. The method according to any one of claims 1 and 2, wherein: The first predetermined distance comprises a user-selected value.

4. The method according to any one of claims 1 to 3, wherein: Controlling the conveyor system includes sending instructions to one or more motor controllers, the instructions causing the conveyor system to retract until the first distance is equal to or greater than the first predetermined distance.

5. The method according to claim 4, wherein: The conveyor system is an extendable conveyor system comprising a first conveyor section and a second conveyor section configured to be nested beneath the first conveyor section, and wherein the one or more motor controllers control relative movement between the first conveyor section and the second conveyor section.

6. The method according to any one of claims 1 to 5, wherein: The first distance is the shortest distance between the front end of the conveyor system and a plurality of objects.

7. The method of any one of claims 1 to 6, further comprising controlling the front end of the conveyor system to move laterally relative to the length of the conveyor system.

8. The method according to claim 7, wherein: Controlling lateral movement of the front end of the conveyor system includes moving the front end in response to measurement data from the sensor system.

9. The method according to claim 7, wherein: Controlling lateral movement of the front end of the conveyor system includes sending instructions to one or more motor controllers that control lateral movement of the conveyor system in response to measurement data from the sensor system.

10. The method according to any one of claims 1 to 9, further comprising: obtaining a second distance between a first side of the conveyor system and a second object from a sensor mounted on at least a first side of the sensor system; obtaining a third distance between the second side of the conveyor system and a third object from a sensor mounted on the second side of the sensor system; determining that a difference between the second distance and the third distance exceeds a threshold difference; and In response, the conveyor system is controlled to move such that the difference is within the threshold difference.

11. The method according to any one of claims 1 to 10, wherein: The conveyor system includes an interface for connecting a robot to the conveyor system; Wherein, acquiring the first distance includes acquiring the first distance from the robot through the interface.

12. The method according to any one of claims 1 to 11, further comprising: acquiring package flow data indicating a rate of package flow along the conveyor system; and Based on the parcel flow data, operation of the independent indexing sections of the conveyor system is controlled.

13. The method according to claim 12, wherein: Controlling the operation of the independent indexing sections includes controlling at least one independent indexing section to adjust a buffer distance between packages by varying a speed of the at least one independent indexing section.

14. One or more non-transitory computer-readable storage media storing instructions that, when executed by at least one processor, cause the at least one processor to perform the method of any one of claims 1 to 13.

15. A system / device comprising: one or more processors / computers; and one or more data storage devices connected to the one or more processors / computers, the one or more data storage devices having instructions stored thereon, which instructions, when executed by the one or more processors / computers, cause the one or more processors / computers to perform the method according to any one of claims 1-13.

16. An extendable conveyor system comprising: a plurality of conveyor segments interlocking in a telescoping configuration wherein the individual conveyor segments at least partially overlap one another; a conveyor extension / retraction system operably coupled to at least one of the conveyor segments and configured to control extension and retraction of the extendable conveyor system by controlling movement of the conveyor segments relative to each other; and A control system in electrical communication with the conveyor extension / retraction system and configured to perform the method of any one of claims 1 to 13.

17. An extendable conveyor system comprising: a plurality of conveyor segments interlocking in a telescoping configuration wherein the individual conveyor segments at least partially overlap one another; a conveyor extension / retraction system operably coupled to at least one of the conveyor segments and configured to control extension and retraction of the extendable conveyor system by controlling movement of the conveyor segments relative to each other; and A control system in electrical communication with the conveyor extend / retract system and configured to perform operations including adjusting the position of one or more conveyor segments in response to data received from a package handling robot in electrical communication with the control system.

18. The extendable conveyor system of claim 17, wherein: Each conveyor section includes one or more indexing sections, and Wherein the operations include controlling the speed of one indexing section independently of the other indexing sections in response to second data received from the package handling robot.

19. The extendable conveyor system according to any one of claims 17 and 18, wherein: A forward-most conveyor segment of the plurality of conveyor segments includes an articulated end portion configured to pivot relative to the forward-most conveyor segment.

20. An extendable conveyor system according to any one of claims 17 to 19, wherein: A base conveyor segment of the plurality of conveyor segments includes a wrap stop configured to be raised and lowered in response to a control signal from the control system.

21. An extendable conveyor system according to any one of claims 17 to 20, wherein: The plurality of conveyor segments include a base conveyor segment, an end conveyor segment, and one or more intermediate conveyor segments, the base conveyor segment being configured to receive packages from a gravity chute, the one or more intermediate conveyor segments being disposed between the base conveyor segment and the end conveyor segment, wherein the base conveyor segment of the plurality of conveyor segments includes a wrap stop configured to be raised and lowered in response to a control signal from the control system, wherein the one or more intermediate conveyor sections each comprise an independently controllable conveyor belt, and Among them, the front conveyor section includes: a plurality of rollers, the plurality of rollers comprising at least a first set of powered rollers and a second set of powered rollers, wherein the first set of powered rollers is separated from the second set of powered rollers by a set of unpowered rollers, and An articulated end portion is configured to pivot relative to a front end of the end conveyor segment.

22. An extendable conveyor system comprising: a plurality of conveyor segments interlocking in a telescoping configuration wherein the individual conveyor segments at least partially overlap one another; a conveyor extension / retraction system operably coupled to at least one of the conveyor segments and configured to control extension and retraction of the extendable conveyor system by controlling movement of the conveyor segments relative to each other; Sensor systems; and a control system in electrical communication with the conveyor extend / retract system and the sensor system, the control system being configured to perform operations including: obtaining from the sensor system a first distance between a front end of the conveyor system and at least one object located in front of the conveyor system; determining that the first distance is less than a first predetermined distance; and In response to the first distance being less than the first predetermined distance, controlling the conveyor extend / retract system to move the conveyor segment to increase the distance from the at least one object.

23. The extendable conveyor system of claim 19, wherein: The plurality of conveyor segments include a base conveyor segment, an end conveyor segment, and one or more intermediate conveyor segments, the base conveyor segment being configured to receive packages from a gravity chute, the one or more intermediate conveyor segments being disposed between the base conveyor segment and the end conveyor segment, wherein the base conveyor segment of the plurality of conveyor segments includes a wrap stop configured to be raised and lowered in response to a control signal from the control system, wherein the one or more intermediate conveyor sections each comprise an independently controllable conveyor belt, and Among them, the front conveyor section includes: a plurality of rollers, the plurality of rollers comprising at least a first set of powered rollers and a second set of powered rollers, wherein the first set of powered rollers is separated from the second set of powered rollers by a set of unpowered rollers, and An articulated end portion is configured to pivot relative to a front end of the end conveyor segment.

Images