Conveying belt packaging flow density adjusting system

Abstract

Methods and apparatus for sensing and detecting parcel flow density on selected sections of feeding and receiving conveyor belts and for adjusting conveyor belt speed to control parcel flow density. The conveyor belt includes a range sensing measurement field at a selected location. The range sensing device has a virtual encoder and a signal generation and detection component extending across a surface of the conveyor belt. The computer component calculates a percentage of a desired occupancy of the receiving conveyor belt and a percentage of an actual occupancy of the receiving conveyor belt. The programmable logic controller controls the belt speed and start-stop movement of the feeding belt and the receiving belt based on the signals received from the range sensing detection device to optimally separate the packages on the feeding belt or the receiving belt.

Description

[0001] Cross-references to related applications This application claims priority to U.S. Provisional Application Serial No. 63526735, filed July 14, 2023, which is incorporated herein by reference in its entirety. Technical Field

[0002] This invention relates to the field of detecting and controlling package flow density on a conveyor belt by adjusting the speed of the feed and receive conveyors to optimize flow density and manage, track, and combine bulk flow, using various sensing and detection methods. Background Technology

[0003] Conveying systems are typically used to align and separate items on the conveyor for processing by downstream sorting systems. Conventional conveying systems generally involve controlling items in such a way that items leaving the sensing subsystem have gaps of approximately a desired length between or beside them. These desired gaps can be variable depending on the length and / or width of one or more of the items in the pair defining the gap, or they can be constant. Regardless of the criteria used to determine the length of the desired gap, it serves to facilitate the sorting of items. Sorting systems generally operate more efficiently if the items being sorted have a certain minimum gap between them. However, gaps exceeding this minimum generally reduce the throughput of the conveying system. It is desirable to create gaps that balance sorting criteria while maximizing throughput for sorting and singulator equipment; however, where packages are fed from various feed points, such as truck unloading stations, to sensing points on multiple conveyor belts, maximum efficiency is achieved by moving as many packages as possible across a given area of ​​the conveyor belt.

[0004] Due to the variability in the amount of product entering on various feed belts, imbalances occur at different merging areas in the conveyor system, resulting in large gaps on the collecting belt, selecting belt, and sorting areas. This fact leads to inefficiency, unnecessary investment in equipment, and a degradation of the overall throughput of the sorting machine. Conventional flow management systems count packages and / or control the speed of the conveyor belts to orient or select packages and create the desired minimum gaps between them for processing. Examples of these devices are proposed in the following patents and / or publications.

[0005] U.S. Patent No. 5,165,520 teaches a conveyor system that separates packages on a belt and includes a camera system that identifies overlapping or crowding of packages and removes non-compliant packages. U.S. Patent No. 8,061,506 teaches the use of information acquired from optical sensors or a camera to merge packages onto a conveyor belt to identify or create gas on a collector belt and to fill these gaps with packages from the feed belt; however, Schafer does not discuss methods for processing information from the camera or optical sensors to control its concentration. Publication (WO2,000,662,800) describes a method using a camera to determine the number of packages and using this information to control the speed of conveyor belts such as package feeder conveyors, accelerator conveyors, buffer conveyors, sorters, and transport conveyors; however, the references do not teach or suggest a concept for controlling the conveyor speed as a function of occupancy on the collector or maximizing the area covered on the conveyor belt just before the sorter. U.S. Patent 6,471,044 teaches that images are transmitted to a control system, wherein the images are interpreted to determine the quantity and average size of the packages in order to adjust the speeds of the package feeder conveyor, buffer conveyor, acceleration conveyor, sorter, and transport conveyor, but not the density of packages on a given area of ​​the conveyor. U.S. Patent 5,141,097 teaches the analysis of images supplied by an imaging device to provide an indication of the quantity of packages present in the image and to increase the conveyor speed to achieve a desired throughput. U.S. Patent 6,401,936 teaches a detection system for monitoring the flow of goods and identifying and / or tracking individual goods passing through the system, the system being used in conjunction with a sorter downstream of a coarse sorter, a holding and releasing or stripping conveyor, wherein a control system is integrated with the detection system to regulate the flow of goods through the system by increasing the speed of the conveyor.

[0006] Conventional systems utilize methods that count the feet or packages released from a container unloading conveyor and adjust the conveyor speed to keep the input flow at manageable levels for the sorting and picking machines. The goal is to keep the system fed without overfeeding. Current package conveyor systems have a picking capacity of 12,150 packages per hour (pph), with a 12-inch gap at 540 feet per minute (fpm) and an average of 20 inches. As a result, system throughput efficiency is limited, and typical sustained performance capacity is expected to be only about 60% of the picking capacity. There is a need for a control system to maximize the occupancy and density of packages on a given area of ​​the receiving conveyor for unloading packages, and a need for a mechanism to sense the physical characteristics of packages from transport vehicles such as railcars, airplanes, ships, or trucks in order to send items to the appropriate picking system and control the speed of item transport. Summary of the Invention

[0007] This application relates to improvements made to the inventions proposed in PCT / US2020 / 042429, filed July 16, 2020, and the corresponding U.S. Patent 11,459,188 ("Range Sensing Apparatus and Method of Measuring and Controlling Density of Parcels on a Conveyor," published October 4, 2022), which are incorporated herein by reference. It relates to the field of determining the parcel flow density on selected sections of feed and receive conveyor belts linearly (1D), area-wise (2D), or volume-wise (3D) using various sensing and detection methods, and adjusting the conveyor belt speed ratio proportionally to the ratio of desired density to current density to increase the density or volume of parcels in the selected area of ​​the receive conveyor belt. Different sensing and detection methods are used to determine the parcel flow density on selected sections of the feed and receive conveyors in 1D linear, 2D area, or 3D volume. The conveyor speed ratio is adjusted proportionally to the ratio of desired density to current density to increase the density or volume of parcels in the selected area of ​​the receive conveyor (boxed parcel mixes typically range in size from 6 inches to 60 inches). Bulk 2D parcels are also adjusted for the sorter to provide continuous throughput with greater sorting accuracy.

[0008] This invention improves upon the concept by the following steps: Proximity transfer between conveyor belts and measurement of bulk flow density using distance sensors mounted on each side of the upstream conveyor belt preceding the transition; distance values ​​are recorded at intervals of belt travel. Based on encoder input, numerical integration calculates the area utilization rate over a defined length of one or more conveyor belts. The speed of the flow density on the collector line is calculated based on proximity to the merging area, and the flow rate from the feed conveyor belt is limited based on the available area on the collector. When bulk parcel flows are transferred between two conveyor belts operating at different speeds, the parcel flow density (conveyor belt area utilization or occupancy rate) before and after the transition will be proportional to the speed ratio between the conveyor belts.

[0009] This invention measures flow density by using distance sensors to measure the flow density of the transmission between adjacent conveyor belts. It is a form of numerical integration. Distance sensors are mounted on each side of the upstream conveyor belt before the transition, and the distance value is based on encoder input at a defined resolution. Figure 4 The values ​​(2 inches in length) are recorded at intervals along the conveyor belt. These values ​​are recorded in an array and used to determine the area utilization over the defined length of the conveyor belt.

[0010] The flow density adjustments on the series of conveyor belt transitions leading to the sorting machine, the dock unloading conveyor belt, and the main sorting collector are all controlled by a flow density adjustment method. This method can be used to separate packages, compress them at various points in the conveyor system, and determine appropriate conveyor speed ratios. At docking and merging transition points, this method can be used to periodically stop the merging conveyor belt to avoid congestion.

[0011] This invention defines a range sensing device for measuring and controlling the density of items on a conveyor belt, comprising or consisting of a feed conveyor, a docking and merging conveyor, and a receiving conveyor, each conveyor having an independent variable-speed drive motor. The feed conveyor includes a range sensing measurement field at a distal unloading end adjacent to the receiving conveyor. The receiving conveyor includes a range sensing measurement field at a receiving end adjacent to or near the unloading end of the feed conveyor. The docking and merging conveyor includes a range sensing measurement field at a distal unloading end adjacent to the receiving conveyor, following the range sensing measurement field of the feed conveyor and preceding the range sensing measurement field of the receiving conveyor. The range sensing device, having a virtual encoder and signal generation and detection components, extends across the surfaces of the feed conveyor measurement field, the docking and merging conveyor measurement field, and the receiving conveyor measurement field. A computer component calculates the percentage of desired occupancy of the receiving conveyor and the percentage of actual occupancy of the receiving conveyor. The programmable logic controller controls the conveyor speed and start-stop movement of the feed conveyor and docking merging conveyor based on signals received from a range sensing detection device. The signals identify gaps between packages on the receiving conveyor, the gaps having sufficient space for inserting additional packages from the feed conveyor, the docking merging conveyor, or the feed conveyor and docking merging conveyor.

[0012] Density measurement equipment and conveyor speed control are applied to the conveyor system to regulate the flow rate of bulk items or parcels to the sorter, providing higher continuous throughput with greater sorting accuracy. When the system is full, the collector conveyor acts as a dynamic buffer, compressing the flow density to fill the collector line to the desired target fullness. Loose and deficient areas of flow are pulled forward and compressed to the target fullness. Overfilled clumps or areas are thinned to reduce the likelihood of downstream blockage.

[0013] Typically, for a 50-foot belt length receiving traffic into the sorter, the optimal bulk parcel flow rate supplied to the single sorter should not be less than 15% and not more than 40% of the conveyor belt's area utilization. The actual required high, low, and average speeds should be determined based on the throughput limits of the conveyor system's average parcel size and the range of average flow density.

[0014] An improved method includes: utilizing a set of sensors to collect multiple measurements of packages moving along a feed conveyor and a collection conveyor; storing and analyzing the multiple measurements in software to determine area utilization over a defined length of the conveyor belts; and employing a programmable logic controller (PLC) to variably control the speeds of the feed conveyor and the collection conveyor to achieve a desired percentage area utilization or desired occupancy percentage of packages on the feed conveyor or the collection conveyor. The set of sensors includes at least one single-vision sensor positioned above the conveyor belts or at least two vision sensors positioned on opposite sides of the conveyor belts. The set of sensors is selected from distance sensors such as ultrasonic sensors, infrared proximity sensors, light detection and ranging (LIDAR) sensors, or vertical-cavity surface-emitting laser (VCSEL) sensors. The feed conveyor is driven by a variable-speed motor networked to the PLC to adjust the conveyor speed to a calculated necessary speed between its minimum and maximum speeds to ensure that the feed conveyor merges packages onto the collection conveyor at appropriate timing to achieve the desired occupancy percentage. If the calculated speed of the feed conveyor drops below its minimum speed, the programmable logic controller (PLC) pauses the feed conveyor and then restarts it when the calculated necessary speed exceeds 110% of its preset minimum speed. The feed conveyor is driven by a single-speed motor networked to the PLC to start and stop it at appropriate intervals to ensure the desired percentage of area utilization is achieved when combined with the collection conveyor. The feed conveyor is paused when its calculated speed drops below its minimum speed and restarted when its calculated necessary speed exceeds 110% of the conveyor's preset minimum speed. The method for optimizing the flow density of packages on the collection conveyor is implemented by variably adjusting the speed of the feed conveyor, which is calculated by the ratio of the desired percentage of occupancy of the feed conveyor to its actual percentage of occupancy and multiplied by the speed of the collection conveyor. The actual percentage occupancy of the feed conveyor belt is determined by numerical integration of pairs of distances measured at regular intervals by a set of opposing distance sensors as the package moves along the feed conveyor belt upstream of its junction with the collection conveyor belt. The regular intervals are determined by inputs from a physical encoder with a defined resolution attached to the conveyor belt, or by inputs from a virtual encoder. Claim 10. The method of claim 1, wherein the speed of the feed conveyor belt is controlled such that the percentage area utilization of the collection conveyor belt is not less than 15% and not more than 40%. The feed conveyor belt is capable of accelerating and decelerating at a rate less than or equal to 0.05 G (0.5 m / s²).

[0015] Density measurement equipment identifies and maximizes the utilization of conveyor belt surface area. Sensing and detection equipment determines the package flow density on selected areas of the feed and receive conveyors linearly (1D), area-wise (2D), or volume-wise (3D), and adjusts the feed and receive conveyor speed ratio proportionally to the ratio of desired density to current density to increase the density or volume of packages in the selected area, thereby enhancing the performance and throughput of the conveyor system. Sensing and / or detection equipment is positioned at the flow inlet or transition point between the feed and receive conveyors. Control algorithms identify the area, volume, or density of each item, the speed or rate at which each object passes through selected areas on the feed and receive conveyor surfaces, and the area utilization of the feed and receive conveyors to maintain the desired density of packages on the receive conveyor surface.

[0016] The bulk parcel flow management system includes or comprises a density-based detection system that identifies belt area utilization and parcel count. The system density detection devices are located at the flow inlet and the sorting machine. The control algorithm requires identification of the rate at which each item passes through and the area utilization of the collection belt. Average parcel size (area or volume), including length, width, and height, can also be considered. Furthermore, the density, defined as the parcel's (area, volume, or weight), can be taken into account in the conveyor belt surface area utilization.

[0017] This invention provides a component that increases the area and / or volume and / or density of a conveyor belt by controlling the movement of a feed and receive conveyor belt, defined as a speed "rate," to fill available space on the receiving collector conveyor belt. The conveyor belt packaging management system can also identify, locate, or track packages, parcels, or other goods on the conveyor belt based on its digital images, scanner barcodes, or occupancy area.

[0018] For optimal performance, the system recommends that all bulk feed conveyors leading to the selector be equipped with variable speed drives networked to the selector's process logic control ("PLC") to receive speeds determined by the filling algorithm every 50 milliseconds or less.

[0019] In addition, key functional characteristics to be considered when the system is full include: the collector conveyor acts as an active buffer, thereby compressing the flow density to fill the collector line to the desired target fullness; flow gaps and deficient areas will be pulled forward and compressed to the target fullness; and overfilled clumps or areas will be thinned to reduce the likelihood of downstream blockage.

[0020] A device for detecting and measuring the density of packages on a selected section of a conveyor surface includes, or is composed of, multiple photoeyes for creating a sensing range, wherein each photoeye has two outputs, and each output is individually adjustable to obtain two different ranges. The multiple photoeyes are mounted at selected distances from the unloading end of the feed conveyor and the receiving end of the receiving conveyor on a first side and an opposite second side of the selected section of the feed conveyor having a conveying surface extending to the receiving conveyor. A virtual encoder is programmable to generate pulses at selected intervals on the feed conveyor. The array includes multiple array elements, each representing a pulse from a virtual encoder of a selected length defining the selected distance. A programmable logic controller has an algorithm for calculating an average measured occupancy rate of the array representing a percentage of the fullness of the receiving conveyor.

[0021] A method for detecting and measuring the density of packages on a selected section of a conveyor surface includes the step of using, or comprising, a table of sensing ranges created by employing multiple photoeyes, each photoeye having two outputs, each output being individually adjustable to obtain two different ranges. The multiple photoeyes are mounted at selected distances from the unloading end of the feed conveyor and the receiving end of the receiving conveyor on a first side and an opposite second side of the selected section of the feed and receiving conveyors. Pulses are generated at selected intervals along the selected section of the conveyor surface using a programmable virtual encoder. An array comprising multiple array elements is formed, each array element representing a pulse from a virtual encoder of a selected length defining the selected distance. The average measured occupancy rate of the array, representing the percentage of fullness of the receiving conveyor, is determined by using a programmable logic controller with an algorithm to determine the combination of photoeye outputs blocked when the encoder pulse occurs. The measured occupancy rate of the feed conveyor is compared to the desired occupancy rate of the receiving conveyor. The speed ratio is calculated by dividing the desired occupancy rate by the measured occupancy rate. The speeds of the feed conveyor belt, the receiving conveyor belt, or both the feed conveyor belt and the receiving conveyor belt are adjusted to achieve the desired occupancy rate on the receiving conveyor belt.

[0022] In addition to range sensing photoelectric eyes, sensors may also include relative or left and right range sensing photoelectric eyes that communicate electrically with a PLC or computer, vibration sensors, thermal detection sensors, weight sensors, imaging devices, and smart light stacks.

[0023] Multiple first packages from a first feed conveyor belt and multiple second packages from a second feed conveyor belt are combined onto an intermediate flow control conveyor belt for feeding a collection conveyor belt. The area utilization rate of the first feed conveyor belt is determined by a set of distance sensors positioned upstream of the junction between the first feed conveyor belt and the intermediate flow control conveyor belt. The area utilization rate of the intermediate flow control conveyor belt is also determined by a set of distance sensors positioned upstream of the junction between the intermediate flow control conveyor belt and the collection conveyor belt. The first packages from the first feed conveyor belt are dynamically fed onto the intermediate flow control conveyor belt by variably adjusting the speed of the first feed conveyor belt to achieve a first desired percentage area utilization rate sufficient to allow the second packages from the second feed conveyor belt to be combined onto the intermediate flow control conveyor belt. The speed of the intermediate flow control conveyor belt is adjusted to achieve a second desired percentage area utilization rate for the collection conveyor belt. The area utilization rate of the second feed conveyor belt is also determined by a set of distance sensors placed upstream of the junction between the second feed conveyor belt and the intermediate flow control conveyor belt. The speed of either the first or second feed conveyor belt can be varied to achieve a first desired percentage area utilization rate for the intermediate flow control conveyor belt. The first feed conveyor belt and the intermediate flow control conveyor belt are arranged linearly, and the second feed conveyor belt is perpendicularly connected to the intermediate flow control conveyor belt. The first and second feed conveyor belts are perpendicularly connected to the intermediate flow control conveyor belt.

[0024] The purpose of this invention is to achieve a speed within 5% that is provided by the selector programmable logic controller (PLC).

[0025] The purpose of this invention is to limit high speeds to 350 feet per minute (fpm), low speeds to 100 fpm, and to target an average speed of 225 fpm.

[0026] The purpose of this invention is to enable the feeder conveyor to accelerate and decelerate at a rate of approximately 0.05 G (0.5 m / s^2) to avoid the need for dynamic braking and reverse torque on the drivetrain.

[0027] The purpose of this invention is to provide a range-sensing conveyor belt packaging management system, which includes a photoelectric sensor that monitors packaging at the merging area of ​​the feed conveyor (all along the collector conveyor, sorter conveyor, and sorter) to identify low-density areas and control the activation and speed of the selected conveyor to increase or decrease the density of goods in a given area of ​​the conveyor.

[0028] The purpose of this invention is to provide a range-sensing conveyor belt packaging management system that uses algorithms and software in a computer for digital data analysis based on information from each photoelectric eye monitoring the conveyor belt, calculating the open or unused area on the conveyor belt by comparing the area covered by packaging on the conveyor belt with the open area.

[0029] The purpose of this invention is to provide a range-sensing conveyor belt packaging management system, wherein a photoelectric sensor is connected to a computer interface, the computer compiles data from the photoelectric sensor, and outputs speed signals of the selected feeder and collector conveyor belts in the system, so as to fill or separate the area on the collector conveyor belt with packages to achieve a selected density in a specific area.

[0030] The range sensing conveyor packaging management system determines the percentage of surface area of ​​collector conveyors, sorter conveyors, and other conveyors covered by packaging, parcels, bags, envelopes, boxes, or other items.

[0031] The range sensing conveyor belt packaging management system counts and identifies the quantity of goods contained on the conveyor belt.

[0032] Range sensing conveyor belt packaging management systems can locate packaging and identify packages, parcels, or other goods on conveyor belts based on their digital images or occupancy area.

[0033] The range sensing conveyor belt packaging management system regulates the speed of the conveyor belts in the system, where photoelectric sensors or other detection components are placed at each feed source of the conveyor belt, thereby allowing control of the speed of each feed conveyor belt as well as the speed of the collector conveyor belt to maximize the flow of packages through the system.

[0034] The range-sensing conveyor packaging management system pushes packages to one side of the collector conveyor via friction, skew rollers, belts, or inclined planes, and causes subsequent feeder conveyors to add packages to the open area next to those packages already on the collector conveyor.

[0035] The range sensing conveyor belt packaging management system identifies the number of objects, the average size of the objects, and the area utilization rate of the conveyor belt.

[0036] A system based on a range-sensing photoelectric eye array can be used to regulate the input flow to a conveyor belt system, wherein photoelectric eyes are placed at each input flow source, thereby allowing control over each input in terms of the maximum permissible input flow to the system.

[0037] The system based on range-sensing photoelectric eyes can identify the number of objects, the average size of the objects, and the area utilization rate of the conveyor belt.

[0038] The range sensing system can determine the fullness of the accumulation area of ​​the conveyor belt system, and more specifically, the fullness of the package sorting machine.

[0039] Virtual or physical encoders are used to generate pulses to trigger the capture of distance values.

[0040] A flow management system based on a range-sensing photoelectric eye array may include photoelectric eyes, a computer processor, and an interface for defining and controlling the conveyor belt control system and integrating with it via Ethernet, Wi-Fi, Bluetooth, and other smart electronic devices (such as telephones, tablets, laptops, and other vision-assisted computer-based devices capable of communicating with the computer system).

[0041] Different sensing and detection methods can be used to determine the parcel flow density on selected sections of the feed and receive conveyors in 1D linear, 2D area, or 3D volume, and adjust the conveyor speed ratio proportionally to the ratio of desired density to current density to increase the density or volume of parcels in the selected area of ​​the receive conveyor.

[0042] This range sensing system can be used in conjunction with a method for managing bulk parcel flow based on photoelectric sensors, the method comprising or consisting of the following steps: selecting a transition zone between a feed conveyor and a receiving conveyor, each having an independent drive motor; selecting the photoelectric sensor field of view for the selected transition zone; assigning an IP address to each photoelectric sensor; setting the online feed conveyor speed to achieve a desired conveyor belt area utilization rate on the downstream receiving conveyor, where V is the rate (conveyor belt speed), DO is the desired occupancy rate, RCO is the receiving conveyor belt occupancy rate, and FCO is the feed conveyor belt occupancy rate, wherein the occupancy rate includes conveyor belt area, conveyor belt volume, or conveyor belt density; selecting a percentage of the photoelectric sensor field of view; selecting a percentage of the feed conveyor belt occupancy rate definition zone; and selecting a percentage of the receiving conveyor belt occupancy rate definition zone. Select the desired percentage of occupancy after merging; feed the package to the receiving conveyor belt occupancy definition area; transport the package to the selected location in the desired occupancy area; and merge the package at the transition section between the feeding and receiving conveyors.

[0043] Apparatus and methods for conveying packages and controlling the speed and direction of packages on a conveyor belt are disclosed in the applicant's U.S. Patents 10,427,884 and 10,773,897, which are incorporated herein by reference. While the applicant's prior patents describe a visual density management system based on a shooting device, the present invention provides an alternative to the shooting device: measuring package density and position based on a range-sensing photoelectric eye.

[0044] Other objects, features, and advantages of the invention will become apparent from the following detailed description taken in conjunction with the accompanying drawings. Attached Figure Description

[0045] The invention will be better understood by referring to the following description taken in conjunction with the accompanying drawings, in which similar numerals refer to similar parts throughout the views. Figure 1 It is a top view of the conveyor belt surface, in which relative range sensing photoelectric eyes are installed at selected intervals on both sides of the conveyor belt section near the exit end, thereby creating a table of sensing or detection range; Figure 2 A density measurement method is illustrated using range-sensing photoelectric eyes to output actual simulated distances. This method utilizes a sensor with simulated outputs, where the true distance from the edge of the strip to the sensed package is known, and distance-sensing photoelectric eyes on both sides of the strip are used to eliminate the influence of the package being centered to one side; and Figure 3 The architecture of an area-sensing photoelectric eye based on an I / O link is shown; Figure 4 The diagram shows a section of conveyor belt on which various packages of different shapes and sizes are passing through multiple encoder pulse positions, with the right photoeye (PER) positioned opposite the left photoeye (PEL), and the conveyor belt being 60 inches wide and 120 inches long, broken down into 2-inch interval measurements, as shown in the array. Figure 5 It is a 2D series conveyor belt system, showing a feed conveyor belt and a receiving conveyor belt, wherein the roller or belt conveyor belt uses an independent motor to transport, arrange and separate packages, and the conveyor belt area utilization and package counting principle can be controlled to effectively feed to the receiving conveyor belt using a system with a range sensing photoelectric eye positioned at the flow inlet point of the selected conveyor belt. Figure 6 This is a 2D feeder and collector conveyor belt application, showing the combination of a side-transfer feeder conveyor belt and a cross collector conveyor belt, wherein the speed of the conveyor belt is set based on a cross-range sensing photoelectric eye system according to the receiving conveyor belt occupancy rate to achieve the desired conveyor belt area utilization on the downstream portion of the collector conveyor belt. Figure 7 This is a perspective view of the range-sensing conveyor belt packaging management system of the present invention, showing the field of view of the range-sensing photoelectric eye of the bulk parcel flow management system, wherein the online conveyor belt speed is set to achieve a desired conveyor belt area utilization on the downstream conveyor belt including the sorter. Figure 8This is a schematic diagram illustrating a range-sensing density flow management system applied to a bulk feeding system from a trailer terminal to a sorting machine. The system includes a control system that adjusts multiple individual inputs based on conveyor belt fullness and sorter fullness at various locations, wherein the conveyor belt speed is adjusted as a function of sorter fullness and input occupancy. Figure 9 It is a top view showing the package flow management system, which senses the unloading of the feed conveyor from the trailer through the sorter and includes a camera with a recirculation loop. Figure 10 The feed conveyor belt and the collector conveyor belt are shown to be combined, including modular sections at the intersection of each conveyor belt and photoelectric eye range sensing arrays; Figure 11 This is a top view of the conveyor belt assembly, showing the package moving forward on a feed conveyor parallel to the collector conveyor belt; Figure 12 yes Figure 11 A top view showing the package moving forward on a feeder conveyor parallel to the collector conveyor, wherein sections of the collector conveyor are controlled to allow space to receive items conveyed by the feeder conveyor. Figure 13 yes Figure 11 A top view showing the package moving forward on a feeder conveyor parallel to the collector conveyor, wherein the items conveyed by the feeder conveyor are set into the receiving section of the collector conveyor. Figure 14 yes Figure 11 A top view showing the package moving forward on a feeder conveyor parallel to the collector conveyor, wherein the items conveyed by the feeder conveyor are fed to a position before the multiple items conveyed on the collector conveyor. Figure 15 yes Figure 11 A top view showing multiple packages moving forward on a collector conveyor belt, where angled feed conveyors and side feed conveyors are controlled to insert packages into blank areas of the collector conveyor belt; Figure 16a This is a top view of two end-to-end conveyors running at different speeds, showing low-density wrapping before and after the application of speed control on the feed conveyors. Figure 16b This is a top view of two end-to-end conveyors running at different speeds, showing low-density wrapping before and after the application of speed control on the feed conveyors. Figure 17 A distance sensor is shown for measuring the flow density of packages being transferred between a feed conveyor and a receiving conveyor. Figure 18An example of a binary start-stop control for a docking and merging conveyor system is shown, wherein the feed conveyor belt will be stopped to prevent blockage caused by packages from a second feed conveyor belt receiving the conveyor belt at a right-angle docking collector; and Figure 19 An example of docking and merging conveyors is shown, which combine and track bulk flow transport from different conveyors operating at different speeds.

[0046] Figure 20 An example of a docking and merging conveyor belt is shown, which combines and tracks the bulk flow from transverse conveyors operating at different speeds. Detailed Implementation

[0047] According to the present invention, a range-sensing parcel flow management system is provided, which uses different sensing and detection methods to determine the parcel flow density on selected sections of a feed conveyor belt and a receiving conveyor belt in 1D linear, 2D area, or 3D volume, and adjusts the conveyor belt speed ratio proportionally to the ratio of desired density to current density to increase the density or volume of parcels in the selected area of ​​the receiving conveyor belt.

[0048] The terminology used herein is for the purpose of describing particular example embodiments only and is not intended to be limiting. As used herein, the singular forms “a” (a, an) and “described” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” and “having” are inclusive and therefore specify the presence of the stated features, integers, steps, operations, elements, and / or components, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring them to be performed in the particular order discussed or illustrated, unless specifically identified as such. It should also be understood that additional or alternative steps may be employed.

[0049] When an element or layer is referred to as being “joined to,” “connected to,” or “coupled to” another element or layer, or being “on” another element or layer, it may be directly joined to, connected to, or coupled to said other element or layer, or an intermediate element or layer may be present. In contrast, when an element is referred to as being “directly joined to,” “directly connected to,” “directly coupled to,” or directly “on” another element or layer, no intermediate element or layer may be present. Other terms used to describe relationships between elements should be interpreted in a similar manner (e.g., “between” vs. “directly between,” “adjacent” vs. “directly adjacent,” etc.). As used herein, the term “and / or” includes any and all combinations relating to one or more of the listed items.

[0050] While the terms first, second, third, etc., may be used herein to describe various elements, components, regions, layers, and / or segments, these elements, components, regions, layers, and / or segments should not be limited by these terms. These terms may only be used to distinguish one element, component, region, layer, or segment from another. Terms such as “first,” “second,” and other numerical terms used herein do not imply a sequence or order unless explicitly indicated by the context. Therefore, without departing from the teachings of the exemplary embodiments, the first element, component, region, layer, or segment discussed below may be referred to as a second element, component, region, layer, or segment.

[0051] Spatial relative terms such as “inner,” “outer,” “below,” “below,” “down,” “above,” and “above,” and similar terms, are used herein for ease of description to describe the relationship between one element or feature and another element(s) or feature(s), as illustrated in the figures. Spatial relative terms may be intended to include different orientations of the device in use or operation, in addition to those depicted in the figures. For example, if the device in the figures is flipped, an element described as “below” or “below” to other elements or features would be oriented “above” to other elements or features. Thus, the example term “below” can encompass both above and below orientations. Devices can be oriented in different ways (rotated 90 degrees or otherwise), and the spatial relative descriptors used herein are interpreted accordingly.

[0052] As used herein, the term “approximately” can be reasonably understood by those skilled in the art to mean slightly higher or lower than the stated value within a range of ±10%.

[0053] As used in this article, the terms “parcel flow density adjustment” and “package flow density adjustment” are equivalent.

[0054] As used in this article, the term "parcels and articles" is a sororous concept and includes items, envelopes, mail, packaging, bags, barrels, boxes, or irregularly shaped goods or containers being delivered.

[0055] As used herein, the term “range sensing” includes one or more imaging devices, including photoelectric eyes, imaging devices, video photoelectric eyes, scanners, lasers, selected light transmission frequency or wavelength or radiation detection devices, or other pixel detection and / or digital imaging devices (collectively referred to as photoelectric eyes).

[0056] The invention will now be described more fully with reference to the accompanying drawings, in which preferred embodiments of the invention are illustrated. However, the invention can be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will be thorough and comprehensive, and will fully convey the scope of the invention to those skilled in the art. Similar numerals denote similar elements throughout.

[0057] According to the present invention, a parcel flow management system based on a density-based range sensing detection system is provided, wherein the density-based range sensing detection system identifies strip area utilization and parcel count.

[0058] The package flow management system includes or comprises a density-based detection system that identifies conveyor belt surface area utilization and package counts. Detection system sensors are positioned at selected flow inlets across the conveyor belt. Control algorithms require the identification of individual goods and the rate at which each object passes through, as well as the conveyor belt surface area utilization, to increase conveyor belt area and control density. Average package size can also be considered. The package management system can also identify, locate, or track packages, parcels, or other goods on the conveyor belt based on its measurements and selected locations within the conveyor belt.

[0059] According to the present invention, a density-based detection system conveyor belt packaging management system is provided, comprising a programmable logic controller or computer, sensors for detecting packages or parcels, a collector "receiver" conveyor belt, or being substantially composed of the present invention, said conveyor belt comprising separate sections of conveyor belt individually driven by separate motors having separate speed controllers. Selected sections of the collector conveyor belt have components, such as low-friction conveying surfaces like skew rollers, or high-friction conveying surfaces capable of pushing packages to selected sides of the collector conveyor belt. Multiple feeder conveyor belts comprise separate sections of conveyor belt individually driven by separate motors having separate speed controllers. Range detection sensors measure the area, volume, or density of goods on the conveyor belt surface leading to each merged area of ​​the feeder conveyor belt and the collector conveyor belt. The speeds of the feed conveyors and collector conveyors leading to each merging area in the collector conveyor system are measured, and the control program within the PLC or computer can control the speeds of the collector conveyor sections and feed conveyor sections based on a comparison of the calculated amount of free space on a given collector section with the occupancy area of ​​the packages on the incoming feed conveyor. The sorting conveyor can be integrated into the conveyor system and fed by the collector conveyors.

[0060] A typical feeder conveyor or collector "receiver" conveyor comprises one or more individual sections of a conveyor belt, each driven individually by a motor with a separate speed controller. Selected sections of the collector conveyor belt may have: low-friction conveying surfaces, such as skew rollers, arranged in a configuration capable of pushing packages onto a selected side of the receiving collector conveyor belt; and / or include higher-friction conveying surfaces, such as belts. Multiple feeder conveying surfaces may comprise individual sections of a conveyor belt, each driven individually by a motor with a separate speed controller.

[0061] The detection range device monitors the area of ​​the feed conveyor leading to each merging area with the collector conveyor in the feed conveyor belt. The bulk parcel flow management system includes a programmable logic controller (PLC) or computer as a control program within the computer or PLC capable of controlling the speed "rate" of the feed and / or collector "receiving" conveyor belt or sections of the collector "receiving" conveyor belt and / or sections of the feed conveyor belt based on a calculated amount of free space thereon. A given collector section is compared to the occupancy area of ​​the parcels on the incoming feed conveyor belt. Calculations performed by photoelectric eyes and a virtual encoder create pulses at selected intervals to create an array to determine the measured occupancy rate as a percentage of the fullness of the parcels on the feed conveyor belt and / or collector "receiving" conveyor belt.

[0062] For example, the current recommended requirement for a controlled conveyor belt with selected area and speed is 7500 packages per hour within 10 minutes, with two (one-minute) slices at 8250 packages per hour (7500 / 12150 = 0.62 = 62% efficiency within a 10-minute test). This invention provides a component for controlling the area utilization of the available conveyor belt surface to achieve a maximum efficiency of 75% for the same conveyor belt, equivalent to 9375 packages per hour. Furthermore, for a conveyor belt in a range-sensing conveyor packaging management system with area utilization according to the invention, a 15% increase results in an increase of 8625 packages per hour.

[0063] Range detection devices are positioned at selected input points and communicate wired or wirelessly with a programmable logic controller (PLC) or computer, which includes process control algorithms, to identify the incoming flow density based on belt utilization and throughput rate. These measures can be used to make adjustments to reduce package input flow and, if the flow is too sparse or too dense, may require stopping the feed line. Similarly, a lack of flow may be identified, prompting an increase in the speed of one or more selected input conveyors.

[0064] The detection device can be positioned to examine the selector surface, and is used in a similar manner to assess buffer capacity utilization primarily based on area coverage identification. This feedback is used to dynamically adapt to the feeder behavior. The use of a range detection photoelectric eye array provides additional benefits in terms of system control room visibility and logging. Variations in parameters used to tune the system can be evaluated more effectively. Blockages and other system problems are better identified.

[0065] Multiple range-sensing photoelectric detection devices communicating with a computer-based conveyor belt packaging management system include the quantity and size of packages in a given area of ​​one or more feeder conveyors or collector conveyors in the packaging handling system. Data is collected and analyzed to measure the available area or space on the conveyor belt and the density of packages thereon to maximize the desired density of packages on one or more selected conveyor belts. The number of feeder conveyors providing the packages and the speed of each conveyor belt are controlled as a function of occupancy on the collector or immediately before the collector. The computer feeds the package density information from the conveyor belt surface to a conveyor belt speed controller to introduce packages from one or more feeder conveyors to the collector conveyor, wherein the area, volume, or density of packages across the conveyor belt surface is detected, and the speed of the selected conveyor belt is controlled to arrange the packages at optimal spacing and to fill the conveyor belt area most efficiently, thereby maximizing the density of packages on the conveyor belt and the system throughput, and correspondingly minimizing the number of conveyor belts required by the system. When the computer determines that there is enough space on one of the conveyor belts (e.g., the collector belt), the computer instructs the controller to add packaging or speed up the conveyor belt, so that the feeder belt adds packaging to the space or empty area on the collector belt.

[0066] The algorithm is used to calculate the "measured occupancy rate," which is a percentage of the belt coverage represented by the sensed distance. Once the "measured occupancy rate" of the conveyor belt is calculated, it is compared with the "desired occupancy rate" of the conveyor belt surface area to determine the speed ratio of the downstream conveyor belt. The "speed ratio" is the desired occupancy rate divided by the measured occupancy rate, and the commanded conveyor belt speed is determined by the following formula, where (FPM) is measured in feet per minute: (Current conveyor belt speed (FPM) = Downstream speed (FPM) * Speed ​​ratio * Power factor).

[0067] The range-sensing conveyor belt packaging management system for measuring and controlling the density of packages on the conveyor belt of the present invention uses different sensing and detection methods to determine the package flow density on selected sections of the feed and receive conveyor belts in 1D linear, 2D area, or 3D volume, and adjusts the conveyor belt speed ratio proportionally to the ratio of desired density to current density to increase the density or volume of packages in the selected area of ​​the feed or receive conveyor belt.

[0068] The 2D discrete distance measurement method uses SICK WTT190L photoeyes to create a table of sensing ranges. Each photoeye has two outputs, each independently adjustable, to obtain two unique ranges. The photoeyes are mounted on either side of the conveyor belt segment at a selected distance of approximately five (5) feet from the exit end of the conveyor belt, as shown below. Figure 1 As shown in the diagram. Optionally, multiple photoelectric eyes can be installed in groups or arrays.

[0069] like Figure 1 As shown, a first side 361 of the conveyor belt, having a width of 61 inches, includes a photoelectric sensor 351 that measures a range across the conveyor belt up to 13 inches, and a relative photoelectric sensor 362 on the opposite second side of the conveyor belt measures a distance of up to 48 inches. A photoelectric sensor 353 on the first side of the conveyor belt measures a range across the conveyor belt up to 25 inches, and a relative photoelectric sensor 364 on the opposite second side of the conveyor belt measures a distance of up to 36 inches. A photoelectric sensor 355 on the first side of the conveyor belt measures a range across the conveyor belt up to 37 inches, and a relative photoelectric sensor 366 on the opposite second side of the conveyor belt measures a distance of up to 24 inches. A photoelectric sensor 357 on the first side of the conveyor belt measures a range across the conveyor belt up to 49 inches, and a relative photoelectric sensor 358 on the opposite second side of the conveyor belt measures a distance of up to 12 inches.

[0070] The virtual encoder is programmed to generate pulses at selected intervals (e.g., two-inch intervals for belt movement). An array is created to represent the last five feet of the feed conveyor section plus an additional five feet, or 120 inches, on the receiving collector conveyor or downstream conveyor section. Each element of the array represents a two-inch section or a pulse from the virtual encoder, with a total of 60 array elements at the conveyor transition.

[0071] The "Measurement Occupancy" value is loaded into the current array element, depending on the combination of photoeye outputs that are blocked when the encoder pulse occurs. "Measurement Occupancy" is a percentage of fullness, with 0 indicating an empty belt or no blocked photoeyes, and 100 indicating all photoeyes are blocked. Photoeyes are re-evaluated with each encoder pulse, and the results are loaded into the current array position. The overall measurement occupancy for a 10-foot section of the conveyor belt (5 feet at the exit of the current belt and 5 feet at the entrance of the downstream belt) is determined by summing all values ​​in the array and then dividing by the total number of array elements.

[0072] The table below describes how a combination of blocked photocells generates the correct measurement occupancy for loading into the array: Table I As shown in Table I, the first left photoeye state is parsed first. Then, the second right photoeye state is parsed to generate the percentage of fullness when encoder pulses are generated, as represented by the values ​​in the graph. Once the correct combination has been found, the algorithm ends, and the generated values ​​are then placed in the current array element. The algorithm stores the last 60 values, adds them all together, and then divides by the total number of array elements to obtain the average measured occupancy, expressed as a percentage ranging from 0 to 100. Note that "Not Applicable" in the above graph means that the condition cannot exist for the photoeye range adjusted as shown in the figure.

[0073] Once the measured occupancy rate of the belt is calculated, it is compared with the belt's "desired occupancy rate," which is then used to determine the downstream belt speed ratio. The "desired occupancy rate" is a configurable parameter. It is expected to be in the range of 30% to 40%, but the final value must be determined on-site. The speed ratio is the desired occupancy rate divided by the measured occupancy rate. Therefore, if the desired occupancy rate is 30% and the measured occupancy rate is found to be 70%, the speed ratio is 30 / 70, or 0.429. The command belt speed is then determined using the following formula: Current belt speed (FPM) = downstream speed (FPM) * speed ratio * power factor.

[0074] Using I / O-based analog distance sensing range The following density measurement method example uses a BALLUFF BOD0020 photoelectric sensor that outputs the actual simulated distance. By using a sensor with an analog output, the true distance from the edge of the strip to the sensed package is known. Distance sensing photoelectric sensors are still needed on both sides of the strip to eliminate the influence of the package being aligned to one side. The sensing distance is set as follows... Figure 2 The maximum number of conveyor belt widths shown is given, where LPE1 is specified as 364 and RPE1 is specified as 363.

[0075] The virtual encoder was programmed to generate pulses at two-inch intervals for each conveyor belt segment. Arrays were created to represent the last five feet of a conveyor belt segment plus an additional five feet, or 120 inches, on the downstream conveyor belt segment. Each element of the array represents a two-inch interval or a pulse from the virtual encoder, and the total number of array elements at the conveyor belt transitions is sixty (60) array elements.

[0076] An algorithm for calculating the "measured occupancy rate" is used and compared to the belt's "desired occupancy rate," which is then used to determine the downstream belt's speed ratio. Sensing distance represents the percentage of belt or "conveyor belt surface area" covered. A package detected at 60 inches will yield a percentage close to 0%, while a package detected at 1 or 2 inches will yield a percentage close to 100%. To obtain the "measured occupancy rate," a combination of distances sensed by the two photoeyes must be used to generate the accurate occupancy rate across the belt. This value is calculated per virtual encoder pulse and placed in the overall measured occupancy rate array. The photoeyes are re-evaluated at each encoder pulse, and the results are loaded into the current array position. The overall measured occupancy rate for a 10-foot section of the conveyor belt (5 feet at the exit of the current belt and 5 feet at the entrance of the downstream belt) is determined by summing all the values ​​in the array and then dividing by the total number of array elements.

[0077] Once the measured occupancy rate of the belt is calculated, it is compared to the belt's "desired occupancy rate," which is then used to determine the downstream belt speed ratio. The "desired occupancy rate" is a configurable parameter. It is expected to be in the range of 30% to 40%, but the final value must be determined on-site. The speed ratio is the desired occupancy rate divided by the measured occupancy rate. Therefore, if the desired occupancy rate is 30% and the measured occupancy rate is found to be 70%, the speed ratio is 30 / 70, or 0.429. The commanded belt speed is then determined using the following formula: (Current belt speed (FPM) = Downstream speed (FPM) * Speed ​​ratio * Power factor).

[0078] As mentioned earlier, the power factor can be used as a configurable parameter in the above formula, and can set the degree of aggressiveness of the current band speed for larger corrections. A higher power factor means more aggressive correction. For a two-dimensional area "2D", the power factor can be set to 1.

[0079] For example, a sensing method for determining the flow density in a linear region "1D" or a two-dimensional region "2D" or a volume definition "3D" is determined, and the conveyor belt speed ratio is adjusted proportionally to the ratio of the desired density to the current density.

[0080] The analog signal obtained from the photoelectric eye is an I / O link; therefore, the main PLC obtains distance information from the photoelectric eye via Ethernet. The 2D architecture based on the I / O link... Figure 3 As shown in the diagram, the IO link 365 device includes a left-range detection photoelectric sensor 366, a right-range detection photoelectric sensor 367, an optional smart lamp stack 368, an optional vibration detection sensor 369, and an optional thermal detection sensor 370. Other sensors known in the art may also be linked.

[0081] The IO link master has the following features that can be used in 2D applications: The I / O link master is a field-installed device. Sensors are directly plugged into the unit via a standard 5-pin European connector. It connects back to the PLC via Ethernet. It allows for the insertion of other I / O link input devices such as temperature and vibration sensors. It also allows for the insertion of I / O link output devices like the smart lights shown above. The smart lights can be configured with multiple colors, multiple flashes, or static configurations. The sensors have diagnostic capabilities via the I / O link to the PLC, allowing dirty photocells to be reported on the HMI (and on the smart lights). Configuration parameters for setting devices (such as range and output units) are stored in the PLC, so device replacement does not require setup once the device has been replaced.

[0082] like Figure 4 As shown, a distance sensor measures the flow density of packages being transported between the feed conveyor and the receiving conveyor as a form of numerical integration. The distance sensor is mounted on each side of the upstream receiving conveyor ahead of conveyor transition 732, and distance values ​​are recorded based on encoder input at a defined resolution (e.g., 2 inches) at a selected belt interval during belt travel. These values ​​are recorded in an array and used to determine the area utilization over a defined length of the feed conveyor. A virtual or physical encoder can be used to generate pulses to trigger the capture of the distance values. The size of the array can be selected according to how large and how the bulk handling conveyor will respond. For example, a typical range is between five and ten feet when the acceleration / deceleration rate is limited to 0.05G.

[0083] Figure 4 The conveyor belt segment shown includes various packages of different shapes and sizes passing through multiple encoder pulse positions 730, with the right photoeye (PER) positioned opposite the left photoeye (PEL). The conveyor belt is 60 inches wide, and the 120-inch length segment is broken down into 2-inch interval measurements, as listed in the array. More specifically, the conveyor belt 710, approximately 60 inches wide “W”, includes a 120-inch long measurement area “L”, which is broken down into 2-inch measurements or segments 712, each representing an encoder pulse position. The right photoeye (PER) 723 and the opposite left photoeye (PEL) 725 are attached directly above the surface of the conveyor belt to complete a loop of light, such as infrared light or other radiating components, extending between them for detecting items positioned between the opposing PEL and PER. The multiple packages or parcels placed in the measurement area L on the conveyor belt include a square box 713, a first small rectangular box 715, a second medium-sized rectangular box 717, a large rectangular box 719, a circle 720, and an internal space 721 representing measurement error (which is insignificant). The actual occupancy rate is determined by the following formula: Actual occupancy rate % (area occupied %) = SUM (incremental measurement width is 1-60) × 2 inches ×100% 60-inch W x 120-inch L The array shows the actual value determined for the area of ​​the items on the conveyor belt.

[0084] As shown in the array: If PEL < 60 and PER < 60, then the measured width = 60 - PER - PEL If PEL > 60 and PER > 60, then the measured width = 0. 2D series conveyor belt system in Figure 5 The diagram shows that the feed conveyor 733 and the receiving conveyor 734 include roller or belt conveyors that utilize independent motors to transport, arrange, and separate packages. The conveyor belt area utilization and package counting principles, utilizing a system with range-sensing photoelectric eyes positioned at the flow inlet point of the selected conveyor belt, can be controlled to efficiently feed the receiving conveyor. A conveyor belt transition section 732 is shown, where the conveyors merge. The feed conveyor moves at a rate (velocity) V1, and the receiving conveyor moves at a rate V2. The measured area (total 120 inches) includes the main portion (96 inches long) of the distal section 736 of the feed conveyor and the secondary portion (24 inches long) of the distal section of the receiving conveyor 737, according to the following formula: Ratio= speed in, DO% is the expected occupancy percentage (also known as conveyor belt area utilization rate). AO% is the actual occupancy percentage (also known as the conveyor belt area utilization rate). Dynamic control of docking and merging The packaging flow density adjustment system can be applied to docking and merging feeder lines, based on, for example... Figure 6 The velocity is calculated using the flow density near the merging region on the collector line shown. Figure 6 The illustration shows a side-feed conveyor belt transporting items, which intersect the flow through the collection conveyor belt at a 90-degree angle. Of course, the intersection angle is a matter of choice and can be any angle up to 90 degrees. This configuration is preferred for either a collector or a receiving conveyor belt. The flow rate from the feed conveyor belt will be limited based on the available area of ​​the receiving conveyor belt or collector.

[0085] A side-feed conveyor belt is shown, in which items are fed to a receiving or collecting conveyor belt, wherein the speed of the side-feed conveyor belt is controlled to achieve a desired conveyor belt area utilization on the receiving or collecting conveyor belt. The speed of the feeding conveyor belt, the receiving conveyor belt, or both the feeding and receiving conveyor belts is determined by a photoelectric array at a selected belt area measurement location, which includes a feeding conveyor belt occupancy definition area and a receiving / collecting conveyor belt occupancy definition area, wherein the combined desired occupancy area 19 has an increased density in the selected area after the items are combined.

[0086] like Figure 6 As shown, the 2D feeder and collector conveyor application illustrates the combination of a side-transmission feeder conveyor and a cross-collector conveyor, wherein the speed of the conveyor belt is set based on a range-sensing photoelectric eye system of the cross-section according to the occupancy rate of the receiving conveyor belt, in order to achieve the desired conveyor belt area utilization on the downstream portion of the collector conveyor belt.

[0087] The collector conveyor belt 734 travels at a rate of V2 and has a selected measurement area 753 of 120 inches (which can be adjusted based on the conveyor belt capacity, occupancy and speed).

[0088] Before the intersection of the feed conveyor belts 751, the collector or receiving conveyor belt 734 occupies 20% of the measurement area 753, which is 50% of the desired occupancy (40% full equals 50% of the target area utilization). The feed conveyor belt 751 travels at a rate (velocity) V1 and has a selected measurement area 752 of 60 inches. The distal portion of the feed conveyor belt is loaded to cover 50% of the measurement area 752. The speed or rate V1 of the feed conveyor belt can be calculated by formula, thereby expressing the desired occupancy (DO) and actual occupancy (AD) as follows: Ratio= speed in: DO% is the expected occupancy percentage (also known as conveyor belt area utilization rate). AO% is the actual occupancy percentage (also known as the conveyor belt area utilization rate). Example: The area of ​​the collector belt is nearly 20% occupied, and the target collector is 40% full or half of the target area utilization rate.

[0089] The load on the end of the feed (5ft for this case) conveyor belt is measured to cover 50% of the area.

[0090] speed A parcel flow management system is used to manage, track, and consolidate bulk flow, and includes or comprises a density-based detection system compatible with a conveyor system having multiple sections 10. These sections include multiple conveyor modules or sections with belts and / or conveyor rollers for transporting and separating items such as envelopes, mail, parcels, packages, bags, drums, boxes, or irregularly shaped goods. As shown, a linear parcel sorter 8 and a recirculating conveyor 14 communicate with the flow system. Multiple photoelectric eye arrays provide a field of view for selected occupancy-defined areas, such as transition areas 70 (measuring areas 15 and 17 or transition points for merging items from one conveyor belt 11 to another conveyor belt 13). Individual motors drive the conveyor modules or sections, thereby creating areas accessible to specific photoelectric eyes via assigned IP addresses.

[0091] At least a range-sensing photoelectric array, a photoelectric sensor, an imaging device, a video capture device, or other pixel detection and / or digital imaging device is positioned at each individual input point, where the control algorithm identifies the incoming flow density based on belt utilization and throughput rate. These measures can be used to make modifications to reduce package input flow, and if the flow is too dense, may require stopping the feed line. Similarly, a lack of flow may be identified, thus prompting an increase in the speed of the input conveyor belt.

[0092] As previously described, the method for detecting and measuring the density of packages on a selected segment of a conveyor surface includes the step of using, or comprising, a table of sensing ranges using multiple photoeyes, each photoeye having two outputs, and each output being individually adjustable to obtain two different ranges. Array 20 includes multiple photoeyes mounted at selected distances from the unloading end of the feed conveyor and the receiving end of the receiving conveyor on a first side and an opposing second side of the selected segment of the feed and receiving conveyors. Pulses are generated at selected intervals along the selected segment of the conveyor surface using a programmable virtual encoder. Array 20 is formed, including multiple array elements (photoeyes). Each array element represents a pulse from a virtual encoder of a selected length defining the selected distance. The average measurement occupancy rate of the array, representing the percentage of fullness of the receiving conveyor, is determined by using an algorithm determined by a programmable logic controller to determine the combination of photoeye outputs blocked when the encoder pulse occurs. The virtual encoder is programmable to generate pulses at selected intervals on the feed conveyor. Array 20 elements represent a pulse of a virtual encoder defining a selected length for a selected distance. A programmable logic controller has an algorithm for calculating the average measured occupancy rate of an array representing the percentage of fullness of a receiving conveyor belt. The measured occupancy rate of the feed conveyor belt is compared with the desired occupancy rate of the receiving conveyor belt. The speed ratio is calculated by dividing the desired occupancy rate by the measured occupancy rate. The speed V1 (rate 1) of the feed conveyor belt, the speed V2 (rate 2) of the receiving conveyor belt, or the speeds of both the feed and receiving conveyors are adjusted to obtain the desired occupancy rate or spacing of packages on the receiving conveyor belt.

[0093] Photoelectric eyes positioned to view the selector surface are used in a similar manner, primarily based on area coverage recognition, to assess buffer capacity utilization. This feedback is used to dynamically adapt to the behavior of the feed line. The use of range-detection photoelectric eye arrays provides additional benefits in terms of system control room visibility. Variations in parameters used to tune the system can be evaluated more effectively. Blockages and other system problems are better identified.

[0094] In such Figure 7In a preferred embodiment shown, the range-sensing photoelectric array and computer-based conveyor packaging management system include a range-sensing photoelectric array that monitors the quantity and size of packages present on feed conveyors 11, 13, 135, and 35, a collector conveyor 14, a sorter conveyor 8, and / or a sorting conveyor in the recycle packaging disposal system. The photoelectric data is used to measure the available area, space, or volume on the conveyor belts to maintain a desired density of packages on one or more selected conveyor belts. The conveyor belt speed is controlled as a function of occupancy on the collector or just before the target conveyor, such as the sorter. The computer feeds information to the conveyor belt speed controller to introduce packages from transport 33 to one or more feed conveyors 44, 46, 47, 48, 50, and then to the collection conveyor 12, as shown. Figure 8 As shown, packages are detected by one or more photoelectric eye arrays 25, 26, 27, 28, 29, and the speed of the selected conveyor belt and / or the rate of the packages or items are controlled to arrange the packages at an optimal spacing that maximizes the density or volume of packages on a given conveyor belt area and the system throughput while minimizing the number of conveyor belts required by the system. When the computer determines that there is sufficient space on one of the conveyor belts (e.g., the collector belt), the computer instructs the controller to add one or more packages by having the feed belt add one or more packages to the space or empty area on the collector belt.

[0095] A line-scanning photoeye with a single row of pixel sensors can be used in this invention. Rows are continuously fed to a programmable controller, a programmable logic controller (PLC), or a computer that combines them to create an image. Multi-row sensors can be used to create color images or to increase sensitivity through TDI (Time Delay and Integration). Maintaining consistent illumination over large 2D areas is traditionally quite difficult, and industrial applications typically require wide fields of view. The use of a line-scanning photoeye provides uniform illumination across the “row” currently being viewed by the photoeye. This makes it possible to obtain clear images of objects passing through the photoeye at high speeds and to use it as an industrial device for analyzing fast processes. A 3D photoeye system utilizing one or more photoeyes or other pixel detection and / or digital imaging devices can also be used to detect the height of packaging and determine volume density.

[0096] A density measurement system based on photoelectric sensors identifies and maximizes the area utilization of the feed conveyor belt. An array of multiple photoelectric sensors can be positioned at selected points on the feed conveyor belt and at the receiving end of the receiving conveyor belt. A computer with control algorithms identifies each item, its area, the area occupied by the item, the passing speed of each object, and the area utilization of the feed conveyor belt.

[0097] Range-sensing photoelectric sensors and computer-based conveyor belt packaging management systems monitor and control the speed of the feed conveyor belt based on the quantity and size of packages present on it. Information from receiving and collecting conveyors or sorting conveyors and / or picking conveyors in the packaging handling system can also be utilized, where photoelectric sensor data is used to measure the available area, space, or volume on the conveyor belt to maintain the desired density of packages on one or more selected conveyors. The conveyor belt speed is controlled as a function of occupancy on the collecting conveyor or just before the sliding sorting conveyor, picking conveyor, or receiving conveyor.

[0098] The range-sensing parcel flow management system includes or comprises a section 10 of a conveyor belt system, wherein multiple photoelectric eyes 20 detect parcels on a main or primary conveyor belt collector conveyor, which is combined with at least one feed conveyor belt 11 and a receiving conveyor belt 13. The receiving conveyor belt is used in conjunction with a selector 8, holding and releasing conveyor belts, accumulators, and / or stripping conveyor belts, typically downstream of the feed conveyor belt 11, and is shown linearly aligned with the selector 8. The conveyor belts utilize mixing / or belts, and each unit is powered by at least one independent motor to convey, arrange, and separate parcels at a selected rate or speed based on the desired occupancy of one or more selected conveyor belts. Therefore, occupancy can be controlled independently of adjacent upstream or downstream conveyor belts for each conveyor belt, and multiple conveyor belts in the conveying system can be started, stopped, or their speed increased or decreased to increase the area of ​​occupancy for a particular conveyor belt. The conveyor belt system section utilizes an independent motor to drive the conveyor belt area.

[0099] Conveyor system segment 10 includes at least one feed conveyor belt 11 and a downstream receiving conveyor belt 13. The selected online feed conveyor belt speed is set to achieve the desired conveyor belt area utilization on the selected downstream receiving conveyor belt 13. As the package is conveyed from the selected location after the transition segment, area, or point 70 where the feed conveyor belt 11 and the receiving conveyor belt 13 merge toward the concentrated desired occupancy area 19, the photoelectric eye 20 is used to present the field of view of the feed conveyor belt occupancy area 15 established by a given rate V2 of the package being fed to the receiving conveyor belt occupancy definition area 17.

[0100] The range-sensing photoelectric eye array parcel flow management system is applicable to bulk feeding systems, from the point where items are unloaded from the trailer to the sensing conveyor belt and all the way to the separation and sorting process. For example... Figure 8As shown, items unloaded from truck 33 are unloaded from any one of multiple unloading sensor conveyors 44, 46, 47, 48, and 50, whereby the speed of conveyors 44, 46, 47, 48, and 50, as well as the collection conveyor 12, is regulated by photoelectric eyes 26, 27, 28, and 29 to provide photoelectric eye fields of view at the merging or corresponding transition points 73, 74, 75, 76, and 77 of the sensor-feed conveyors 44, 46, 47, 48, and 50 and the collection conveyor 12. The collection conveyor 12 may be dedicated to unloading the sensor conveyors or to flow from other sources such as the recycling conveyor 14, due to a full output channel from the sorting area. The sensor-feed conveyors 44, 46, 47, 48, and 50 are regulated as a function of the speed of the collection conveyor 12 and the percentage of items occupancy on the collection conveyor 12. An accumulation conveyor belt or accumulator 35 may be positioned upstream of the sorter 8 and downstream of the collector conveyor belt 12, and serves as a receiving conveyor belt. The movement of the feed and / or collector conveyor belts may be adjusted as a function of the accumulator conveyor belt 35 immediately preceding the sorter, and based on the area of ​​the conveyor belt occupied by the packages, to provide a smooth feed to the sorter 8. The downstream sorter 8 includes: an array of sorter photoelectric eyes 32 providing a field of view 319 for items on the sorter 8; and a photoelectric eye array 41 providing a field of view 329 for items merged at the transition point 78 of the sorter 8 fed from the adjacent accumulator conveyor belt 35.

[0101] A computer or microprocessor control system 500 controls a bulk parcel flow management system based on a range-sensing photoelectric eye array, adjusting multiple individual inputs based on the selector fill level. The conveyor belt speeds of the feed conveyor 11, sensing conveyor belts 44, 46, 47, 48 and 50, collector conveyor 12, recycling conveyor 14, selector 8 and accumulator 35 can be controlled and adjusted as a function of selector fill level and input percentage occupancy.

[0102] The range-sensing photoelectric eye array includes at least one pair of opposing intelligent photoelectric eye modules 20, which are capable of processing range-sensing data and determining the distance of the conveyor belt across a defined area. The optimal conveyor belt speed can be adjusted for each photoelectric eye by zooming in or out or by selecting a specific array or area on a smart device. The intelligent photoelectric eye modules process the range-sensing data and determine the occupancy percentage within the defined area. Each photoelectric eye array 20 is assigned a photoelectric eye IP address. For example, the photoelectric eye can be programmed or configured to allow a simple "right-click" to define its IP address. An Ethernet system provides components for transmitting signals to a computer via a command PC, PLDC, or VLC control system for calculating the percentage of occupancy information and the desired conveyor belt speed. The interface is implemented via smartphones, tablets, laptops, smartwatches, standalone terminals, and / or networks. Configuration software provides a convenient interface for configuring control areas and inputting control parameters. Individual photoelectric eye IP addresses are assigned to each photoelectric eye in the range-sensing photoelectric eye array system.

[0103] The bulk parcel flow management system includes a component that opens a configuration window to define "monitoring" parameters and defines the occupancy rate at any time for any range of photoelectric sensor arrays, defining the area to be measured.

[0104] The control algorithm requires the identification of individual goods and the rate at which each object passes through, as well as the area utilization of the collection conveyor belt. It can also consider average item size and shape. Photoelectric arrays and computer-based conveyor packaging management systems monitor the quantity and size of packages present on feed conveyors, collection conveyors, sorting conveyors, and sorting conveyors within the packaging handling system. Photoelectric data is used to measure the available area or space on the conveyor belts to maintain the desired density of packages on one or more selected conveyor belts. It is even possible to track and / or trace individual items based on their tags, codes, or physical characteristics, from receiving items from self-unloading trucks and unloading docks to the point of distribution vehicles.

[0105] like Figure 9As shown, packages are unloaded from the cargo carrier onto selected sensor-feed conveyor belts 44, 46, 47, 48, and 50, which communicate flow with a collector conveyor belt 12, which is composed of modular units of sections of conveyor belts 120-134. For example, sensor-feed conveyor belt 50 intersects with collector conveyor belt section 121 and feeds items onto it, sensor-feed conveyor belt 48 intersects with collector conveyor belt section 124 and feeds items onto it, sensor-feed conveyor belt 47 intersects with collector conveyor belt section 127 and feeds items onto it, feed conveyor belt 46 intersects with conveyor belt section 129 and feeds items onto it, and feed conveyor belt 44 intersects with collector conveyor belt section 132 and feeds items onto it.

[0106] The recycling (recirculating) conveyor belt 14 intersects with and feeds into the conveyor belt segment 134. The photoelectric eye array 20 can be installed at any intersection of the conveyor belts to control the density of the downstream conveyor belts.

[0107] according to Figure 10 The collection conveyor 12 begins at the first feed conveyor 50 and extends to the accumulator 35 and / or the selector 8, intersecting with a selected number of sensor feed conveyors 44, 46, 47, 48, and 50. The recycling conveyor 14 also feeds items to the accumulator 35 or other conveyors that intersect with the collection conveyor 12 preceding the selector conveyor 8. The sensor feed conveyors include a selected number of modules or sections. For example, sections 502, 504, 506, 508, 510, and 512 are sections of the sensor feed conveyor that include at least one transition point, wherein the selected sensor feed conveyor speed is set to achieve a desired conveyor area utilization on the selected downstream receiving conveyor 13. As the selected location, after being transported towards a concentrated desired occupancy area following the transition section region where the sensor feed conveyor belt and receiving conveyor belt 12 merge, is wrapped, photoelectric eye arrays 200, 210, 220, 230 and 240, 250 are used to present the field of view of the sensor feed conveyor belt occupancy area 15 established by a given rate V2 of packages being fed to the occupancy-defined area of ​​the receiving conveyor belt. Feed conveyor belts 44, 46, 47, 48 and 50 also include modules or conveyor belt sections with designated motors that operate individually to decrease or increase the density of items on the collection conveyor belt 12.

[0108] Each section of the conveyor belt or conveyor belt is driven by an independent variable-speed motor. This allows for the acceleration and deceleration of the individual sections of the conveyor belt 50, enabling packages to be separated or concentrated in a given area in a desired manner depending on the optimal flow rate, for processing by the aggregator 35 or the selector 8. For example, when a large gap is detected between two specific packages, the speed of the section of the conveyor belt between the packages is increased to close the gap between the packages.

[0109] A range-sensing photocell array determines the density of packages on the feed conveyor belt before they merge onto the collector belt 12 at their respective photocell array regions 200-250. Another photocell array 32 monitors region 319, which includes the selector conveyor belt 8. Photocells 260, 270, 280, 290, 300, and 320 monitor selected sections of conveyor belt 12 located before the region where the feed conveyor belt merges with the collector conveyor belt 12. An electrical control box 51 contains a video computer 500 that receives video input data from photocell arrays 200-250 and 32. The electrical control box 52 contains speed controllers for the motors of all conveyor belts 44-50. The computer is capable of counting individual packages and also calculating the package size "area" based on information from the various photocells monitoring the conveyor belts.

[0110] The sorting conveyor 8 receives randomly distributed packages and aligns them in a single row by relative movement of the conveyor belt. Examples of sorting conveyors are described in U.S. Patents 5,701,989 and 10,773,897, which are incorporated herein by reference in their entirety.

[0111] The sorting conveyor belt 8 receives packages and items, such as bags or envelopes, parcels, boxes, luggage, mail, or other goods, from the upstream conveyor belt 12. After the sorting conveyor belt 8, the individual packages are sorted and sent to the recycling conveyor belt 14. The recycling conveyor belt 14 returns packages that have been removed during the alignment process to the selected receiving conveyor belt, the collector conveyor belt 12, for re-sorting on the sorting machine. The primary objective of this invention is to ensure that the sorting conveyor belt 8 is kept fully supplied with a stable flow of packages without clogging the collector conveyor belt 12 due to sudden surges and intermittent slowdowns in packages received from the upstream feed conveyor belt.

[0112] The sorting conveyor system is capable of handling packages of random sizes. Preferably, the packages on the feed conveyor are in a single row; however, as the packages are unloaded from the truck onto the selected feed conveyors 44, 46, 47, 48, and 50, it is not uncommon for the packages to be irregularly separated and oriented in random directions. Unloading typically occurs in intermittent bursts, with a large number of packages being unloaded in short periods of time.

[0113] For example, photoelectric array 30 detects packages in occupancy areas conveyed to conveyor belt segments 122 and 123. If the packages in the area have a low density in the occupancy area 210 as monitored by photoelectric array 210, digital image data (pixels) is processed by the controller, and the computer controls the conveyor belt 48 to start, stop, slow down, or increase the feed rate of packages onto the collector conveyor belt segment 124.

[0114] As packages move downstream toward conveyor belt segment 35 through transition sections between conveyor belts and through subsequent occupancy areas of range-sensing photoeye arrays, they are monitored via photoeye arrays 260, 270, 280, 290, 300, and 310. A computer program analyzes the overall load on the conveyor belt segment on a pixel-by-pixel basis. Packages within specific occupancy areas are monitored by photoeyes, and a digital image of the package's occupancy area is confirmed by computer 500. The computer determines the maximum area of ​​the conveyor belt based on the feed rate and downstream load. The range-sensing photoeye array-based packaging management system utilizes the area of ​​the entire conveyor belt assembly to control the flow of packages to sorters, separators, scanners, or processing stations. The conveyor belt speed is controlled as a function of occupancy on the collector or just before the sorter. The computer feeds information to the conveyor belt speed controller to introduce packages from one or more feed conveyors to the collection conveyor, where the packages are detected by one or more photoeye arrays. The speed of the selected conveyor belt is controlled to arrange the packages at an optimal spacing that maximizes the density of packages on the conveyor belt and the throughput of the system while minimizing the number of conveyor belts required by the system.

[0115] As the density of the packages decreases in the transition area between the feed conveyor and the collector conveyor 12, gaps are formed between the packages, thereby causing an increase in the speed of the selected feed conveyor in order to maintain the desired flow rate of packages to the collector to maximize the throughput of the selector.

[0116] This control scheme prioritizes any selected conveyor belt. For example, a first feed conveyor belt may be prioritized at the beginning of the collector conveyor belt 12, where the collector conveyor belt 12 will tend to be empty or have a less dense load. Therefore, the packages on the first feed conveyor belt will typically have more free space. Selected sections of the collector conveyor belt 12 can be slowed down or even stopped to allow subsequent feed conveyors to unload, as may be desired. Furthermore, the collector conveyor belt 12 can be slowed down or stopped to push more packages from the feed conveyors to push additional items onto the collector conveyor belt 12, thus filling the area of ​​the collector conveyor belt.

[0117] The packaging flow management control system 5 maximizes the throughput of packages onto the sorting conveyor belt and into the sorting system by utilizing the maximum area on the collecting conveyor belt 12 or the aggregator preceding the sorting machine 8. The other conveyor belts in the conveyor system are controlled based on the maximum capacity of the sorting machine, determined at a constant speed rather than an average of rapidly increasing capacity. This increased efficiency allows the system to minimize the required number of conveyor belts and the area, width, and / or length of the conveyor belts in the system to achieve the desired throughput with maximum efficiency.

[0118] Computer 500 utilizes a multi-range sensor array of photoelectric eyes to monitor the occupancy rate of selected areas on the conveyor belts leading to the sorting machine or separation process. The computer compares the amount of free space on the selected conveyor belt with the size of the packages on the feed conveyor belt. If sufficient space exists, the feed conveyor belt will transport the packages. The amount of space required for a given package is determined by the programmer. For example, the program may require the amount of space on the collector conveyor belt to be 1.5 or even 2 times the occupied area of ​​a given package, depending on the orientation of adjacent items. The speed variation rate of the various conveyor belts is also controlled by the computer to ensure that the sorting machine conveyor belt is fully supplied. The computer sends speed control signals to the speed controllers of all conveyor belt sections to regulate the throughput of packages.

[0119] like Figure 11-14 As shown in the best illustration, the items on the feed conveyor belt intersect with the collector conveyor belt, illustrating in sequence how package 89 is inserted from feed conveyor belt 11 onto receiving / collecting conveyor belt 12, which contains multiple packages 81-88, thereby inserting package 89 into the gap 90 between other packages on the moving collector conveyor belt 12.

[0120] like Figure 15 As illustrated, multiple packages 91 are conveyed on a collector conveyor belt 12. An angled feed conveyor belt 92 and a vertical side feed conveyor belt 93, each carrying a package 89, intersect with the collector conveyor belt 12, whereby the speeds of both feed conveyor belts 92 and 93 are controlled to insert the packages 89 into the gaps formed between the pre-existing packages 91 on the collector conveyor belt 12.

[0121] The range sensing photoelectric eye array package flow management system includes multiple feed conveyors: a sensing feed conveyor that is in line with or at an angle of up to 90 degrees to the receiving conveyor, an optional recirculation conveyor 14, an optional aggregator, a sorting channel, and a sorting machine conveyor 8.

[0122] Adjusting the bulk parcel flow rate to the sorting machine provides higher continuous throughput and accuracy. This invention enables the application of density measurement equipment and conveyor speed control to conveyor systems to regulate the flow rate of bulk 2D (two-dimensional) bales to the sorter in a manner that provides higher continuous throughput with greater sorting accuracy. When the system is full, the collector conveyor acts as a dynamic buffer, compressing the flow density to fill the collector line to the desired target fullness. Loose and deficient areas of flow are pulled forward and compressed to the target fullness. Overfilled clumps or areas are thinned to reduce the likelihood of downstream blockage.

[0123] Typically, for a 50-foot belt length of incoming traffic to the sorter, the optimal bulk parcel flow rate supplied to the single sorter should not be less than 15% of the conveyor belt's area utilization and should not exceed 40% of the conveyor belt's area utilization. The actual required high, low, and average speeds should be determined based on the throughput limits of the conveyor system's average parcel size and the range of average flow density.

[0124] The flow density adjustment system determines the required speed ratio between conveyor belts to generate the target flow density after transmission to the downstream conveyor belt. When a bulk parcel flow is transported between two end-to-end conveyor belts operating at different speeds, the parcel flow density (conveyor belt area utilization or occupancy) before and after the transition will be proportional to the speed ratio between the conveyor belts, such as... Figure 16a and Figure 16b As shown. Figure 16a As shown, conveyor belt V1 has a 40% area utilization rate before transmission, and conveyor belt V2 has a 20% area utilization rate after transmission, and (V1 = 0.5 × V2). Figure 16b As shown, conveyor belt V1 has a 20% area utilization rate before transmission, and conveyor belt V2 has a 40% area utilization rate after transmission, and (V1 = 2 × V2).

[0125] Flow density adjustment systems can be applied to any number of series transitions, changing as a function of the variability of feed flow and system-level flow priority. For example, packaging flow density adjustment systems can be applied to areas where congestion and blockage are anticipated, such as 90-degree docking merging of applications including unloading dock collectors and main sorting collectors, or as... Figure 5 The collection line leading to the selector, as shown earlier.

[0126] In addition to feeding the selector, the packaging flow density adjustment system can also be used in particular for flow thinning before the conveyor belt docking and merging, so that a lower target can be included to ensure that the collector has enough space to merge the flow and avoid blockage.

[0127] After the merging zone, adjustments are made to provide a higher target density on the receiving conveyor belt. Therefore, the parcel flow is thinned before the merging zone, and as... Figure 17 The merged region shown in the image is then compressed / adjusted back to the target.

[0128] Binary start-stop control for docking and merging conveyor belts like Figure 18 As shown, the feeder and collector conveyor application illustrates the merging of a side-transfer feeder conveyor and a cross-collector "receiving" conveyor. The conveyor speed is set based on a range-sensing photoelectric eye system at the intersection according to the occupancy rate of the receiving conveyor, to achieve the desired conveyor area utilization on the downstream section of the collector conveyor. Even in the absence of a variable speed drive for the conveyor, a package flow density adjustment bulk flow array can be used to manage, track, and merge bulk flows by prioritizing the flow on the collector or receiving conveyor. When insufficient space is available on the collector or receiving conveyor to receive near-end flow of the feeder conveyor, the feed line can be stopped to avoid congestion.

[0129] The collector conveyor belt 734 travels at a rate (velocity) of V2 and has a selected measurement area 753 of 120 inches (the measurement area can be adjusted based on conveyor belt capacity, occupancy, and rate). Before the intersection with the feed conveyor belt 751, the collector or receiving conveyor belt 734 occupies 20% of the measurement area 753, which is 50% of the desired occupancy (40% full equals 50% of the target area utilization). The feed conveyor belt 751 travels at a rate (velocity) of V1 and has a selected measurement area 752 of 60 inches. The distal portion of the feed conveyor belt is loaded to cover 50% of the measurement area 752. The speed or rate V1 of the feed conveyor belt can be calculated by formulas, thereby expressing the desired occupancy (DO) and actual occupancy (AO) as follows: if Then stop feeding. if Then the feeding begins in: DO% is the expected occupancy percentage (also known as conveyor belt area utilization rate). AO% is the actual occupancy percentage (also known as the conveyor belt area utilization rate). like Figure 19As shown, the packaging flow density adjustment bulk flow array can be used to manage, track, and combine bulk flows, and to combine and track bulk flows transported from different conveyor belts operating at different speeds. Utilization data from each bulk flow array can be used to determine the appropriate conveyor belt speed ratio.

[0130] The collector receiving conveyor belt 734 travels at a rate (velocity) V2 and has a selected measurement area 737 (which can be adjusted based on conveyor belt capacity, occupancy, and rate). Before the intersection with the feed conveyor belt 751, the collector or receiving conveyor belt 734 is occupied in the measurement area 737, which has a selected desired occupancy rate based on the target area utilization. The feed conveyor belt 753 travels at a rate (velocity) V1 and has a selected measurement area 736. The distal portion of the feed conveyor belt is loaded to cover a selected percentage of the measurement area 736. The speed or rate V1 of the feed conveyor belt can be calculated by formula, thereby expressing the desired occupancy rate (DO) and the actual occupancy rate (AO) as follows: if Then stop feeding. if Then the feeding begins in: DO% is the expected occupancy percentage (also known as conveyor belt area utilization rate). AO% is the actual occupancy percentage (also known as the conveyor belt area utilization rate). Each pulse of the virtual encoder width value in the array measurement area 736 is measured from the last register and added to the value in the first register of the photodetector. Each virtual encoder pulse with an accumulated value in the first register is shifted to the second register, and the first register is set to zero. The area utilization is the sum of the values ​​in the array. A third collector feed conveyor 739 runs parallel to and in the opposite direction to the receiving conveyor 734 at a rate V3, and includes a selected measurement area 738 (which can be adjusted based on conveyor capacity, occupancy, and rate), intersecting with the feed conveyor 751. The combined bulk flow array can be used to track bulk flow transmissions from different conveyors with different speeds.

[0131] Figure 20An example of dynamic merging integrated with a start-stop conveyor is shown to calculate the speed ratio with multiple variable-speed conveyors. For example, PDF-3 stops when the fill level of the receiver array at the bottom of the ramp exceeds 60% and restarts when it drops below 45%. For each dummy pulse of PDF-3, a width value is virtually added to the first register at the bottom of the ramp. The actual occupancy rate used to trigger the start-stop of PDF-3 should only use a portion of the PDF-4 array. For each recirculation dummy pulse, the value in the last register is moved to the PC7-4 array at the opening position. The recirculation speed is calculated using a collector bulk array based on a dynamic docking merging formula, which includes the sum of values ​​contributed by recirculation and feed from the recirculation inlet region.

[0132] Therefore, the range-sensing photoelectric array device for measuring and controlling the density of items on a conveyor belt includes, or is composed of, a feed conveyor, a docking and merging conveyor, and a receiving conveyor, each with an independent drive motor. The feed conveyor includes a range-sensing measurement field at the far end adjacent to the receiving conveyor. The receiving conveyor includes a range-sensing measurement field at the far end adjacent to the feed conveyor. The docking and merging conveyor includes a range-sensing measurement field at the far end adjacent to the receiving conveyor, following the range-sensing measurement field of the feed conveyor and preceding the range-sensing measurement field of the receiving conveyor. At least one range-sensing photoelectric array, having a virtual encoder and signal generation and detection components, extends over the surfaces of the feed conveyor measurement field, the docking and merging conveyor measurement field, and the receiving conveyor measurement field. A computer component calculates the percentage of the desired occupancy of the receiving conveyor and the percentage of the actual occupancy of the receiving conveyor. The programmable logic controller controls the conveyor speeds of the feed conveyor, docking and merging conveyor, and receiving conveyor, and the start-stop movement of the feed conveyor and / or docking and merging conveyor, based on signals received from a range sensing detection device. The signals identify the gaps between items on the receiving conveyor for sufficient space to insert additional packages from the feed conveyor, as well as the density of items on the feed and docking and merging conveyors.

[0133] The detailed description above is provided primarily for clarity of understanding and should not be interpreted as unnecessarily limiting, as modifications will be readily apparent to those skilled in the art upon reading this disclosure and can be made without departing from the spirit of the invention and the scope of the appended claims. Accordingly, the invention is not intended to be limited to the specific examples presented above. Rather, it is intended to be covered but rather to fall within the spirit and scope of the appended claims. Claims (as amended under Article 19 of the Treaty) 1. A method for adjusting packaging flow density, comprising the following steps: A set of sensors is used to collect multiple measurements of packages moving along a feed conveyor belt with a variable speed motor and a collection conveyor belt; the multiple measurements are stored and analyzed in software to determine the area utilization rate above a defined length of the conveyor belt; and the speed of the feed conveyor belt and the collection conveyor belt is variably controlled using a programmable logic controller to achieve a desired percentage area utilization rate or desired occupancy percentage of the packages on the feed conveyor belt or the collection conveyor belt. If the calculated speed of the conveyor belt drops below its minimum speed, the programmable logic controller pauses the feed conveyor belt and then restarts the conveyor belt when the calculated necessary speed exceeds its preset minimum speed. 2. The method of claim 1, wherein the set of sensors is at least a single vision sensor positioned above the conveyor belt or at least two vision sensors positioned on opposite sides of the conveyor belt. 3. The method of claim 1, wherein the set of sensors is a distance sensor, such as an ultrasonic sensor, an infrared proximity sensor, a light detection and ranging (LIDAR) sensor, or a vertical cavity surface emitting laser (VCSEL) sensor. 4. The method of claim 1, wherein if the calculated speed of the conveyor belt drops below its minimum speed, the programmable logic controller pauses the feed conveyor belt and then restarts the conveyor belt when the calculated necessary speed exceeds 110% of its preset minimum speed. 5. The method of claim 1, wherein the feed conveyor belt is driven by a single-speed motor, the single-speed motor being networked to the programmable logic controller to start and stop the feed conveyor belt at appropriate intervals to ensure that the desired percentage area utilization is achieved when combined with the collection conveyor belt. 6. The method of claim 5, wherein the feeder conveyor is paused when its calculated speed drops below its minimum speed, and is restarted when its calculated necessary speed exceeds 110% of the preset minimum speed of the conveyor. 7. A method for optimizing the flow density of packages collected on a conveyor belt by: A set of sensors is used to collect multiple measurements of a package moving along a feed conveyor belt with a variable speed motor and a collection conveyor belt; the multiple measurements are stored and analyzed in software to determine the area utilization rate above a defined length of the conveyor belt; and the speed of the feed conveyor belt is variably adjusted, the adjusted speed of the feed conveyor belt being calculated by the ratio of the desired occupancy percentage of the feed conveyor belt to the actual occupancy percentage of the feed conveyor belt and multiplied by the speed of the collection conveyor belt. If the calculated speed of the conveyor belt drops below its minimum speed, the programmable logic controller pauses the feed conveyor belt and then restarts the conveyor belt when the calculated necessary speed exceeds 110% of its preset minimum speed. 8. The method of claim 7, wherein the actual occupancy percentage of the feed conveyor belt is determined by numerical integration of a pairwise set of distances measured at regular intervals by a set of opposing distance sensors as the package moves along the feed conveyor belt upstream of the junction with the collection conveyor belt. 9. The method of claim 8, wherein the regular interval is determined by input from a physical encoder with a defined resolution attached to the conveyor belt, or by input from a virtual encoder. 10. The method of claim 1, wherein the speed of the feed conveyor belt is controlled such that the percentage area utilization of the collection conveyor belt is not less than 15% and not more than 40%. 11. The method of claim 1, wherein the feed conveyor belt is capable of accelerating and decelerating at a rate less than or equal to 0.05 G (0.5 m / s^2). 12. The packaging flow density adjustment method as described in claim 1, further comprising the following steps: Multiple first packages from a first feed conveyor belt and multiple second packages from a second feed conveyor belt are combined into an intermediate flow control conveyor belt, which feeds a collection conveyor belt; wherein the area utilization rate of the first feed conveyor belt is determined by a set of distance sensors placed upstream of the junction between the first feed conveyor belt and the intermediate flow control conveyor belt. The area utilization rate of the intermediate flow control conveyor belt is determined by a set of distance sensors placed upstream of the junction between the intermediate flow control conveyor belt and the collection conveyor belt. The first package from the first feed conveyor belt is dynamically fed onto the intermediate flow control conveyor belt by variably adjusting the speed of the first feed conveyor belt to achieve a first desired percentage area utilization of the intermediate flow control conveyor belt, which is sufficient to allow the second package from the second feed conveyor belt to be incorporated onto the intermediate flow control conveyor belt. The speed of the intermediate flow control conveyor belt is adjusted to achieve a second desired percentage area utilization rate for the collection conveyor belt. 13. The method of claim 12, wherein the area utilization rate of the second feed conveyor belt is also determined by a set of distance sensors placed upstream of the junction between the second feed conveyor belt and the intermediate flow control conveyor belt, and the speed of the first feed conveyor belt or the second feed conveyor belt can be changed to achieve the first desired percentage area utilization rate of the intermediate flow control conveyor belt. 14. The method of claim 12, wherein the first feed conveyor belt and the intermediate flow control conveyor belt are arranged linearly, and the second feed conveyor belt and the intermediate flow control conveyor belt are perpendicularly connected and merged. 15. The method of claim 12, wherein the first feed conveyor belt and the second feed conveyor belt are perpendicularly connected to the intermediate flow control conveyor belt. 16. The method of claim 12, wherein at least two feed conveyors are combined with the intermediate flow control conveyor. 17. A method for adjusting packaging flow density, comprising the following steps: A set of sensors is used to collect multiple measurements of packages moving along a feed conveyor belt with a variable speed motor and a collection conveyor belt; the multiple measurements are stored and analyzed in software to determine the area utilization rate above a defined length of the conveyor belt; and the speed of the feed conveyor belt and the collection conveyor belt is variably controlled using a programmable logic controller to achieve a desired percentage area utilization rate or desired occupancy percentage of the packages on the feed conveyor belt or the collection conveyor belt. If the calculated speed of the conveyor belt drops below its minimum speed, the programmable logic controller pauses the feed conveyor belt and then restarts the conveyor belt when the calculated necessary speed exceeds 110% of its preset minimum speed. Further steps include: selecting a transition area between the feed conveyor belt and the receiving conveyor belt and before adjacent docking and merging conveyor belts, each conveyor belt having an independent drive unit; Define the range of sensing measurement fields within the selected transition region; Determine the percentage of actual occupancy for the defined area of ​​the feeder conveyor belt occupancy rate; Determine the percentage of actual occupancy for the defined area of ​​the receiving conveyor belt occupancy rate; After multiple packages are merged from the feed conveyor belt into the receiving conveyor belt, a percentage of the desired occupancy rate is selected for the receiving conveyor belt; The packages from the feed conveyor are fed at a selected rate to the receiving conveyor occupancy defined area, thereby reducing the flow of packages before the receiving conveyor merge area. The packages are merged in the transition area between the feed conveyor and the receiving conveyor, and the conveyor speed ratio is adjusted proportionally to the ratio of desired density to current density to increase the density or volume of the packages in a selected area of ​​the receiving conveyor, and the packages on the collection conveyor are compressed after the merging area; and The flow density is compressed to fill the collector conveyor belt to the desired target fullness, pulling it forward and compressing the package to prevent flow gaps and deficient areas and to thin out overfilled areas, thereby reducing the possibility of downstream blockage. 18. The parcel flow density adjustment method of claim 17, further comprising the step of using a plurality of range-sensing photoelectric eye arrays to create a table of sensing ranges, wherein each range-sensing photoelectric eye array includes two outputs, and each output is individually adjustable to obtain two different ranges, and the plurality of range-sensing photoelectric eye arrays are mounted at selected distances from the unloading end of the feed conveyor and the receiving end of the receiving conveyor on a first side and an opposite second side of a selected measurement field of the feed conveyor and the receiving conveyor, and pulses are generated at selected intervals along the measurement field of the conveyor surface using a programmable virtual encoder. 19. The package flow density adjustment method of claim 17, comprising the step of forming an array comprising a plurality of range-sensing photoeye arrays, each of the plurality of range-sensing photoeye arrays representing a pulse of the virtual encoder defining the selected distance of the selected distance, and the average measured occupancy of the array representing a percentage of the fullness of the receiving conveyor belt being calculated by using a programmable logic controller with an algorithm to determine the combination of the range-sensing photoeye outputs that are blocked when the encoder pulse occurs, wherein the measured occupancy of the feed conveyor belt and the docking merging conveyor belt is compared with the desired occupancy of the receiving conveyor belt, and the feed conveyor belt and / or the docking merging conveyor belt is started-stopped, or a speed ratio is calculated by dividing the desired occupancy by the measured occupancy, and the speed of the feed conveyor belt, the docking merging conveyor belt, or the receiving conveyor belt, or the feed conveyor belt and the docking merging conveyor belt and the receiving conveyor belt, is adjusted to obtain the desired occupancy on the receiving conveyor belt. 20. A method for adjusting package flow density to measure and control the density of packages on a conveyor belt, comprising the following steps: The system includes a feed conveyor belt, a receiving conveyor belt, and a docking and merging conveyor belt, each with its own independent drive motor. The feeding conveyor belt includes a range sensing measurement field at the far unloading end adjacent to the receiving conveyor belt; The receiving conveyor belt includes a range sensing measurement field at the far end of the receiving end adjacent to the feeding conveyor belt; The docking and merging conveyor belt includes a range sensing measurement field at the far end of the receiving conveyor belt adjacent to the receiving conveyor belt. A range-sensing photoelectric eye array with a virtual encoder and signal generation and detection components extends across the surface of the feed conveyor measurement field, the docking and merging conveyor, and the receiving conveyor measurement field; A computer component for calculating the percentage of expected occupancy of the receiving conveyor belt and the percentage of actual occupancy of the receiving conveyor belt; A programmable logic controller (PLC) for controlling the speed and movement of the conveyor belt based on signals received from the photoelectric array, the signals identifying sufficient space between packages on the receiving conveyor belt for inserting additional packages from the feed conveyor belt or the docking and merging conveyor belt, wherein if the calculated speed of the conveyor belt drops below its minimum speed, the PLC pauses the feed conveyor belt and then restarts the conveyor belt when the calculated necessary speed exceeds 110% of its preset minimum speed; and The receiving conveyor belt acts as an active buffer, thereby compressing the flow density to fill the collector conveyor belt to the desired target fullness, pulling forward and compressing the package to prevent flow gaps and deficient areas and thinning overfilled clumps and areas, thereby reducing the possibility of downstream blockage. 21. The parcel flow density adjustment method as described in claim 20, wherein density includes area, volume, and weight, or a combination thereof. 22. The package flow density adjustment method of claim 20, wherein a plurality of the range detection photoelectric eye arrays are positioned at selected input points, are wired or wirelessly connected to a programmable logic controller (PLC) or a computer, and include a process control algorithm for identifying the incoming flow density based on bandwidth utilization and throughput rate. 23. The parcel flow density adjustment method as described in claim 20, wherein the range detection photoelectric eye array defines a density-based detection system for identifying the area utilization rate of the identification zone and the parcel count. 24. The parcel flow density adjustment method of claim 20, wherein the control algorithm identifies each item and the rate at which the each item passes through, and the area utilization rate of the collection belt. 25. The parcel flow density adjustment method as described in claim 20, wherein the control algorithm identifies the average parcel size based on area, volume, parcel length, parcel width, parcel weight, and parcel height. 26. The parcel flow density adjustment method of claim 20, comprising the step of a control algorithm identifying, locating, or tracking packages, parcels, or other goods on the feed conveyor belt based on their digital images, scanner codes, or digital occupancy areas. 27. The package flow density adjustment method of claim 20, wherein the range sensing device is positioned at selected input points and is wired or wirelessly connected to a programmable logic controller (PLC) or computer including process control algorithms to identify the incoming flow density based on the band utilization and throughput rate. 28. The parcel flow density adjustment method as described in claim 20, wherein the computer is connected to and integrated with the conveyor belt computer control system via an interface of a smart electronic device and controls the system thereon, the smart electronic device including a smartphone, a tablet computer, a laptop computer, and a vision-assisted computer-based device capable of communicating with the computer system. 29. A package flow density adjustment device for measuring and controlling the density of articles on a conveyor belt, comprising: Feeding conveyor belts and receiving conveyor belts, each with its own independent drive motor; The feeding conveyor belt includes a range sensing measurement field at the far unloading end adjacent to the receiving conveyor belt; The receiving conveyor belt includes a range sensing measurement field at the far end of the receiving end adjacent to the feeding conveyor belt; An array of at least one range-sensing photoelectric eyes, having a virtual encoder and signal generation and detection components, extends across the surfaces of the feed conveyor measurement field and the receiving conveyor measurement field. At least one detection device selected from the group consisting of a shooting device, a pixel detection device, a digital imaging device, and combinations thereof, is positioned at the input point of the receiving conveyor belt, the collecting conveyor belt, the sorting conveyor belt, or a combination thereof. A computer component for calculating the percentage of expected occupancy of the receiving conveyor belt and the percentage of actual occupancy of the receiving conveyor belt; A programmable logic controller (PLC) for controlling the speed and movement of the conveyor belt based on signals received from the range sensing detection device, the signals identifying sufficient space gaps between packages on the receiving conveyor belt for inserting additional packages from the feed conveyor belt, wherein if the calculated speed of the conveyor belt drops below its minimum speed, the PLC pauses the feed conveyor belt and then restarts the conveyor belt when the calculated necessary speed exceeds its preset minimum speed; and The receiving conveyor belt acts as an active buffer, thereby compressing the flow density to fill the collector conveyor belt to the desired target fullness, pulling forward and compressing the package to prevent flow gaps and deficient areas and thinning overfilled clumps and areas, thereby reducing the possibility of downstream blockage. 30. A package flow density adjustment device for measuring and controlling the density of items on a conveyor belt, comprising: The system includes a feed conveyor belt, a docking and merging conveyor belt, and a receiving conveyor belt, each with its own independent drive motor. The feeding conveyor belt includes a range sensing measurement field at the far unloading end adjacent to the receiving conveyor belt; The receiving conveyor belt includes a range sensing measurement field at the far end of the receiving end adjacent to the feeding conveyor belt. The docking and merging conveyor belt includes a range sensing measurement field located at the far end of the receiving conveyor belt, adjacent to the far end of the receiving conveyor belt, after the range sensing measurement field of the feeding conveyor belt and before the range sensing measurement field of the receiving conveyor belt. At least one range-sensing photoelectric eye array having a virtual encoder and signal generation and detection components extends across the surface of the feed conveyor measurement field, the docking and merging conveyor measurement field and the receiving conveyor measurement field; A computer component for calculating the percentage of expected occupancy of the receiving conveyor belt and the percentage of actual occupancy of the receiving conveyor belt; A programmable logic controller (PLC) is configured to control the conveyor speeds of the feed conveyor, the docking and merging conveyor, and the receiving conveyor, and the start-stop movement of the feed conveyor and / or the docking and merging conveyor, based on signals received from the range sensing detection device, wherein the signals identify sufficient space gaps between packages on the receiving conveyor for inserting additional packages from the feed conveyor. If the calculated speed of the conveyor belt drops below its minimum speed, the programmable logic controller pauses the feed conveyor belt and then restarts the conveyor belt when the calculated necessary speed exceeds its preset minimum speed. 31. The parcel flow density adjustment device of claim 30, further comprising at least one detection device selected from the group consisting of an imaging device, a pixel detection device, a digital imaging device, and combinations thereof, positioned at the input point of the receiving conveyor belt, the collector conveyor belt, the sorting conveyor belt, or a combination thereof. 32. The package flow density adjustment device of claim 30, further comprising a plurality of relative range sensing photoelectric eye arrays for creating a sensing range, wherein each range sensing photoelectric eye array has two outputs and each output is individually adjustable to obtain two different ranges, the plurality of range sensing photoelectric eye arrays comprising: a first range sensing photoelectric eye array mounted on a first side of the conveyor belt; and a second range sensing photoelectric eye array mounted on a relative second side of the conveyor belt in the transition region, the transition region including the range sensing measurement field of the feeding conveyor belt and the range sensing measurement field of the receiving conveyor belt. 33. The parcel flow density adjustment device of claim 30, wherein the virtual encoder is programmable to generate pulses at selected intervals of the feed conveyor belt. 34. The parcel flow density adjustment device as claimed in claim 30, wherein the computer is connected to and integrated with the conveyor belt computer control system via an interface of a smart electronic device and controls the system thereon, the smart electronic device including a smartphone, a tablet computer, a laptop computer, and a vision-assisted computer-based device capable of communicating with the computer system. 35. The package flow density adjustment device of claim 30, wherein the range sensing photoelectric eye array comprises a plurality of array elements, each of the array elements representing a pulse of the virtual encoder defining a selected length of the range sensing measurement field.

Claims

1. A method of package flow density adjustment comprising the steps of: collecting a plurality of measurements of packages moving along a feed conveyor and a collection conveyor with variable speed motors using a set of sensors; storing and analyzing the plurality of measurements in software to determine the area utilization over a defined length of the conveyor; and variably controlling the speed of the feed conveyor and the collection conveyor with a programmable logic controller to achieve a desired percentage area utilization or desired occupancy percentage of packages on the feed conveyor or the collection conveyor.

2. The method of claim 1, wherein, the set of sensors is at least a single vision sensor positioned above the conveyor or at least two vision sensors positioned on opposite sides of the conveyor.

3. The method of claim 1, wherein, the set of sensors is a distance sensor such as an ultrasonic sensor, an infrared proximity sensor, a light detection and ranging (LIDAR) sensor or a vertical cavity surface emitting laser (VCSEL) sensor.

4. The method of claim 1, wherein, if the calculated speed of the conveyor falls below its minimum speed, the programmable logic controller pauses the feed conveyor and then restarts the conveyor when the calculated necessary speed exceeds 110% of its preset minimum speed.

5. The method of claim 1, wherein, the feed conveyor is driven by a single speed motor that is networked to the programmable logic controller in order to start and stop the feed conveyor at appropriate intervals to ensure that the desired percentage area of utilization is achieved when merged with the collection conveyor.

6. The method of claim 5, wherein, the feed conveyor is paused when its calculated speed falls below its minimum speed and restarted when its calculated necessary speed exceeds 110% of the conveyor's preset minimum speed.

7. A method of optimizing the flow density of packages on a collection conveyor by variably adjusting the speed of a feed conveyor, the adjusted speed of the feed conveyor being calculated by the ratio of the desired occupancy percentage of the feed conveyor and the actual occupancy percentage of the feed conveyor and multiplied by the speed of the collection conveyor.

8. The method of claim 7, wherein, the actual occupancy percentage of the feed conveyor is determined by numerically integrating pairs of sets of distances measured at regular intervals by a set of opposing distance sensors as packages move along the feed conveyor upstream of the junction with the collection conveyor.

9. The method of claim 8, wherein, the regular intervals are determined by a physical encoder input attached to the conveyor with a defined resolution or by a virtual encoder input.

10. The method of claim 1, wherein, the speed of the feed conveyor is controlled so that the percentage area utilization of the collection conveyor is no less than 15% and no more than 40%.

11. The method of claim 1, wherein, the feed conveyor can accelerate and decelerate at a rate less than or equal to 0.05 G (0.5 m / s^2).

12. A method of package flow density adjustment comprising the steps of merging a plurality of first packages from the first feed conveyor and a plurality of second packages from the second feed conveyor into an intermediate flow control conveyor, the intermediate flow control conveyor feeding the collection conveyor; wherein the area utilization of the first feed conveyor is determined by a set of distance sensors placed upstream of the junction between the first feed conveyor and the intermediate flow control conveyor; The area utilization of the intermediate flow control conveyor is determined by a set of distance sensors placed upstream of the juncture between the intermediate flow control conveyor and the collection conveyor; The first packages from the first feed conveyor are dynamically fed onto the intermediate flow control conveyor by variably adjusting the speed of the first feed conveyor to achieve a first desired percentage area utilization of the intermediate flow control conveyor, which is sufficient to merge the second packages from the second feed conveyor onto the intermediate flow control conveyor; And the speed of the intermediate flow control conveyor is adjusted to achieve a second desired percentage area utilization of the collection conveyor.

13. The method of claim 12, wherein, The area utilization of the second feed conveyor is also determined by a set of distance sensors placed upstream of the juncture between the second feed conveyor and the intermediate flow control conveyor, and the speed of the first feed conveyor or the second feed conveyor can be changed to achieve the first desired percentage area utilization of the intermediate flow control conveyor.

14. The method of claim 12, wherein, The first feed conveyor and the intermediate flow control conveyor are linearly arranged, and the second feed conveyor and the intermediate flow control conveyor are perpendicularly docked to merge.

15. The method of claim 12, wherein, The first feed conveyor and the second feed conveyor perpendicularly dock the intermediate flow control conveyor.

16. The method of claim 12, wherein, At least two feed conveyors merge with the intermediate flow control conveyor.

17. A method of improving conveyor belt wrapping traffic density adjustment, wherein, Parcel flow is measured and controlled from feed and receiving conveyors using programmable logic controllers; Transition zones are selected between feed and receiving conveyors and before adjacent dock merge conveyors, each having independent drive components; Range sensing measures fields are determined in selected transition zones; Percentages of actual occupancy are determined for feed conveyor occupancy definition zones; Percentages of actual occupancy are determined for receiving conveyor occupancy definition zones; Percentages of desired occupancy are selected for the receiving conveyor after a number of parcels are merged from the feed conveyor to the receiving conveyor; The parcels from the feed conveyor are fed to the receiving conveyor occupancy definition zones at a selected rate of speed, thinning the flow of parcels before the receiving conveyor merge zone; The parcels are merged at the conveyor zone of the transition zone between the feed and receiving conveyors, and conveyor speed ratios are adjusted in proportion to the ratio of desired density to current density to increase the density or volume of the parcels in the selected area of the receiving conveyor, and to compress the parcels on the collection conveyor after the merge zone; wherein the improvement comprises each of the feed conveyor and the receiving conveyor being an active buffer, compressing the flow density to fill the collection conveyor to a desired target fullness, pulling forward and compressing the packages to prevent voids and lean areas of flow and thinning out overfilled clumps and areas, thereby reducing the likelihood of downstream jams.

18. The package flow density adjustment method of claim 17, including the step of creating a table of sensed ranges using a plurality of range sensing photo eye arrays, wherein each range sensing photo eye array includes two outputs, and each output is individually adjustable to obtain two different ranges, and the plurality of range sensing photo eye arrays are mounted on first and opposite second sides of selected measurement fields of the feed conveyor and the receiving conveyor at selected distances from the discharge end of the feed conveyor and the receiving end of the receiving conveyor, and pulses are generated using programmable virtual encoders at selected intervals along the measurement fields of the conveyor surfaces.

19. The package flow density adjustment method of claim 17, including the step of forming an array comprising a plurality of range sensing photo eye arrays, each of the plurality of range sensing photo eye arrays representing one pulse of the virtual encoder defining a selected length of the selected distance, and the average measured occupancy of the array representing a percentage of fullness of the receiving conveyor is determined using an algorithm using programmable logic controller wherein the measured occupancy of the feed conveyor and the butt merge conveyor are compared to a desired occupancy of the receiving conveyor, and start-stop the feed conveyor and / or the butt merge conveyor, or calculate a speed ratio by dividing the desired occupancy by the measured occupancy, and adjust the speed of the feed conveyor, the butt merge conveyor, or the receiving conveyor, or the feed conveyor and the butt merge conveyor and the receiving conveyor to obtain a desired occupancy on the receiving conveyor.

20. A package flow density adjustment method for measuring and controlling the density of packages on a conveyor, comprising the steps of: a feed conveyor, a receiving conveyor, and a butt merge conveyor, each conveyor having an independent drive motor; the feed conveyor including a range sensing measurement field adjacent a distal discharge end of the receiving conveyor; the receiving conveyor including a range sensing measurement field adjacent a distal receiving end of the feed conveyor; the butt merge conveyor including a range sensing measurement field adjacent a distal receiving end of the receiving conveyor; a range sensing photo eye array having a virtual encoder and signal generation and detection components extending across the surfaces of the feed conveyor measurement field, the butt merge conveyor, and the receiving conveyor measurement field; a computer component to calculate the desired percentage of occupancy of the receiving conveyor and the actual percentage of occupancy of the receiving conveyor; a programmable logic controller to control the conveyor speed and movement based on signals received from the photo eye array that identify gaps of sufficient space between packages on the receiving conveyor for additional packages from the feed conveyor or the docking merge conveyor to be inserted; the receiving conveyor becomes an active buffer, compressing the flow density to fill the collection machine conveyor to a desired target fullness, pulling forward and compressing the packages to prevent gaps and lean areas of flow and to thin out excess filled clumps and areas, reducing the likelihood of downstream jams.

21. The package flow density adjustment method of claim 20, wherein, Density includes area, volume, and weight or combinations thereof.

22. The package flow density adjustment method of claim 20, wherein, A plurality of the range detection photo eye arrays are positioned at selected individual input points in wired or wireless communication with programmable logic controllers "PLCs" or computers and include process control algorithms that identify incoming flow density according to belt utilization and throughput rates.

23. The package flow density adjustment method of claim 20, wherein, The range detection photo eye arrays define a density-based detection system that identifies belt area utilization and package counts.

24. The package flow density adjustment method of claim 20, wherein, The control algorithms identify individual items and the rate at which the individual items pass and the area utilization of the collection machine belt.

25. The package flow density adjustment method of claim 20, wherein, The control algorithms identify average package size according to area, according to volume, package length, package width, package weight, and package height.

26. The package flow density adjustment method of claim 20, including the step of the control algorithm identifying, locating, or tracking packages, parcels, or other items on the feed conveyor according to their digital images, scanner codes, or digital occupancy areas.

27. The package flow density adjustment method of claim 20, wherein, The range sensing devices are positioned at selected individual input points in wired or wireless communication with programmable logic controllers "PLCs" or computers that include process control algorithms to identify incoming flow density according to belt utilization and throughput rates.

28. The package flow density adjustment method of claim 20, wherein, The computer interfaces and integrates with and controls the conveyor computer control system via intelligent electronic devices including smart phones, computer tablets, laptop computers, and vision-assisted computer-based devices capable of communicating with the computer system.

29. A package flow density adjustment apparatus for measuring and controlling the density of items on a conveyor, comprising: a feed conveyor and a receiving conveyor, each having independent drive motors; the feed conveyor including a range sensing measurement field adjacent the distal offload end of the receiving conveyor; the receiving conveyor including a range sensing measurement field adjacent the distal receiving end of the feed conveyor; at least one range sensing photo eye array having virtual encoders and signal generation and detection components extending across the surfaces of the feed conveyor measurement field and the receiving conveyor measurement field; the control algorithms identify average package size according to area, according to volume, package length, package width, package weight, and package height. at least one detection device selected from the group consisting of a camera, a pixel detection device, a digital imaging device, and combinations thereof positioned at an input point of the receiving conveyor or the collector conveyor or the sortation conveyor or the sortation conveyor or a combination thereof; a computer component for calculating a percentage of a desired occupancy of the receiving conveyor and a percentage of an actual occupancy of the receiving conveyor; a programmable logic controller for controlling the conveyor speed and movement based on signals received from the range-sensing detection device identifying gaps of sufficient space between packages on the receiving conveyor for insertion of additional packages from the feed conveyor; and the receiving conveyor becomes an active buffer compressing the flow density to fill the collector conveyor to a desired target fullness, pulling forward and compressing the packages to prevent gaps and lean areas of flow and thinning out overfilled clumps and areas, reducing the likelihood of downstream jams.

30. A package flow density adjustment apparatus for measuring and controlling the density of articles on a conveyor, comprising: a feed conveyor, a merge and conveyor, and a receiving conveyor, each having independent drive motors; the feed conveyor including a range-sensing measurement field adjacent a distal offloading end of the receiving conveyor; the receiving conveyor including a range-sensing measurement field immediately adjacent a distal receiving end of the feed conveyor; the merge and conveyor including a range-sensing measurement field adjacent a distal offloading end of the receiving conveyor after the range-sensing measurement field of the feed conveyor and before the range-sensing measurement field of the receiving conveyor; at least one range-sensing photo eye array having virtual encoders and signal generation and detection components extending across the surfaces of the feed conveyor measurement field, the merge and conveyor measurement field, and the receiving conveyor measurement field; a computer component for calculating a percentage of a desired occupancy of the receiving conveyor and a percentage of an actual occupancy of the receiving conveyor; a programmable logic controller for controlling the conveyor speed and start-stop movement of the feed conveyor and / or the merge and conveyor based on signals received from the range-sensing detection device identifying gaps of sufficient space between packages on the receiving conveyor for insertion of additional packages from the feed conveyor.

31. The package flow density adjustment apparatus of claim 30, further comprising at least one detection device selected from the group consisting of a camera, a pixel detection device, a digital imaging device, and combinations thereof positioned at an input point of the receiving conveyor or the collector conveyor or the sortation conveyor or the sortation conveyor or a combination thereof.

32. The package flow density adjustment apparatus of claim 30, further comprising a plurality of relative range sensing photo eye arrays for creating a table of sensing ranges, wherein each range sensing photo eye array has two outputs and each output is individually adjustable to obtain two different ranges, the plurality of range sensing photo eye arrays comprising: a first range-sensing photo eye array mounted on a first side of the conveyor; a second range-sensing photo eye array mounted on a second side of the conveyor; and a third range-sensing photo eye array mounted on a third side of the conveyor. and a second range-sensing photo eye array mounted on an opposite second side of the conveyor belt in the transition zone, the transition zone including the range-sensing measurement field of the feed conveyor belt and the range-sensing measurement field of the receiving conveyor belt.

33. The package flow density adjustment apparatus of claim 30, wherein, The virtual encoder is programmable to produce pulses at selected intervals of the feed conveyor belt.

34. The package flow density adjustment apparatus of claim 30, wherein, The computer is interfaced and integrated with and controls a conveyor computer control system via a smart electronic device, including a smart phone, a computer tablet, a laptop computer, and a vision-assisted computer-based device capable of communicating with the computer system.

35. The package flow density adjustment apparatus of claim 30, wherein, The range-sensing photo eye array includes a plurality of array elements, each of the array elements representing one pulse of the virtual encoder defining a selected length of the range-sensing measurement field.

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