PACK SORTING TRANSFER MODULE AND SYSTEMS AND METHOD FOR IT

Description

FIELD OF THE INVENTION

[0001] The present disclosure relates generally to material handling systems and specifically to plastic conveyor belts with rotating elements and simple drive components used to configure individual transfer modules that can be used to divert and son letters, bundles, packages, parcels, etc.BACKGROUND

[0002] The volume of products being transported and sorted by material handling systems has increased dramatically in the United States and the developing world. Much of this volume increase can be attributed to the rise of fulfillment centers" where goods are sorted for distribution to businesses and customers through a variety of distribution channels.

[0003] Automatic sorter systems are one of the key technologies that enable there organizations to handle the tremendous volume of packages and collect them by destination as they move from sender to receiver. High speed, low cost, and automated operations are key technologies far efficiency and competitiveness in this business. Two of the most common sorter types are the "LOOP" sorter and the "LINEAR" sorter.

[0004] A loop sorter is typically housed in a large building and it resembles a small train with multiple package-holding segments (hereinafter "cars" or "sorter trays") moving around a closed loop at speed. At one pan of the loop, packages are moved onto individual cars of the sorter at what are called "induction stations". As the sorter cars move around the loop there are a multitude of locations called "sort points" where the contents of the train can be moved off, or sorted, into a waiting container or subsequent conveyors. Various technologies are used to "move off" the product from the sorter car and they include tipping the car to the side, driving a transverse conveyor belt that is on top of the car, or dropping the product through the car with bomb bay doors.

[0005] Linear sorters perform the same transport and sorting function as loop sorters. This style of sorter inducts product onto a single straight-line conveyor where packages can be expelled to containers positioned on the right or left of the sorter spine. The conveyor itself has features that move packages to the right or left at a precise time to discharge into a waiting container designated by the sorter system. Typical discharge methods include "Shoe Sorters," where features on the conveyor move right or left to move the package, and "Pushers" where some external actuator interfaces with the package and pushes it off of the sorter to the right or left.

[0006] Recently there is a family of sorters that use a linked plastic conveyor belt with rotating elements embedded in the conveyor belt structure, such as is disclosed in published patent application US2011 / 0022221. The tops of the rotating elements contact the product being transported and the bottoms of the rotating elements contact fixed or moving features underneath the conveyor belt itself. When these rotating elements touch features underneath the conveyor belt, their rotational behavior can be changed and this will change the resultant movement of the product on the top surface. These sorters are typically constructed from a single length of plastic conveyor belt with multiple zones where features underneath the conveyor can activate and divert the product off of the main flow. The length of these sorters requires a much more powerful drive system and the entire conveyor belt must stay in motion to move product over the length of the sorter.

[0007] US 5238099 A1 discloses a transfer module assembly according to the preamble of claim 1, and a transfer module assembly method according to the preamble of claim 10. In particular, the document discloses a conveying system that includes a first continuous belt supported horizontally at two ends by a pair of rollers. A plurality of balls are mounted to the belt for rotation. A second conveyor belt is positioned within the space between the rollers defined by the upper and lower portions of the first belt such that the upper surface of the second belt contacts the balls of the first belt. As the two belts are rotated, articles may be conveyed by the first belt and rotation of the balls by the second belt causes the articles to move diagonally over the upper surface of the first belt whereupon they may be justified to one side or the other of the belt.

[0008] US 2006 / 219526 discloses a conveyor constructed of a single belt or a plurality of abutting belts arranged side by side in the conveyor, in which the belt or belts have rollers arranged to rotate on axes oriented at multiple angles oblique to the direction of belt travel. A gradual or monotonic, stepped change in the axes of the rollers across the width of the conveyor can be used to make a conveyor capable of converting a mass flow of articles into a single stream of separated articles.

[0009] US 2016 / 325315 discloses a sortation conveyor that has an endless apron supported for longitudinal movement on an elongate frame. An induction conveyor deposits articles on an offset lateral portion of a top conveying run of the apron. A pin guide assembly is coupled between the elongate frames and is upwardly presented to selectively receive the pin of pushers that laterally move across the apron. An upstream pre-sort section thereof positions articles from the offset lateral portion to an opposite lateral portion of the top conveying run. A downstream divert section of the pin guide assembly selectively diverts the articles to a divert target on the corresponding lateral side to the selected one of offset lateral position and the opposite lateral position.

[0010] Needs exist for improved sorting systems and methods.SUMMARY

[0011] The invention concerns the matter of the attached independent claims 1 and 10.

[0012] A new low-cost method allow the construction of individual transfer modules that can be used singularly to transfer package. These same transfer modules can be combined with other modules to create a sorter of nearly any length or size. Each transfer module has its own simple drive system that can use smaller and lower-powered components for each of the individual modules instead of the large centralized high-powered drive systems used in the large linear or loop sorters. Each transfer module can be operated independently so that product can be moved by just powering the module when the product is present. The design and operation of the transfer modules offers many benefits including lower cost, lower noise lower wear, and fewer alignment issues. Constructing sorters from these individual transfer modules has the added benefit of installation flexibility, lower power consumption, and the ability to change the size and configurations in the future.

[0013] A transfer module can be configured from a length of plastic conveyor belt where the conveying surface incorporates a multitude of freely rotating balls whose surface extends slightly above and below the belt. These rotating elements may be freely rotating sphere or roller with an axle mounted in a rotating assembly with a geometry that causes the assembly, with the roller, to turn in response to a compound movement of the conveyor belt riding over a secondary moving belt underneath. The plastic conveyor belt runs in a continuous loop over a support surface that causes the balls to rotate from their contact with the surface underneath. A package on the top surface is propelled by touching a multitude of the balls and its speed is also increased because of the tangential velocity of the rotating elements combined with the translational speed of the conveyer belt itself.

[0014] A second flat belt is positioned underneath as the support structure for the rotating elements of the plastic conveyor belt. Using a belt is a cost-effective approach to contact a wide area of rotating elements. When the second flat belt is moved it will impart, a compound motion to the rotating elements of the plastic conveyor belt which will cause a package riding on the top of the rotating elements to change directions.

[0015] One specific configuration is to orient the second flat belt at 90 degrees direction of motion of the plastic conveyor belt with the rotating elements. When the second flat belt is moved to the right or to the left it will impart a motion to the rotating elements of the plastic conveyor belt to move a package on the conveying surface to the right or left directions. A computer control system activates the secondary belt at the correct time. When the belts are controlled by a control system, this change in direction can be used to move the packages off and onto different conveyor sections and thus sort the package to a different path.

[0016] If many transfer modules are set tip in series, the control system can track individual packages and control individual transfer modules to create a sorter system. This modular approach to a sorter system is different from the traditional loop sorters or linear sorters and allows high degree of customization to meet the operational constraints of where they can be installed. Modules can be added or taken away as the sortation requirements change in the future. Modules can be grouped in specific areas along a conveyor line and other features, such as curves, inclines, and elevators, can be incorporated into the overall sorter installation.

[0017] Features of the modular concept include the physical ability to transfer product between modules and a low-cost drive system for the multiple individual transfer modules. The traditional method used to drive the plastic conveyor belt is to use a multitude of sprocket type elements mounted on a common shaft at both ends of the conveyor section. The sprocket elements engage with features in the plastic conveyor belt. The sprocket shaft can be powered by a belt drive, gear drive, internal motor, or other means to provide power to rotate the sprockets and move the plastic conveyor belt.

[0018] Some embodiments of the present invention replace the sprocket drive system with a friction-based approach using a specially contoured roller that is driven by a belt drive, gear drive, internal motor, or other means. The contoured roller has specific features to accommodate the plastic conveyor belt, providing both friction surfaces to propel the plastic belt and clearances for the roller elements.

[0019] The contoured roller is designed to interface with the geometry of the plastic roller belt. A simple design can be a cylindrical roller of high friction material that has been shaped to incorporate cylindrical grooves along its length to allow clearances for the rows of rotating elements of the plastic belt. The depth of grooves can be selected depending on the application. For very small packages, according to the invention, the depth of the groove is engineered so that the rotating elements contact the roller inside the groove to prevent them from rotating at the same time as the remaining surface of the roller maintains contact with the plastic belt itself. In this way a very small package can be moved by the rotating element and will continue to move by translation alone around the drive roller when the rotating elements are "locked" by contact with the roller groove. Using this approach, a "dead zone" can be avoided where the rotating elements turn freely and provide no motive power to the package.

[0020] The contoured friction drive roller has many other benefits in the design and construction of a plastic conveyor system with rotating elements. A friction drive roller can be fabricated inexpensively by adding a covering to existing drive rollers. This feature can be easily added to a motorized drive roller (MDR), which is a common drive element used in many modem conveyor systems.

[0021] The diameter of the friction drive with the added covering can be kept to a minimum since there are no sprocket teeth required. Minimizing the diameter allows multiple conveyor sections to be replaced end to end while minimizing the discontinuity in the transition between conveying surfaces, therefor accommodating smaller packages.

[0022] The design of the transfer module is simplified, since the friction drive rollers can propel the plastic conveyor using friction that is maintained by the small catenary force of the return conveyor hanging underneath and between the rollers. There is no need to have a tensioning mechanism or to perform frequent adjustments.

[0023] Sprocket-type drive systems are prone to wear due to the mechanical interface, and they require careful tensioning. Sprocket teeth can wear as well as the pitch length of the plastic conveyor itself. Either condition can require the replacement of both the chain and the sprocket.

[0024] The friction drive proposed in some embodiments of the present invention does not have this limitation. The contact position is arbitrary, and as a result not sensitive to wear or pitch length.

[0025] Sprocket drives also make more noise, since there is a. mechanical interface between sprocket teeth and the plastic conveyor. This is a noted drawback for the commercial use of large sprocket drive systems that must run continuously with workers sharing the same work space. The friction drive system provides a smoother power transmission that is quiet and does not change with wear.

[0026] The secondary flat belt that is activated to change the direction of the package being transported has specific features to enable this method of package transfer. The secondary flat belt will frequently be activated while the plastic conveyor belt with rotating features is in motion. Moving both belts at the same time will frequently perform the transfer motion at the greatest speed. This is important in a sorter application where sortation rates are critical to the overall operations. Moving both belts at the same time imparts a significant side loading to both belts. Features on the top surface of the module and along the sides of the plastic belt can constrain its sideways deflection and provide a bearing surface along the edge. The secondary flat belt underneath can be a much thinner profile and there is less room to provide a bearing surface underneath the plastic belt to constrain the sidewise deflection of the flat belt underneath. Alternative methods can be used in the transfer module design to secure the secondary flat belt and control its deflection. A profile on the back of the belt can be used to interface with a mating profile on the drive rollers and on the conveyor bed that it rides on. This profile resists the sideways deflection of the belt instead of restraining it along the sides. Multiple profiles and mating grooves, and even crowned rollers can be used in any combination to resist the most aggressive side loading.

[0027] According to the invention, the transfer module assembly has a frame, a conveyor belt with internal rotating elements, where the conveyer belt is supported by the frame, conveyor drive rollers supported by the frame and configured to drive the conveyor belt, a flat transfer belt mounted beneath the conveyor belt and configured to contact undersides of the internal rotating elements of the conveyor belt in operation, and flat transfer belt drive rollers supported by the frame and configured to drive the flat transfer belt. The conveyor drive rollers are friction-based and operate without use of a sprocket, and have depressions for receiving the internal rotating elements of the conveyor belt.

[0028] According to the invention, the depressions are grooves spaced to match a spacing of the internal rotating elements of the conveyor belt, a depth and geometry of the grooves being configured to provide multiple contact points between a surface of the conveyor belt and the conveyor drive rollers.

[0029] In some embodiments, the conveyor drive rollers have a friction coating, the friction coating including a rubberized sleeve or lagging.

[0030] In some embodiments, the conveyor belt and the flat transfer belt are configured to be driven in different directions. The direction in which the flat transfer belt is configured to be driven may be perpendicular to the direction in which the conveyor belt is configured to be driven. Tracking features on the flat transfer belt may be configured to resist deflection of the flat transfer belt. In some embodiments the tracking features include tracking grooves on the flat transfer belt drive rollers and features on the flat transfer belt that engage with the tracking grooves. In some embodiments, the .assembly includes a low-friction slider bed support surface below the flat transfer belt, and the tracking features include tracking grooves incorporated in the slider bed that align with the tracking grooves in the flat transfer belt drive rollers.

[0031] In some embodiments, the conveyor drive rollers propel the conveyor belt using friction maintained by a catenary force of a return portion of the conveyor belt hanging underneath and between the conveyor drive rollers, and the conveyor drive rollers have no tensioning mechanisms.

[0032] In some embodiments, the assembly includes a control unit configured to control speed and direction of movement of the conveyor belt and flat transfer belt, and the control unit is configured to control relative speed and direction of the conveyor belt and flat transfer belt to achieve movement of an object on the conveyor belt in a predetermined direction, where the predetermined direction may be any direction along a surface of the conveyor belt.

[0033] A new sorter includes a plurality of transfer module assemblies as described above arranged in series, an induction station configured to collect information about objects to be conveyed and to induct the objects onto the plurality of transfer module assemblies, zone sensors configured to determine progress of the objects on the plurality of transfer module assemblies, discharge bins configured to receive the objects from the plurality of transfer module assemblies, and a control system configured to receive data regarding the progress of the objects on the plurality of transfer module assemblies from the zone sensors and to activate transfer modules based on the received data to discharge the objects into appropriate discharge bins.

[0034] In some embodiments, each of the plurality of transfer modules assemblies is configured to be controlled by the control system independently.

[0035] A new sorter method includes placing a first object on a sorter as described above, tracking a position of the first object, determining a desired direction of movement for the first object, and controlling speed and direction of motion of the conveyor belt and flat transfer belt of the module on which the first object is positioned in order to move the first object in the desired direction.

[0036] According to the invention, the transfer module assembly method includes providing a frame, supporting a conveyor belt with internal rotating elements on the frame, supporting conveyor drive rollers on the frame and configuring the conveyor drive rollers to drive the conveyor belt, mounting a flat transfer belt beneath the conveyor belt and configuring the flat transfer belt to contact undersides of the internal rotating elements of the conveyor belt in operation, and supporting flat transfer belt drive rollers on the frame and configuring the flat transfer belt drive rollers to drive the flat transfer belt. The conveyor drive rollers are friction-based and operate without use of a sprocket, and have depressions for receiving the internal rotating elements of the conveyor belt.

[0037] According to the invention, the depressions include grooves spaced to match a spacing of the internal rotating elements of the conveyor belt, a depth and geometry of the grooves being configured to provide multiple contact points between a surface of the conveyor belt and the conveyor drive rollers.

[0038] In some embodiments, the conveyor drive rollers have a friction coating including a rubberized sleeve or lagging.

[0039] In some embodiments, the conveyor belt and the flat transfer belt are configured to be driven in perpendicular directions. The method may also include providing tracking features and configuring the tracking features to resist deflection of the flat transfer belt, and the tracking features may include tracking grooves on the flat transfer belt drive rollers and features on the flat transfer belt that engages with the tracking grooves. The method may also include providing a low-friction slider bed support surface below the flat transfer belt, the tracking features including tracking grooves incorporated in the slider bed that align with the tracking grooves in the flat transfer belt drive rollers.

[0040] In some embodiments, the conveyor drive rollers propel the conveyor belt using friction maintained by a catenary force of a return portion of the conveyor belt hanging underneath and between the conveyor drive rollers, and the conveyor drive rollers have no tensioning mechanisms.

[0041] In some embodiments, the method also includes providing a control unit configured to control speed and direction of movement of the conveyor belt and flat transfer belt, and configuring the control unit to control relative speed and direction of the conveyor belt and flat transfer belt to achieve movement of an object on the conveyor belt in a predetermined direction, wherein the predetermined direction may be any direction along a surface of the conveyor belt.

[0042] These and further and other objects and features of the invention are apparent in the disclosure, which includes the above and ongoing written specification, with the drawings.BRIEF DESCRIPTION OF THE DRAWINGS

[0043] The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate exemplary embodiments and, together with the description, further serve to enable a person skilled in the pertinent art to make and use these embodiments and others that will be apparent to those skilled in the art. FIG. 1 illustrates a transfer module, according to an embodiment of the present invention. FIG. 2 illustrates a sprocket drive, in an embodiment not according to the invention. FIG. 3 illustrates a sprocket drive shaft in an embodiment not according to the invention. FIG, 4 illustrates a roller drive, according to an embodiment of the present invention. FIG. 5 illustrates a drive roller, according to an embodiment of the present invention. FIG. 6 illustrates tracking features, according to an embodiment of the present invention. FIG. 7 illustrates a transfer belt and slider bed interface, according to an embodiment of the present invention. FIG. 8 illustrates a sorter configuration, according to an embodiment of the present invention. DETAILED DESCRIPTION

[0044] This disclosure details package sorting transfer modules and systems and methods therefor. This specification discloses one or more embodiments that incorporate features of the invention. The embodiment(s) described, and references in the specification to "one embodiment", "an embodiment", "an example embodiment" etc., indicate that the embodiment(s) described may include a particular feature, structure, or characteristic. Such phrases are not necessarily referring to the same embodiment. When a particular future, structure, or characteristic is described in connection with an embodiment, persons skilled in the art may effect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described.

[0045] In the several figures, like reference numerals may be used for like elements having like functions even in different drawings. The embodiments described, and their detailed construction and elements, are merely provided to assist in a comprehensive understanding of the invention. Also well-known functions or constructions are not described in detail since they would obscure the invention with unnecessary detail. Any signal arrows in the drawings figures should be considered only as exemplary, and not unless otherwise specifically noted.

[0046] The description is not to be taken in a limiting sense, but is made merely for the purpose of illustration the general principles of the invention, since the scope of the invention is defined by the appended claims.

[0047] It will be understood that although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without departing from the scope of example embodiments. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. As used herein, the singular forms "a", "an" and "the" are intended to include the plural forma as well, unless the context indicates otherwise.

[0048] It should also be noted that in some alternative implementations, the functions / acts noted may occur out of the order noted in the figures. For example, two figures shown in succession may in fact be executed substantially concurrently or may sometimes be executed in the reverse order, depending upon the functionality / acts involved.

[0049] Figure 1 shows an overall depiction of a transfer module assembly, with the top conveyor belt partially cut away to expose the assembly beneath. A frame 100 provides the structural components to support the plastic conveyor belt 200 with internal rotating elements 300 mounted above the flat transfer belt 400. The frame supports the plastic conveyor drive rollers 500 and the flat transfer belt drive rollers 600 mounted at 90 degrees and underneath. With this configuration the rotating elements of the plastic conveyor belt move over the flat transfer belt which can be activated and move to the right or left and at 90 degrees to the direction of motion of the plastic conveyor belt.

[0050] Figure 2 shows a traditional way that a plastic conveyor belt interfaces with a drive roller using a sprocket style drive toner 700 to engage the plastic conveyor belt 800 with rotating elements 900 and provide motive power. The sprocket drive design results in a larger diameter nose roller 1000 because of the clearance required to establish teeth onto a cylindrical roller. One or more sprockets are used over the length of the drive roller. Figure 3 shows a representative sprocket drive system where a common shaft 1500 is outfitted with multiple sprockets 1200. The sprockets engage features in the plastic conveyor chain 1900 to provide the motive force. The rotating elements 1800 are free of the sprocket engagement area and can rotate.

[0051] Figure 4 shows the roller-style drive roller 1500 approach where the plastic conveyor belt 1600 with relating elements 1700 runs in a continuous loop using the friction of the drive roller 1500 to transmit the driving force. The roller approach results in a smaller diameter nose roller 1800 since there are no raised teeth required to interface with the plastic conveyor belt. The roller can have a minimal diameter and can be smooth. A very cost-effective approach is to simply cover a commercially available drive roller with a rubberized coating and then cut shallow grooves in it to accommodate the rotating elements that extend below the conveyor belt. The smaller diameter nose roller is a very important feature when connecting multiple transfer modules together. The smaller diameter rollers minimize "valley" between adjacent transfer units and allow the transport of smaller packages than could be processed with a sprocket driven conveyor.

[0052] Figure 5 provides a detailed view of the grooved friction drive roller 1900. The drive roller incorporates a friction coating 2000 that may be a rubberized sleeve or lagging that has been attached to the outside of the roller. This rubberized sleeve incorporates grooves 2100 that are evenly spaced and match the spacing of the rotating elements 2200 incorporated in the plastic conveyor belt 2300. The depth and geometry of the grooves is selected so that there are multiple contact points 2400 between the surface of the plastic conveyor belt and the drive roller 1900. In this embodiment the geometry of the grooves in the roller is designed to contact the rotating elements of the conveyor as well as the conveyor itself to assure that a very small package could not get stalled in a dead zone where the rotating elements slipped and turned freely without providing motive power.

[0053] Tracking features are used to resist deflection of the flat transfer belt as illustrated in Figure 6. The flat transfer belt drive rollers 2500 may be equipped with one or more tracking grooves 2600 that engage features on the flat transfer belt itself (shown in Fig 7). The slider bed 2700 is a low friction support surface below the flat transfer belt. Tracking grooves 2800 are also incorporated in the slider bed and these align with the tracking grooves in the transfer belt drive rollers. These tracking features are provided for the flat transfer belt which runs underneath the plastic conveyor belt that runs at 90 degrees to the transfer belt and is driven by the plastic drive belt rollers 2900.

[0054] Figure 7 illustrates a transfer belt and slider bed interface, according to an embodiment of the invention. The flat transfer ha 3000 may incorporate one or more belt tracking profiles 3100 attached to the back side. The flat transfer belt is supported by a low friction slider bed 3200 and this surface incorporates tracking grooves 3300 that align with the tracking features (i.e. 3100) of the flat transfer belt. There are many possible configurations for the shape of the grooves and the tracking profiles of the flat transfer belt, including passive designs as shown or even active designs where there are rollers or other features that resist the deflection of the transfer belt. These features prevent the top conveyor belt (e.g., 2300) from deflecting the flat transfer belt 3000 in the direction of motion of the top conveyor belt.

[0055] Figure 8 shows transfer modules combined to form a modular sorter system according an embodiment of the present invention. For this application an induction station 3400 is used to input packages into the sorter. Data is collected from scanners or other means and the package is inducted onto a string of one or more transfer modules 3500. Packages are transferred from one module to another and their progress is determined by zone sensors 3600 or other means such as calculation of the package position by the control system. Zone sensors 3600 may for example be photoelectric sensors, also called "photo eyes", and / or in some embodiments, ultrasonic motion sensors, cameras, radar, laser scanner, etc. When the package reaches the transfer module that services the appropriate bin discharge 3700, the transfer module activates and discharges the package into the correct discharge bin. This modular sorter solution can be expanded car reduced by simply adding car taking away transfer modules. This approach provides a scalable solution that can be easily changed to meet changing processing requirements.

[0056] The invention is not limited to the particular embodiments illustrated in the drawings and described above in detail. Those skilled in the art will recognize that other arrangements could be devised.

Claims

1. A transfer module assembly, comprising: a frame (100); a conveyor belt (200, 1600, 2300) with internal rotating elements (300, 2200), wherein the conveyor belt is supported by the frame; conveyor drive rollers (500, 1900) supported by the frame (100) and configured to drive the conveyor belt; a flat transfer belt (400, 3000) mounted beneath the conveyor belt and configured to contact undersides of the internal rotating elements of the conveyor belt in operation; and flat transfer belt drive rollers (600, 2500) supported by the frame and configured to drive the flat transfer belt; wherein the conveyor drive rollers (500, 1900) are friction-based and operate without use of a sprocket, and comprise grooves which are spaced to match a spacing of the internal rotating elements of the conveyor belt, a depth and geometry of the grooves is configured to provide multiple contact points (2400) between a surface of the conveyor belt and the conveyor drive rollers; characterized in that the internal rotating elements contact the conveyor drive roller inside the groove to prevent the internal rotating elements from rotating at the same time as the remaining surface of the conveyor drive roller maintains contact with the conveyor belt.

2. The assembly of claim 1, wherein the conveyor drive rollers (500, 1900) comprise a friction coating, the friction coating (2000) comprising a rubberized sleeve or lagging.

3. The assembly of claim 1, wherein the conveyor belt (200, 1600, 2300) and the flat transfer belt (400, 3000) are configured to be driven in different directions, preferably wherein the direction in which the flat transfer belt is configured to be driven is perpendicular to the direction in which the conveyor belt is configured to be driven.

4. The assembly of claim 3, further comprising tracking features (3100) configured to resist deflection of the flat transfer belt (400, 3000), preferably wherein the tracking features comprise tracking grooves (2600) on the flat transfer belt drive rollers (600, 2500) and features (2100) on the flat transfer belt that engage with the tracking grooves, optionally further comprising a low-friction slider bed support surface (3200) below the flat transfer belt wherein the tracking features comprise tracking grooves (2800) incorporated in the slider bed that align with the tracking grooves in the flat transfer belt drive rollers.

5. The assembly of claim 1, wherein the conveyor drive rollers propel the conveyor belt (200, 1600, 2300) using friction maintained by a catenary force of a return portion of the conveyor belt hanging underneath and between the conveyor drive rollers (500, 1900), wherein the conveyor drive rollers have no tensioning mechanisms.

6. The assembly of claim 4, further comprising a control unit configured to control speed and direction of movement of the conveyor belt (200, 1600, 2300) and flat transfer belt (400, 3000), wherein the control unit is configured to control relative speed and direction of the conveyor belt and flat transfer belt to achieve movement of an object on the conveyor belt in a predetermined direction, wherein the predetermined direction may be any direction along a surface of the conveyor belt.

7. A sorter, comprising: a plurality of transfer module assemblies according to claim 1 arranged in series; an induction station (3400) configured to collect information about objects to be conveyed and to induct the objects onto the plurality of transfer module assemblies; zone sensors (3600) configured to determine progress of the objects on the plurality of transfer module assemblies; discharge bins configured to receive the objects from the plurality of transfer module assemblies; and a control system configured to receive data regarding the progress of the objects on the plurality of transfer module assemblies from the zone sensors and to activate transfer modules based on the received data to discharge the objects into appropriate discharge bins.

8. The sorter of claim 7, wherein each of the plurality of transfer modules assemblies is configured to be controlled by the control system independently.

9. A sorter method, comprising: placing a first object on the sorter of claim 7; tracking a position of the first object; determining a desired direction of movement for the first object; and controlling speed and direction of motion of the conveyor belt (200, 1600, 2300) and flat transfer belt (400, 3000) of the module on which the first object is positioned in order to move the first object in the desired direction.

10. A transfer module assembly method, comprising: providing a frame (100); supporting a conveyor belt (200, 1600, 2300) with internal rotating elements (300, 2200) on the frame; supporting conveyor drive rollers (500, 1900) on the frame (100) and configuring the conveyor drive rollers to drive the conveyor belt; mounting a flat transfer belt (400, 3000) beneath the conveyor belt and configuring the flat transfer belt to contact undersides of the internal rotating elements of the conveyor belt in operation; and supporting flat transfer belt drive rollers (600, 2500) on the frame and configuring the flat transfer belt drive rollers to drive the flat transfer belt; wherein the conveyor drive rollers are friction-based and operate without use of a sprocket, and comprise grooves for receiving the internal rotating elements of the conveyor belt; wherein the grooves are spaced to match a spacing of the internal rotating elements of the conveyor belt, a depth and geometry of the grooves being configured to provide multiple contact points (2400) between a surface of the conveyor belt and the conveyor drive rollers, the transfer module assembly method being characterized in that the internal rotating elements contact the conveyor drive roller inside the groove to prevent the internal rotating elements from rotating at the same time as the remaining surface of the conveyor drive roller maintains contact with the conveyor belt.

11. The method of claim 10, wherein the conveyor drive rollers (500, 1900) comprise a friction coating (2000), the friction coating comprising a rubberized sleeve or lagging.

12. The method of claim 10, further comprising configuring the conveyor belt (200, 1600, 2300) and the flat transfer belt (400, 3000) to be driven in perpendicular directions, preferably further comprising: providing tracking features (3100) and configuring the tracking features to resist deflection of the flat transfer belt, wherein the tracking features comprise tracking grooves (2600) on the flat transfer belt drive rollers (600, 2500) and features on the flat transfer belt that engage with the tracking grooves, further comprising providing a low-friction slider bed support surface below the flat transfer belt, wherein the tracking features comprise tracking grooves (2800) incorporated in the slider bed that align with the tracking grooves in the flat transfer belt drive rollers; or providing a control unit configured to control speed and direction of movement of the conveyor belt and flat transfer belt, and configuring the control unit to control relative speed and direction of the conveyor belt and flat transfer belt to achieve movement of an object on the conveyor belt in a predetermined direction, wherein the predetermined direction may be any direction along a surface of the conveyor belt.

13. The method of claim 10, wherein the conveyor drive rollers (500, 1900) propel the conveyor belt (200, 1600, 2300) using friction maintained by a catenary force of a return portion of the conveyor belt hanging underneath and between the conveyor drive rollers, wherein the conveyor drive rollers have no tensioning mechanisms.