Telescopic conveyor

Abstract

An extendable conveyor system and method of operation for an extendable conveyor system. The extendable conveyor system includes a plurality of conveyor segments, a conveyor extension / retraction system, and a control system. The plurality of conveyor segments are coupled together in a telescoping configuration in which the individual conveyor segments at least partially overlap one another. The conveyor extension / retraction system is operatively coupled to at least one of the conveyor segments and configured to control extension and retraction of the extendable conveyor system by controlling movement of the conveyor segments relative to one another. The control system is in electrical communication with the conveyor extension / retraction system and is configured to perform operations including adjusting the position of one or more conveyor segments in response to data received from a baggage handling robot in electronic communication with the control system.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of the filing dates of U.S. Provisional Application No. 63 / 448,038, filed February 24, 2023, and U.S. Patent Application No. 18 / 444,442, filed February 16, 2024. The contents of U.S. Patent Application Nos. 63 / 448,038 and 18 / 444,442 are incorporated herein by reference in their entireties. [Background technology]

[0002] Conveyor systems are used in many different industries to efficiently move objects within a facility. For example, conveyor systems are used in manufacturing to move individual components within a manufacturing facility. Conveyor systems are also used in distribution facilities to move packages throughout the facility. Conveyor systems are used in shipping facilities to route packages to sorting facilities and shipping containers or vehicles. Improvements in such conveying systems are sought to continually improve the efficient transfer of objects within such industries. Summary of the Invention [Means for solving the problem]

[0003] TECHNICAL FIELD This disclosure relates to extensible conveyor systems and the operation of such systems.

[0004] In general, novel aspects of the subject matter described herein can be embodied in a method that includes operations of obtaining, from a sensor system, a first distance between a front end of a conveyor system and at least one object positioned in front of the conveyor system. The operations include determining that the first distance is less than a first predetermined distance. And, in response to the first distance being less than the first predetermined distance, the operations include controlling the conveyor system to move to increase the distance from the at least one object. Other implementations of this aspect include corresponding systems, apparatus, and computer programs configured to perform the actions of the method encoded on a computer storage device. These and other implementations each optionally include one or more of the following features.

[0005] In some implementations, determining that the first distance is less than the first predetermined distance includes comparing the first distance measurement to the first predetermined distance.

[0006] In some implementations, the first predefined distance comprises a user-selected value.

[0007] In some implementations, controlling the conveyor system includes sending a command to one or more motor controllers to retract the conveyor system until the first distance is greater than or equal to the first predetermined distance.

[0008] In some implementations, the conveyor system is an extensible conveyor system comprising a first conveyor segment and a second conveyor segment configured to nest below the first conveyor segment, and one or more motor controllers control relative movement between the first conveyor segment and the second conveyor segment.

[0009] In some implementations, the first distance is the shortest distance between the front end of the conveyor system and the plurality of objects.

[0010] In some implementations, the movement includes controlling a leading end of the conveyor system to move laterally relative to the length of the conveyor system.

[0011] In some implementations, controlling the laterally moving leading end of the conveyor system includes moving the leading end in response to measurement data from the sensor system.

[0012] In some implementations, controlling the lateral movement of the leading end of the conveyor system includes sending instructions to one or more motor controllers to control the lateral movement of the conveyor system in response to measurement data from the sensor system.

[0013] In some implementations, the operations include obtaining a second distance between a first side of the conveyor system and a second object from a sensor mounted on at least a first side of the sensor system; obtaining a third distance between the second side of the conveyor system and a third object from a sensor mounted on a second side of the sensor system; determining that a difference between the second distance and the third distance exceeds a threshold difference value; and, in response, controlling the conveyor system to move so that the difference is within the threshold difference value.

[0014] In some implementations, the conveyor system includes an interface for connecting the robot to the conveyor system, and the act of obtaining the first distance includes obtaining the first distance from the robot via the interface.

[0015] In some implementations, the operations include obtaining parcel flow data indicative of a flow rate of parcels along the conveyor system, and controlling operation of an independent indexing section of the conveyor system based on the parcel flow data.

[0016] In some implementations, controlling the operation of the independent indexing sections includes controlling at least one independent indexing section to adjust a buffer distance between loads by varying a speed of the at least one independent indexing section.

[0017] Another general aspect can be embodied in an extensible conveyor system including a plurality of conveyor segments, a conveyor extension / retraction system, and a control system. The plurality of conveyor segments are coupled in an extend / retract configuration in which the individual conveyor segments at least partially overlap one another. The conveyor extension / retraction system is operatively coupled to at least one of the conveyor segments and configured to control extension and retraction of the extensible conveyor system by controlling movement of the conveyor segments relative to one another. The control system is in electronic communication with the conveyor extension / retraction system and is configured to perform operations including adjusting the position of one or more conveyor segments in response to data received from a baggage handling robot in electronic communication with the control system. In some implementations, the control system can be configured to perform any one or more of the operations described above.

[0018] In some implementations, each conveyor segment includes one or more indexing sections, and operation of the control system includes controlling a speed of one indexing section independent of the other indexing sections in response to second data received from the baggage handling robot.

[0019] In some implementations, a front conveyor segment of the plurality of conveyor segments includes an articulating end configured to pivot relative to the front conveyor segment.

[0020] In some implementations, a base conveyor segment of the plurality of conveyor segments includes a load stop configured to raise and lower in response to control signals from a control system.

[0021] In some implementations, the plurality of conveyor segments includes a base conveyor segment configured to receive loads from the gravity chute, a terminal conveyor segment, and one or more intermediate conveyor segments disposed between the base conveyor segment and the terminal conveyor segment.

[0022] In some implementations, a base conveyor segment of the plurality of conveyor segments includes a load stop configured to raise and lower in response to control signals from a control system.

[0023] In some implementations, the one or more intermediate conveyor segments each comprise an independently controllable conveyor belt.

[0024] In some implementations, the front conveyor segment includes a plurality of rollers including at least a first set of powered rollers and a second set of powered rollers, the first set of powered rollers being separated from the second set of powered rollers by a set of non-powered rollers.

[0025] In some implementations, the front conveyor segment includes an articulating end configured to pivot relative to the front end of the terminal conveyor segment.

[0026] Another general aspect can be embodied in an extensible conveyor system including a plurality of conveyor segments, a conveyor extension / retraction system, a sensor system, and a control system. The plurality of conveyor segments are coupled in an extendable / retractable configuration in which the individual conveyor segments at least partially overlap one another. The conveyor extension / retraction system is operatively coupled to at least one of the conveyor segments and configured to control extension and retraction of the extensible conveyor system by controlling movement of the conveyor segments relative to one another. The control system is in electrical communication with the conveyor extension / retraction system and the sensor system, and is configured to perform operations including: obtaining a first distance between a front end of the conveyor system and at least one object positioned in front of the conveyor system from the sensor system; determining that the first distance is less than a first predetermined distance; and, in response to the first distance being less than the first predetermined distance, controlling the conveyor extension / retraction system to move the conveyor segment to increase the distance from the at least one object. In some implementations, the control system can be configured to perform any one or more of the operations described above.

[0027] In some implementations, the plurality of conveyor segments includes a base conveyor segment configured to receive loads from the gravity chute, a terminal conveyor segment, and one or more intermediate conveyor segments disposed between the base conveyor segment and the terminal conveyor segment.

[0028] In some implementations, a base conveyor segment of the plurality of conveyor segments includes a load stop configured to raise and lower in response to control signals from a control system.

[0029] In some implementations, the one or more intermediate conveyor segments each comprise an independently controllable conveyor belt.

[0030] In some implementations, the front conveyor segment includes a plurality of rollers including at least a first set of powered rollers and a second set of powered rollers, the first set of powered rollers being separated from the second set of powered rollers by a set of non-powered rollers.

[0031] In some implementations, the front conveyor segment includes an articulating end configured to pivot relative to the front end of the terminal conveyor segment.

[0032] Particular implementations of the subject matter described herein can be implemented to achieve one or more of the following advantages: The implementations may improve the efficiency of the loading operation. The implementations may reduce operator fatigue by maintaining an appropriate distance between the end of the conveyor and the loading location.

[0033] The details of one or more implementations of the subject matter described herein are set forth in the accompanying drawings and the description below. Other features, aspects, and advantages of the subject matter will become apparent from the description, drawings, and claims. [Brief explanation of the drawings]

[0034] [Figure 1] FIG. 1 is an elevational view of an exemplary extensible conveyor system in a transport configuration for a shipping vehicle according to an implementation of the present disclosure. [Figure 2] FIG. 2 is an elevational view of the extensible conveyor system of FIG. 1 in an extended configuration in accordance with an implementation of the present disclosure. [Figure 3] FIG. 2 is an elevational view of one configuration for adjustable height at the feed end of the extensible conveyor system of FIG. 1. [Figure 4] FIG. 2 is an elevational view of one configuration for adjustable height at the feed end of the extensible conveyor system of FIG. 1. [Figure 5] FIG. 2 is an elevational view of one configuration for adjustable height at the feed end of the extensible conveyor system of FIG. 1. [Figure 6]FIG. 2 is an elevational view of one configuration for adjustable height at the feed end of the extensible conveyor system of FIG. 1. [Figure 7] FIG. 1 is a perspective view of an exemplary implementation of an extensible conveyor system in a retracted configuration configured to interact with a load handling robot. [Figure 8] 1 is an elevation view of an exemplary implementation of an extendable conveyor system in a retracted configuration interacting with a baggage handling robot. FIG. [Figure 9] FIG. 12 is a detailed view of a side edge of an implementation of an extensible conveyor system. [Figure 10] FIG. 1 is a block diagram of an exemplary control system for an extensible conveyor system. [Figure 11] 11 is a flowchart of an alignment process for an extensible conveyor system that may be implemented by the control system of FIG. 10. [Figure 12A] 1 is one of a series of diagrams illustrating the alignment operation of an extensible conveyor system within a shipping vehicle. [Figure 12B] 1 is one of a series of diagrams illustrating the alignment operation of an extensible conveyor system within a shipping vehicle. [Figure 12C] 1 is one of a series of diagrams illustrating the alignment operation of an extensible conveyor system within a shipping vehicle. [Figure 12D] 1 is one of a series of diagrams illustrating the alignment operation of an extensible conveyor system within a shipping vehicle. [Figure 13A] FIG. 10 is a perspective view of another embodiment of an extendable conveyor system in an extended configuration. [Figure 13B] FIG. 13B is a perspective view of an implementation of the extensible conveyor system of FIG. 13A in a retracted configuration. [Figure 13C] FIG. 13B is a perspective view of an implementation of the extensible conveyor system of FIG. 13A in a retracted configuration. [Figure 14] FIG. 13B is a detailed view of the articulated end of the extensible conveyor system implementation of FIG. 13A. DETAILED DESCRIPTION OF THE INVENTION

[0035] Like reference numbers and designations in the various drawings indicate like elements.

[0036] Implementations of the present disclosure generally relate to an extensible conveyor system. The conveyor system can be configured to automatically extend and retract under user control or through interaction with a robot. The extensible conveyor system is described in the context of an exemplary use in a loading and shipping trailer. However, such a system may be used in a variety of other contexts and / or industries, such as warehousing, manufacturing, agricultural, etc.

[0037] 1 and 2, an extensible conveyor system 30 according to an embodiment of the present disclosure is shown. As shown, the extensible conveyor system 30 is configured for loading shipping vehicles such as flatbed trailers. The extensible conveyor system 30 includes an assembly of conveyor segments 32 supported by a frame 34. The frame 34 forms a support structure from which the conveyor segments 32 extend and into which they retract. The assembly of conveyor segments 32 can include a base conveyor segment 36 and one or more extension conveyor segments 38 nested below the base conveyor segment 36. The conveyor segments 36, 38 of the conveyor segment assembly 32 are slidably coupled to one another for arrangement in a transport or storage configuration 42 (FIG. 1) or an operating or extension configuration 44 (FIG. 2). The base conveyor segment 36 and each extension conveyor segment 38 may include a transport ramp 46 extending from each conveyor segment 38 in a distal (forward) direction 48 to form an inclined transition between successive conveyor segments 36, 38. The assembly of conveyor segments 32 may be laterally dimensioned to extend over a flatbed trailer 50 or other shipping vehicle. In some implementations, the conveyor system 30 is configured to extend the entire length of a 53-foot trailer from a truck dock, allowing robot access inside and outside doors, and to collapse to a footprint that creates a small footprint inside a building. For example, the number of conveyor segments 32 and / or the length of each individual segment 32 may be configured to extend beyond 53 feet while achieving a small collapsed footprint.

[0038] In some implementations, the frame 34 can be configured as a movable transport dolly. In such implementations, the frame 34 can include casters 62. In some embodiments, each of the elongated conveyor segments 38 is supported at a distal end using a support frame 66 attached to the casters 68. In some embodiments, the extensible conveyor system 30 includes one or more stabilizers 72 that can be selectably extended from the frame 34. In some implementations, the extensible conveyor system 30 includes a drive unit 74 attached to the support frame 66 of a leading (foremost) conveyor segment 76 of the conveyor segment assembly 32. The drive unit 74 contacts the flatbed trailer 50 and includes drive wheels 78 driven, for example, using a motor (not shown). The drive unit 74 can be rotatable about a vertical steering axis 80. In some implementations, the frame 34 is a fixed frame.

[0039] Functionally, the extendable conveyor system 30 facilitates loading of cargo onto a shipping vehicle, such as a flatbed trailer 50. The nesting configuration of the assembly of conveyor segments 32 allows the extension conveyor segment 38 to be extended in a distal direction 48 relative to the base conveyor segment 36. In an embodiment in which the assembly of conveyor segments 32 is appropriately dimensioned, the extension conveyor segment 38 as well as the base conveyor segment 36 and frame 34 can be positioned at the rear end 92 of the flatbed trailer 50.

[0040] The stabilizer 72 serves to selectively secure the frame 34. The drive unit 74 serves to guide the leading conveyor segment 76 in the distal direction 48, thereby extending the extension conveyor segment 38 as the leading conveyor segment 76 advances in the distal direction. In some embodiments, the drive unit 74 is rotated about a vertical steering axis 80 to steer a leading end 94 of the leading conveyor segment 76 relative to the frame 34. In some embodiments, the drive unit 74 also guides the leading conveyor segment 76 in a proximal direction 96 to reposition the leading end 94 as loading of the flatbed trailer 50 progresses.

[0041] In operation, the extensible conveyor system 30 is positioned in the transport configuration 42 adjacent to the rear end of the flatbed trailer 50. In some embodiments, one of the stabilizers 72 is brought into contact with the ground, allowing the frame 34 to pivot about the stabilizer 72 as the drive unit 74 extends the assembly of conveyor segments 32 and maneuvers it onto the flatbed trailer 50. Once the assembly of conveyor segments 32 reaches the desired extension, whichever stabilizer 72 is not in contact with the ground can be brought into contact with the ground to secure the extensible conveyor system 30 adjacent to the rear end 92 of the flatbed trailer 50.

[0042] 3-6, configurations for vertically positioning the front end 94 of the leading conveyor segment 76 at a desired height 112 are illustrated, according to implementations of the present disclosure. In some implementations, when in the extended configuration 44, all of the conveyor segments 36, 38 of the assembly 32 are vertically rotated about a pivot 114 located on or adjacent to a rear upright 116 of the frame 34 to achieve the desired height 112 (FIG. 3). In some implementations, only the conveyor segments 36, 38 of the assembly 32 are vertically rotated about the pivot 114, which is located on or adjacent to a front upright 118 of the frame 34 (FIG. 4). In some embodiments, a pivot 114 is disposed on or proximate the support frame 66 of one of the elongated conveyor segments 38, thereby allowing any of the elongated conveyor segments 38 distal to the support frame 66 to tilt to achieve the desired height 112 (FIG. 5). In some embodiments, a pivot 114 is disposed along the leading conveyor segment 76 to articulate the leading conveyor segment 76 to the desired height 112 (FIG. 6).

[0043] In some implementations, the front end 94 of the leading conveyor segment 76 is vertically positioned using a jack (not shown) attached to the support frame 66 of the leading conveyor segment 76. The jack can be manually or power driven. In some implementations, the support frame 66 as well as the front upright 118 of the frame 34 are configured to be vertically adjusted as needed to accommodate changing heights of the respective conveyor segments 36, 38 while adjusting the desired height 112 of the leading end 94. Height adjustment of the support frame 66 can be passive, with support provided by pneumatic or hydraulic cylinders.

[0044] In some implementations, the extensible conveyor system 30 is configured to automatically align the front end 94 within an enclosed area, such as within a flatbed trailer 50. For example, a trailer may shift relative to a loading dock due to parking variations, and such an embodiment allows the conveyor system 30 to adjust for such variations while maintaining alignment with the trailer walls as the conveyor system 30 extends into the trailer. In such implementations, the extensible conveyor system 30 can automatically adjust the alignment of the conveyor system 30 within the trailer 50 as loads 122 are loaded into the trailer 50. For example, the extensible conveyor system 30 can include a system of alignment sensors 124 disposed at the front end 94. The alignment sensors 124 can include distance measurement sensors, such as laser sensors, IR sensors, ultrasonic sensors, imaging sensors, stereo sensors, or combinations thereof. The alignment sensor system 124 is configured to measure a distance 128 between the front end 94 of the extensible conveyor system 30 and an object in front of the extensible conveyor system 30, for example, a load wall 120 formed within a flatbed trailer 50, a rear wall of the trailer 50, or a load handling robot. In a manual loading configuration, the extensible conveyor system 30 can be configured to adjust its position within the flatbed trailer 50 in response to measurements from the alignment sensor system 124. For example, as the distance 128 decreases while an operator adds loads 122 from the extensible conveyor system 30 onto the load wall 120, the extensible conveyor system 30 can automatically retract to provide the operator with additional space between the front end 94 and the load wall 120. Additionally, as described in more detail below, some implementations are configured to laterally align the front end 94 of the extensible conveyor system 30 within the trailer 50 using measurement data from the alignment sensor system 124.

[0045] In some implementations, the extensible conveyor system 30 is configured to automatically buffer the packages 122 as they are transported along the conveyor. For example, the extensible conveyor system 30 can include a package sensor system 126. In an exemplary implementation, the package sensor system 126 can be configured such that a set of sensors 126 is positioned along the extensible conveyor system 30. The package sensor system 126 can include gating sensors and / or vision sensors. For example, the gating sensors can include line break sensors, e.g., optical sensors, positioned along the extensible conveyor system 30 that detect the passage of packages moving along the extensible conveyor system 30. A control system (described below) can calculate the package flow rate and adjust the speeds of the independently controlled conveyors along the extensible conveyor system 30 to maintain manageable spacing between packages relative to a worker or robot stacking the packages 122 at the leading end 94. As another example, the package sensor system 126 can be configured with vision sensors and can use object identification processes, e.g., machine learning networks, to detect package spacing and flow rates along the extensible conveyor system 30. Package buffers can be used to slow down package flow rates or increase flow rates depending on the rate at which package stacking robots or workers remove packages from the conveyor system 30. In some examples, the conveyor system can stop one or more conveyors to conserve energy, for example, when the flow rate of packages from elsewhere in the logistics system is slow or sporadic due to the frequency of incoming deliveries.

[0046] FIG. 7 is a perspective view of an exemplary implementation of the extensible conveyor system 30 in a retracted configuration, and FIG. 8 is an elevation view of the extensible conveyor system 30 in a retracted configuration. For example, in a sorting facility, the extensible conveyor system 30 is shown with the base conveyor segment 36 aligned below a gravity feed 134. The gravity feed 134 can be, for example, a metal sheet chute, a chute with a load stop, or a chute with a powered conveyor and / or a load stop. Each conveyor segment 32 of the extensible conveyor system 30 can include an impact surface 140 and one or more independently controlled conveyor indexing sections 138. For example, in the illustrated implementation, the base segment 36 includes the impact surface 140 and two conveyor indexing sections 138. The other extension segments 38 can be configured similarly to the base conveyor segment 36. The impact surface 140 is configured using a set of free-spinning rollers. In some implementations, the rollers can be mounted on bearings supported by rubber or another type of shock-absorbing material to absorb the impact of a load falling onto the impact surface 140. The conveyor indexing sections 138 are independently controllable sections of a motorized conveyor. For example, each conveyor indexing section 138 can be an individual conveyor belt that is driven by a motor and can be configured to operate independently of the other conveyor indexing sections 138. In some implementations, the conveyor indexing sections 138 can be motorized rollers that can be configured to operate independently of the other conveyor indexing sections 138. In some implementations, the conveyor indexing sections can be configured using a combination of motorized rollers and free-spinning rollers. The motorized rollers can be configured to operate independently of the other conveyor indexing sections 138.

[0047] The front end 94 is configured as a cantilevered end 132 to allow access underneath the front end 94. For example, the cantilevered end 132 can be configured to allow a load handling robot 130 to fit underneath. For example, the cantilevered end 132 can allow a loading platform of the robot 130 to fit underneath the front end 94 so that loads drop from the extensible conveyor system 30 onto the robot's platform. The robot 130 can be programmed to remove loads from the conveyor, and the robot 130 may have a presentation conveyor or platform onto which loads drop before being stacked by the robot 130.

[0048] In some implementations, the extensible conveyor system 30 is configured to interact with a load-handling robot 130. For example, in some implementations, the extensible conveyor system 30 may include an interface that couples the robot 130 to the extensible conveyor system 30. The interface may be configured for communication between a control system of the extensible conveyor system 30 and the robot 130 (e.g., a wired or wireless communication interface) or may include a mechanical connection that allows the robot 130 to manipulate the front end 94 of the extensible conveyor system 30. When used with the robot 130, the robot sends manipulation commands to the extensible conveyor system 30 to control the movement of the conveyor system 30, for example, to maintain a gap between the robot 130 and the end of the conveyor system 30 when both enter and exit a trailer.

[0049] In some implementations, the extensible conveyor system 30 is configured to interact with the gravity feed section 134 to form a smooth transition between the gravity feed section 134 and the base conveyor segment 36 of the extensible conveyor system 30. For example, the base conveyor segment 36, the gravity feed section 134, or both, can be oriented at an angle to form a smooth transition between the two.

[0050] 9 shows a detailed view of a side edge of the extensible conveyor system 30. Each segment 32 of the extensible conveyor system 30 can include an edging 202 that extends at an upward angle from the top surface of the conveyor belt 204 and / or rollers 200.

[0051] 10 shows a block diagram of an exemplary control system 300 for the extensible conveyor system 30. The control system 300 includes a controller 302 in communication with various input and output systems. The controller 302 includes one or more processors 304 and computer memory 306. The computer memory can store instructions that are executed by the processor 304 to implement the control system operations described below.

[0052] Each of the input and output systems can be configured as one or more computer-executable software modules, hardware modules, or a combination thereof. For example, one or more of the input and output systems can be implemented as blocks of software code including instructions that cause one or more processors of the control system 300 to perform the operations described herein. Additionally or alternatively, one or more of the input and output systems can be implemented as electronic circuits, such as programmable logic circuits, field programmable logic arrays (FPGAs), or application-specific integrated circuits (ASICs). Input systems can include a conveyor alignment sensor system 308, a package flow sensor system 310, a user control interface 312, and, in some cases, a robot communication interface 314. Output systems can include a conveyor extension / retraction system 316, a conveyor alignment system 318, and a package buffering system 320.

[0053] The conveyor alignment sensor system 308 can include the conveyor alignment sensors 124 described above. Additionally, the conveyor alignment sensor system 308 can include sensors directed outward from the sides of the leading end 94 of the extensible conveyor system 30 and positioned to obtain measurements indicative of the distance between the sides of the extensible conveyor system 30 and the side walls of the trailer 50 (see FIGS. 12A-12D). The conveyor alignment sensor system 308 sensors can be positioned to help maintain lateral alignment of the leading end 94 within the enclosed space and manage its distance from the load wall 120.

[0054] The parcel flow sensor system 310 can include the parcel sensor system 126 described above. In some implementations, the parcel sensor system 126 includes an imaging sensor, and the parcel flow sensor system 310 can execute image processing algorithms to identify parcels in the images and pre-process the images before sending parcel flow data to the controller 302. For example, the parcel flow sensor system 310 can use image processing algorithms to determine parcel flow rates and parcel spacing along the extensible conveyor system 30. The parcel flow sensor system 310 can send the parcel flow rate and parcel spacing data to the controller 302. In some implementations, the parcel flow sensor system 310 includes a machine learning model trained to receive image data (e.g., a series of images or video) along the extensible conveyor system 30 as input and output parcel flow and spacing data. In some implementations, the parcel flow sensor system 310 can be configured to determine parcel flow and spacing using a series of line break sensors. For example, the parcel flow sensor system 310 can determine parcel flow rate and spacing based on the operating speed of the individual conveyor indexing sections 138 adjacent to each sensor and the timing between detected line breaks. Similarly, the parcel flow sensor system 310 can determine the size of each parcel based on the operating speed of the individual conveyor indexing sections 138 adjacent to each sensor and the duration of the line break. For example, a line break refers to an interruption of the optical signal between two sensors positioned on either side of the extensible conveyor system 30.

[0055] In response, the controller 302 can use the package flow rate and spacing data to adjust the speed of the individual conveyor indexing sections 138 to maintain appropriate package spacing. For example, appropriate package spacing is the spacing between packages that matches the speed at which a worker or robot can remove packages from the extensible conveyor system 30 and stack them on the trailer 50. The control system 300 can be configured to adjust the appropriate package spacing to accommodate changes in the speed at which the worker or robot operates. For example, the package flow sensor system 310 can include a sensor at the front end 94 that measures the time interval between packages being removed from the extensible conveyor system 30 by a worker or robot. The controller 300 can determine the speed at which to operate the conveyor indexing sections 138 so that packages arrive at approximately the same rate as the worker or robot is stacking them.

[0056] The user control interface 312 allows a user to manually control the operation of the control system 300 and calibrate system operation. For example, the user control interface 312 may allow a user to operate the extensible conveyor system 30 to manually extend / retract and / or align the leading end 94. In some implementations, the user control interface 312 may allow a user to calibrate the automated operation of the extensible conveyor system 30 by adding or adjusting default values, such as the distance to be maintained between the leading end 94 and the load wall 120, the lateral position of the extensible conveyor system 30 within the trailer 50, the load flow rate to be maintained, etc. The user control interface 312 may be hardwired to the extensible conveyor system 30 or may be configured to interact wirelessly with the control system 300. For example, the user control interface 312 may be a touchscreen display or a mobile computing device (e.g., a tablet computer or laptop computer). In some implementations, the user control interface 312 may include a joystick for operating the extensible conveyor system 30.

[0057] The robot communication interface 314 is an electrical communication interface that allows the load handling robot 130 to communicate with the controller 302. For example, in some implementations, the operation of the extensible conveyor system 30 can be controlled or guided by the robot 130. For example, the controller 302 can receive commands from the robot 130 through the robot communication interface 314 and operate the extensible conveyor system 30 in response to such commands.

[0058] The conveyor extension / retraction system 316 is configured to control the extension and retraction operation of the extendable conveyor system 30. For example, the conveyor extension / retraction system 316 includes one or more motors 324 coupled to one or more conveyor segments 36 and configured to extend and retract the conveyor segments 36 of the extendable conveyor system 30. Additionally, the conveyor extension / retraction system 316 includes one or more motor controllers 322 for controlling the operation of the motors 324. For example, the motor controllers 322 can be configured to receive digital commands from the controller 302 and operate the motors 324 according to the commands. The conveyor extension / retraction system 316 can include two independent drive motors coupled to the drive wheels 78 described above. In some implementations, the motors are coupled to the drive wheels via a set of reduction gears. The extendable conveyor system 30 can be extended or retracted by controlling the drive motors. In some implementations, the conveyor extension / retraction system 316 may include a drive wheel 78 and a drive motor on each extension segment 36 so that each extension segment 36 can extend and retract independently relative to neighboring segments. Generally, the conveyor extension / retraction system 316 receives commands from the controller 302 and operates the drive wheels 78 in accordance with such commands to extend and retract the extendable conveyor system 30.

[0059] In some implementations, the conveyor extension / retraction system 316 may include other mechanisms for extending and retracting the extendable conveyor system 30. For example, the conveyor extension / retraction system 316 may use motor-driven worm gears or gear-and-rack arrangements mounted between adjacent conveyor segments 36 to extend and retract the segments relative to one another.

[0060] The conveyor alignment system 318 is configured to control lateral movement of the front end 94 of the extensible conveyor system 30. The conveyor alignment system 318 includes one or more motors 328 coupled to the extensible conveyor system for moving the front end 94 laterally (or in an arc if the extensible conveyor system 30 is fulcrum-mounted at the rear end). Additionally, the conveyor alignment system 318 includes one or more motor controllers 326 for controlling operation of the motors 328. As noted above, the motor controllers 326 can be configured to receive digital commands from the controller 302 and operate the motors 324 according to the commands. The conveyor alignment system 318 can also operate the drive wheels 78. For example, the conveyor alignment system 318 can include a motor (e.g., a servo motor) coupled to a drive motor support for pivoting the drive wheels 78 90 degrees so that the front end 94 can be steered left and right. In some implementations, the conveyor alignment system 318 may be included within or may be a subsystem of the conveyor extension / retraction system 316. Generally, the conveyor alignment system 318 receives commands from the controller 302 and operates the drive wheels 78 in accordance with such commands to manipulate the front end 94 of the extendable conveyor system 30.

[0061] The load buffering system 320 is configured to control the operation of the conveyor indexing sections 138 to maintain a buffer distance between loads transported along the extensible conveyor system 30. The buffering system 320 includes a motor 332 coupled to a drive unit of each indexing section 138. The drive unit may include one or more drive rollers in the belt conveyor or one or more drive rollers in the set of rollers in each indexing section 138. As noted above, the motor controller 330 may be configured to receive digital commands from the controller 302 and operate the motor 332 according to the commands. The individual indexing sections 138 may be independently controlled by the controller 302 in response to input from the load flow sensor system 310 (e.g., a vision system) or independently controlled by the robot 130 in communication with the controller 302. The controller 302 can independently control and vary the speed of the indexing sections 138 to maintain a parcel spacing and flow rate commensurate with the rate at which parcels are removed from the front end of the conveyor system. Each indexing section 132 can be stopped or reversed independently of the other indexing sections 132 to maintain a desired parcel flow. In some examples, an indexing section 138 can be stopped when no parcels are present on the indexing section 138, for example, to reduce power usage.

[0062] The load buffering system 320 may also control a series of one or more load stops 602 along the length of the conveyor system 30. The load stops 602 may be controlled to allow loads to enter the conveyor system (e.g., from the gravity feed section 134) automatically and at a controlled rate. For example, the controller 302 may control the rate at which loads move along the indexing section 138 as well as raise and lower the load stops 602 as load flow gates. The controller 302 may control the operation of the load stops 602 based on input from the load flow sensor system 310 (e.g., a vision system) or based on input commands from the robot 130 with a vision system.

[0063] Generally, the load buffering system 320 receives commands from the controller 302 and adjusts the individual speeds of the appropriate indexing sections 138 in response to the commands. For example, the controller 302 receives load flow and spacing data from the load flow sensor system 310 and / or the robot 130. The controller 302 can then determine whether the load flow rate is too high or too low compared to the rate at which an operator or robot removes loads from the front end 94. For example, the controller 302 can use data from the load flow sensor system 310 to determine load dwell time to track how long a load is located at the front end 94 before an operator removes it and stacks it on the trailer 50. For example, load dwell time can be determined from an imaging sensor at the front end that detects the arrival of a load and tracks how long the load remains at the front end 94 before an operator or robot removes it. As another example, load dwell time can be determined based on the duration for which a load triggers a line break sensor at the front end 94. If the luggage dwell time is too long, e.g., exceeds a threshold time, the controller 302 can operate the indexing section 138 to decrease the luggage flow rate. Alternatively, if the luggage dwell time is too short (e.g., indicating that luggage was removed immediately upon arrival), the controller 302 can operate the indexing section 138 to increase the luggage flow rate.

[0064] In some situations, packages may arrive at variable intervals. The controller can control the upstream indexing sections 138 to adjust package spacing. For example, if data from the package flow sensor system 310 indicates that two packages have arrived, with one arriving shortly after the other, the controller 302 can temporarily slow down or stop the first indexing section 138 immediately after the first package passes from the first indexing section to the next subsequent indexing section on the extensible conveyor system 30. In this way, the two packages can be properly spaced apart. In implementations using imaging sensors (e.g., computer vision), the controller 302 can monitor the spacing between all packages along the extensible conveyor system 30 and, using real-time feedback provided by the imaging sensors, independently adjust each conveyor indexing section 138 to maintain proper package spacing.

[0065] In some implementations, the load buffering system 320 includes a load stop (e.g., load stop 604, described below). The control system 300 can control the operation of the load stop to help buffer the load. For example, the control system 300 can operate motors and / or hydraulic actuators to raise and lower the load stop 604 to direct the flow of loads onto the extendable conveyor system 30.

[0066] 13A-13C illustrate another implementation of the extensible conveyor system 30. The implementation illustrated in FIGS. 13A-13C is generally similar to the implementation described above, except for some optional modifications. The extensible conveyor system 30 is configured to be mounted below the gravity feed section 134. For example, the base conveyor segment 36 is shortened, thereby allowing the frame to be positioned below the gravity feed section 134. The base conveyor segment 35 also includes a load stop 602. The control system 300 can control the operation of the load stop 602 to help buffer loads passing through the extensible conveyor system 30. For example, the load stop 602 can be controlled to selectively raise and lower to control the flow of loads 122 into the extensible conveyor system 30. For example, the control system 300 can operate the load stop 602 to allow loads 122 to pass individually or in groups.

[0067] The base conveyor segment 36 and each extension conveyor segment 38 have transition ramps 606 between them. The transition ramps 606 can be flat, low-friction surfaces or can have free-spinning rollers. In some implementations, the transition ramps 606 can have powered rollers to help move loads in the reverse direction, i.e., upstream through the extendable conveyor system 30, to aid in loading and unloading trailers, for example.

[0068] The base conveyor segment 36 and each extension conveyor segment 38 each have only one conveyor indexing section 138a implemented as a conveyor belt, as shown. The final extension segment 638 has a different configuration than the three middle segments 38. The extension segment 638 uses all rollers, with the three conveyor indexing sections 138b using motorized rollers, to aid in load buffering, for example, at the ends of the extendable conveyor system 30. The control system 300 can independently control the direction and speed of each indexing section 138b to buffer loads, as described above.

[0069] As shown in FIG. 13C , the extension segment 638 can have an interface for attaching a purge cart 610. The purge cart 610 can be used to sort loads 122 that cannot be handled by the robot 130, such as damaged loads 122 or oddly shaped loads 122. The purge cart 610 can be removably coupled to the extension segment 638 using a latch assembly and / or a pair of magnets. For example, the purge cart interface can be coupled to a sidewall or frame of the extension segment 638. The purge cart connection interface allows the purge cart 610 to move alongside the extensible conveyor system 30 as the extensible conveyor system 30 is extended and retracted. In some examples, the purge cart is lower than the articulation end 604 so that unremovable loads can be pushed in.

[0070] 13C, a power supply 612 is mounted to the frame 34. Flexible electrical conduits 614 are used to provide power to the conveyor segments 32.

[0071] The front end of the extension segment 638 includes an articulating end 604. The articulating end can be manually controlled or controlled by the control system 300 to provide height and / or lateral adjustment. FIG. 14 is a detailed view of the extension segment 638 at the articulating end 604. As shown in FIG. 14, the articulating end 604 can be configured to articulate vertically to adjust the height of the extensible conveyor system 30 at the front end 94. For example, the articulating end 604 can be attached to the extension segment 638 at a hinge joint 616 to allow the articulating end 604 to be pivoted automatically (via the control system 300) or manually. The articulating end 604 is shown in three positions. Position A is substantially horizontal and extends at the same height as the extension segment 638. This position can be used to interact with the baggage handling robot 130. In Position B, the articulating end 604 is pivoted downward. This position may be used to manually unload or load cargo onto the extensible conveyor system 30. Position C is a storage position. In some implementations, the articulated end 604 may be mounted on a vertical pivot that allows the articulated end 604 to pivot laterally from side to side. The articulated end 604 may include motors or hydraulic devices controlled by the control system 300 arranged to enable automated movement of the articulated end 604 relative to the remainder of the extension segment 638.

[0072] The articulating end 604 includes, for example, a load stop 622 to prevent loads from falling off the end. The load stop 602 can be fixed. In some implementations, the load stop 602 is movable and can be raised / lowered similar to the load stop 602. The articulating end 604 can have a load indexing section 138 (e.g., a powered conveyor belt or motorized rollers) similar to the other conveyor segments 32.

[0073] The articulating end 604 may include a bumper 618 at the end. In some implementations, the bumper has a pressure sensor to detect if / when the articulating end 604 hits an object. The pressure sensor may serve to alert the control system 300, which may retract or stop movement of the extensible conveyor system 30 upon detecting a collision. In some examples, the articulating end 604 includes lights and / or reflectors on the front end 94 and / or sides.

[0074] The movement of the articulated end 604 can be controlled independently by the controller 302 or via commands from the robot 130. That is, the controller 302, operating independently or via commands from the robot 130, can control the rotation of the articulated end 604 (e.g., pivoting up and down or left and right), the operation of the conveyor or motorized rollers relative to the indexing section 138 of the articulated end 604, and the operation of the load stop 602. In some implementations, the articulated end 604 serves as a load removal zone for the robot 130 or a worker. For example, when operating with the robot 130, there can be multiple loads on the articulated end 604 at one time (e.g., three loads in a row). When the robot 130 is to remove a load that is not in the middle or rear of the articulated end 604 (e.g., the second load in a row), the robot 130 can instruct the controller 302 to advance the indexing section 138. This causes loads at the rear of the articulating end 604 to move forward, while the front load is prevented from falling off the edge by the load stop 602. In some implementations, the controller 302 can automatically sense where a load is located on the articulating end 604 and advance the indexing section 138 appropriately without control from the robot 130. For example, the controller 302 can control the movement of the indexing section 138 relative to the articulating end 604, similar to that described above, but in response to input from a load flow sensor system 310 (e.g., a vision system) or an array of pressure sensors below the indexing section 138 that indicates the position of the load on the indexing section 138.

[0075] Figure 11 shows a flowchart of alignment processes 400, 420 for operating an extensible conveyor system. Processes 400 and 420 can be performed by one or more computing systems, including but not limited to, the control system 300 described above for controlling the extensible conveyor system 30. Processes 400 and 420 are described with reference to Figure 11 and Figures 12A-12D. Figures 12A-12D show a series of top views illustrating the operation of processes 400 and 420.

[0076] Process 400 is a process for automatically controlling the retraction of the extensible conveyor system 30 as luggage is loaded into the trailer 50. The control system 300 obtains (402) a first distance measurement between the front end of the conveyor system and at least one object positioned in front of the conveyor system. For example, the control system can obtain one or more distance measurements (e.g., d1 and d2) from the alignment sensor 124. In some implementations, the robot 130 can perform the measurement and transmit the measurement to the control system 300. The object may be, for example, the luggage wall 120, the front wall of the trailer 50, or the luggage handling robot 130. For example, when the extensible conveyor system 30 is used with the luggage handling robot 130, the control system 300 can maintain a desired distance from the robot 130 so that the end of the extensible conveyor system 30 is within reach of the robot 130. In such implementations, the control system 300 can store different distance settings. For example, the desired distance from the wall of the load under manual operation may be different from the desired distance from the robot 130 (e.g., the front end 94 may be configured in a cantilevered manner above a portion of the robot, so that the desired distance from the robot may be shorter than the desired distance from the wall of the load under manual operation).

[0077] The control system 300 determines that the first distance is less than a first predetermined distance (404). For example, the control system 300 can compare a predetermined spacing (e.g., an operating distance) between the front end 94 and the rear of the trailer or the load wall 120 with the measured distance. If the measured spacing is less than the predetermined spacing, the control system 300 can retract the extensible conveyor system 30 (406). If the measured distance is greater than the predetermined spacing, the control system 300 can extend the extensible conveyor system 30. In some implementations, a variance distance can be used to avoid excessive movement of the extensible conveyor system 30. For example, the variance distance can define an acceptable variance (e.g., 6 inches) from a specified spacing. If the difference between the measured distance and the predetermined distance is within the variance, the control system 300 will not extend or retract the extensible conveyor system 30. The control system 300 can control the retraction / extension of the extendable conveyor system 30 by sending commands to one or more motor controllers to retract / extend the conveyor system until the measured distance is equal to or greater than the predetermined interval.

[0078] The default interval may be a user-set value, for example, in the case of a manual trailer loading process. In some implementations, the user may adjust the default interval value during operation.

[0079] In some implementations, the control system 300 can use a time delay to respond to temporary obstructions of one or more alignment sensors 124 due to loading operations. For example, the control system 300 may require that any change in measured distance persist for a certain period of time (e.g., 1-2 seconds) before any action is taken to retract the extensible conveyor system 30.

[0080] In some implementations, the control system 300 can use multiple distance measurements, as shown in FIGS. 12A-12C. For example, the control system may require multiple distance measurements to be less than a predetermined interval before initiating action to retract the extensible conveyor system 30. As shown in FIG. 12A, because the package is placed in front of the leftmost sensor, distance d1 is less than the predetermined interval. However, distance d2 is still within the predetermined interval, and therefore the control system 300 does not yet retract the extensible conveyor system 30. When the package is placed in front of the rightmost sensor (as shown in FIG. 12B), both d1 and d2 are less than the predetermined interval, and therefore the control system 300 retracts the extensible conveyor system 30 (FIG. 12C) until the average or mean of all forward distance measurements (d1 and d2) is within the allowed variance of the predetermined interval. The control system can wait to retract the extensible conveyor system until all distance measurements are less than a predetermined distance, or the control system can use a majority voting process to retract the extensible conveyor system until a majority of the forward-facing sensors measure a distance less than a predetermined distance.

[0081] The control system 300 can control the retraction of the extendable conveyor system 30 by sending commands to one or more motor controllers to retract the conveyor system until the measured distance is equal to or greater than the predetermined spacing.

[0082] In some implementations, a baggage handling robot 130 can perform the process 400. In such implementations, the robot 130 can control the operation of the extensible conveyor system 30 by sending comments to the control system 300. For example, the robot 130 can use its sensors to determine when to extend or retract the extensible conveyor system 30 and then issue appropriate commands to the control system 300, causing the control system 300 to operate the extensible conveyor system 30 in response to the determination.

[0083] 11 and 12D, process 420 is a process for automatically aligning an extensible conveyor system 30 within an enclosed space (e.g., a trailer 50). The control system 300 obtains (422) first and second distance measurements from opposite sides of the conveyor at the front end 95. One measurement is the distance (e.g., d4) between the right side of the conveyor and the right side wall 550 of the trailer, and the other measurement is the distance (e.g., d3) between the left side of the conveyor and the left side wall 552 of the trailer. For example, the measurements may be obtained from an alignment sensor 124 positioned to obtain distance measurements from the sides of the extensible conveyor system 30.

[0084] The control system determines (424) the difference between the first distance measurement and the second distance measurement. If the measurements differ, the extensible conveyor system 30 is out of position within the trailer. The control system 300 can compare the difference to a threshold (e.g., 6 inches). If the difference is greater than the threshold, the control system 300 can control the extensible conveyor system 30 to adjust the lateral position of the extensible conveyor system 30 within the trailer (426). For example, the control system 300 can control the extensible conveyor system 30 to move toward the sensor that measured the greater distance to reduce the difference between the two measurements. For example, the control system 300 can send commands to one or more motor controllers to pivot the drive wheels and move the front end 94 to the left (as shown in FIG. 12D).

[0085] While the extensible conveyor system 30 has been described as performing trailer loading operations, it can also be used in a loading / unloading configuration. For example, the conveyor can be operated in reverse, and the process 400 can similarly be performed to incrementally extend the extensible conveyor system 30 into the trailer as loads are removed from the trailer. When the measured distance is longer than the predetermined spacing, the extensible conveyor system 30 is incrementally extended to maintain the spacing. Furthermore, in implementations capable of performing both loading and unloading operations, the transition ramp 606 can be designed with a low profile and / or include powered rollers to help move the loads upstream of the conveyor.

[0086] Implementations of the subject matter and functional operations described herein can be implemented in digital electronic circuitry, tangibly implemented computer software or firmware, computer hardware, including the structures disclosed herein and their structural equivalents, or one or more combinations thereof. Implementations of the subject matter described herein can be implemented as one or more computer programs, i.e., one or more modules of computer program instructions encoded on a tangible, non-transitory program carrier for execution by or control the operation of a data processing apparatus. A computer storage medium can be a machine-readable storage device, a machine-readable storage substrate, a random or serial access memory device, or a combination of one or more of these.

[0087] The term “controller” refers to data processing hardware and encompasses all types of apparatus, devices, and machines for processing data, including, by way of example, a programmable processor, a computer, or multiple processors or computers. An apparatus can also be or further include special-purpose logic circuitry, such as a central processing unit (CPU), an FPGA (field-programmable gate array), or an ASIC (application-specific integrated circuit). In some implementations, the data processing apparatus and / or the special-purpose logic circuitry may be hardware- and / or software-based. An apparatus may, in some cases, include code that creates an execution environment for a computer program, such as code that constitutes processor firmware, a protocol stack, a database management system, an operating system, or one or more combinations thereof. The present disclosure contemplates the use of data processing apparatuses that may or may not be accompanied by a conventional operating system, such as Linux, UNIX, Windows, Mac OS, Android, iOS, or any other suitable conventional operating system.

[0088] A computer program, which may be called or described as a program, software, software application, module, software module, script, or code, can be written in any form of programming language, including compiled or interpreted languages, or declarative or procedural languages, and can be deployed in any form, including as a stand-alone program or as a module, component, subroutine, or other unit suitable for use in a computing environment. A computer program may, but need not, correspond to a file in a file system. A program can be stored in part among other programs or data, e.g., a markup language document, a single file dedicated to the program, or multiple coordinating files, e.g., one or more modules, one or more subprograms, or one or more portions of code stored in the file. A computer program can be deployed to run on one computer or on multiple computers located at one site or distributed across multiple sites and interconnected by a communications network. While some portions of the programs illustrated in the various figures are shown as individual modules that implement various features and functionality through various objects, methods, or other processes, the programs may instead include several sub-modules, third-party services, components, libraries, etc., as appropriate. Conversely, the features and functionality of various components may be combined into a single component as appropriate.

[0089] The processes and logic flows described herein may be implemented by one or more programmable computers executing one or more computer programs to perform functions by operating on input data and generating output. The processes and logic flows may also be implemented by, or an apparatus may be implemented as, special purpose logic circuitry, such as a central processing unit (CPU), an FPGA (field programmable gate array), or an ASIC (application-specific integrated circuit).

[0090] A computer suitable for executing a computer program can include or be based on, by way of example, a general-purpose microprocessor, a special-purpose microprocessor, or both, or any other type of central processing unit. Generally, the central processing unit receives instructions and data from a read-only memory, a random-access memory, or both. The essential elements of a computer are a central processing unit for performing or executing instructions and one or more memory devices for storing instructions and data. Generally, a computer includes one or more mass storage devices, e.g., magnetic disks, magneto-optical disks, or optical disks, for storing data, or is operatively coupled to receive data from or transfer data to them, or both. However, a computer need not have such devices. Furthermore, a computer can be incorporated into another device, e.g., a mobile phone, a personal digital assistant (PDA), a mobile audio or video player, a game console, a global positioning system (GPS) receiver, or a portable storage device, e.g., a universal serial bus (USB) flash drive, to name just a few.

[0091] Computer-readable media (transitory or non-transitory, as appropriate) suitable for storing computer program instructions and data include all forms of non-volatile memory, media, and memory devices, including, by way of example, semiconductor memory devices such as EPROM, EEPROM, and flash memory devices, magnetic disks such as internal hard disks or removable disks, magneto-optical disks, and CD-ROM and DVD-ROM disks. The memory may store various objects or data, including caches, classes, frameworks, applications, backup data, jobs, web pages, web page templates, database tables, repositories that store business and / or dynamic information, and any other suitable information, including any parameters, variables, algorithms, instructions, rules, constraints, or references thereto. In addition, the memory may include any other suitable data, such as logs, policies, security or access data, reporting files, etc. The processor and memory may be supplemented by, or incorporated in, special-purpose logic circuitry.

[0092] To provide for user interaction, implementations of the subject matter described herein can be implemented on a computer having a display device, e.g., a CRT (cathode ray tube), LCD (liquid crystal display), or plasma monitor, for displaying information to the user, and a keyboard and pointing device, e.g., a mouse or trackball, by which the user can provide input to the computer. Other types of devices can also be used to provide for user interaction; for example, feedback provided to the user can be any form of sensory feedback, e.g., visual feedback, auditory feedback, or tactile feedback, and input from the user can be received in any form, including acoustic, speech, or tactile input. Additionally, a computer can interact with a user by sending documents to and receiving documents from a device used by the user, e.g., by sending a web page to a web browser on the user's client device in response to a request received from the web browser.

[0093] Implementations of the subject matter described herein can be implemented in a computing system that includes a back-end component, e.g., as a data server, or includes a middleware component, e.g., an application server, or includes a front-end component, e.g., a client computer having a graphical user interface or web browser through which a user can interact with an implementation of the subject matter described herein, or includes any combination of one or more such back-end, middleware, or front-end components. The components of the system can be interconnected by any form of digital data communication, e.g., a communications network or medium thereof. Examples of communications networks include a local area network (LAN), a wide area network (WAN), e.g., the Internet, and a wireless local area network (WLAN).

[0094] A computing system may include clients and servers. Clients and servers are generally remote from each other and typically interact through a communication network. The relationship of client and server arises by virtue of computer programs running on the respective computers and having a client-server relationship to each other.

[0095] While this specification contains detailed descriptions of numerous specific implementations, these should not be construed as limitations on the scope of any invention and what may be claimed, but rather as descriptions of features that may be unique to particular implementations of a particular invention. Some features described herein in the context of separate implementations may also be combined and implemented in a single implementation. Conversely, various features described in the context of a single implementation may also be implemented separately in multiple implementations or in any suitable subcombination. Furthermore, while features may be described above as acting in a combination and in some cases even claimed as such, one or more features in a claimed combination may, in some cases, be deleted from the combination, and the claimed combination may be directed to a subcombination or a variation of the subcombination.

[0096] Similarly, although the figures depict operations in a particular order, this should not be understood as requiring such operations to be performed in the particular order shown, or sequentially, or that all of the depicted operations be performed, to achieve desired results. In some situations, multitasking and parallel processing may be useful. Furthermore, the separation of various system modules and components in the above-described implementations should not be understood as requiring such separation in all implementations, and it should be understood that the described program components and systems may generally be integrated into a single software product or packaged in multiple software products.

[0097] While this document contains detailed descriptions of numerous specific implementations, these should not be construed as limitations on the scope of what may be claimed, but rather as descriptions of features that may be specific to particular implementations or embodiments. Some features that are described herein in the context of separate embodiments may also be combined and implemented in a single embodiment. Conversely, various features that are described in the context of a single implementation may also be implemented in multiple embodiments separately or in any suitable subcombination. Furthermore, while features may be described above as acting in a combination and in some cases even claimed as such, one or more features in a claimed combination may, in some cases, be deleted from the combination, and the claimed combination may be directed to a subcombination or a variation of the subcombination. [Explanation of symbols]

[0098] 30 Extendable conveyor system 32 conveyor segments 34 frames 36 base conveyor segments 38 Extension conveyor segment, intermediate segment 42 Transport or storage configuration 44 Activated or Extended Configuration 46 Transport Ramp 48 Distal 50 Trailer 62 Caster 66 Support Frame 68 Caster 72 stabilizer 74 Drive Unit 76 Tip conveyor segment 78 Drive Wheel 80 vertical control axis 92 Rear end 94 Front end 96 Proximal 112 desired height 114 Pivot 116 Rear upright part 118 Front upright part 120 Luggage Wall 122 Luggage 124 Alignment sensor, alignment sensor system 126 Luggage Sensor System 128 distance 130 Baggage handling robot, robot 132 Cantilever end 134 Gravity feed section 138 Conveyor Indexing Section 138a Conveyor Indexing Section 138b Conveyor Indexing Section 140 Impact Surface 200 Rollers 202 Edging 204 Conveyor Belt 300 Control System 302 Controller 304 processor 306 Computer Memory 308 Conveyor Alignment Sensor System 310 Baggage Flow Sensor System 312 User Control Interface 314 Robot Communication Interface 316 Conveyor Extension / Retraction System 318 Conveyor Alignment System 320 Luggage buffer system 322 Motor Controller 324 Motor 326 Motor Controller 328 Motor 330 motor controller 332 Motor 550 Right side wall 552 Left side wall 602 Luggage Stop 604 Load stop, connecting end 606 Transition Ramp 610 Purge Cart 612 Power supply 614 Power Lines 616 Hinge Joint 618 Bumper 622 Luggage Stop 638 Extension Segment

Claims

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

2. The method of claim 1 , wherein the step of determining that the first distance is less than the first predetermined distance comprises comparing the first distance measurement to the first predetermined distance.

3. The method of claim 1 or 2, wherein the first predetermined distance comprises a user-selected value.

4. 4. The method of claim 1, wherein the step of controlling the conveyor system includes sending a command to one or more motor controllers to retract the conveyor system until the first distance is equal to or greater than the first predetermined distance.

5. 5. The method of claim 4, wherein the conveyor system is an extendable conveyor system comprising a first conveyor segment and a second conveyor segment configured to nest below the first conveyor segment, and the one or more motor controllers control relative movement between the first conveyor segment and the second conveyor segment.

6. The method of claim 1 , wherein the first distance is the shortest distance between the front end of the conveyor system and a plurality of objects.

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

8. 8. The method of claim 7, wherein the step of controlling to laterally move the leading end of the conveyor system includes moving the leading end in response to measurement data from the sensor system.

9. 8. The method of claim 7, wherein the step of controlling the leading end of the conveyor system to move laterally includes sending instructions to one or more motor controllers to control lateral movement of the conveyor system in response to measurement data from the sensor system.

10. obtaining a second distance between a first side of the conveyor system and a second object from a sensor attached to at least a first side of the sensor system; obtaining a third distance between the second side of the conveyor system and a third object from a sensor attached to a second side of the sensor system; determining that a difference between the second distance and the third distance exceeds a threshold difference value; responsively controlling the conveyor system to move so that the difference is within the threshold difference value; 10. The method of claim 1, further comprising:

11. the conveyor system includes an interface for connecting a robot to the conveyor system; The method of claim 1 , wherein the step of obtaining the first distance comprises obtaining the first distance from the robot via the interface.

12. acquiring tote flow data indicative of tote flow along the conveyor system; controlling operation of an independent indexing section of the conveyor system based on the package flow data; 12. The method of claim 1, further comprising:

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

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

15. A system / apparatus comprising:

14. A system / apparatus comprising one or more processors / computers and one or more data stores coupled to said one or more processors / computers, said data stores storing instructions that, when executed by said one or more processors / computers, cause said one or more processors / computers to perform a method according to any one of claims 1 to 13.

16. 1. An extensible conveyor system, comprising: a plurality of conveyor segments ganged together in a telescoping configuration in which the individual conveyor segments at least partially overlap one another; a conveyor extension / retraction system operatively coupled to at least one of the conveyor segments and configured to control extension and retraction of the extendable conveyor system by controlling movement of the conveyor segments relative to one another; a control system in electrical communication with the conveyor extension / retraction system and configured to implement the method of any one of claims 1 to 13; 1. An extensible conveyor system comprising:

17. 1. An extensible conveyor system, comprising: a plurality of conveyor segments ganged together in a telescoping configuration in which the individual conveyor segments at least partially overlap one another; a conveyor extension / retraction system operatively coupled to at least one of the conveyor segments and configured to control extension and retraction of the extendable conveyor system by controlling movement of the conveyor segments relative to one another; a control system in electrical communication with the conveyor extension / retraction system and configured to perform operations including adjusting the position of one or more conveyor segments in response to data received from a load handling robot in electronic communication with the control system; 1. An extensible conveyor system comprising:

18. Each conveyor segment comprises one or more indexing sections; 18. The extensible conveyor system of claim 17, wherein the operations include controlling a speed of one indexing section independent of other indexing sections in response to second data received from the load handling robot.

19. 19. The extensible conveyor system of claim 17 or 18, wherein a frontmost conveyor segment of the plurality of conveyor segments includes an articulated end configured to pivot relative to the frontmost conveyor segment.

20. 20. The extensible conveyor system of any one of claims 17 to 19, wherein a base conveyor segment of the plurality of conveyor segments comprises a load stop configured to raise and lower in response to control signals from the control system.

21. the plurality of conveyor segments comprising a base conveyor segment configured to receive loads from a gravity chute, a terminal conveyor segment, and one or more intermediate conveyor segments disposed between the base conveyor segment and the terminal conveyor segment; the base conveyor segment of the plurality of conveyor segments includes a load stop configured to raise and lower in response to control signals from the control system; the one or more intermediate conveyor segments each comprise an independently controllable conveyor belt; The front conveyor segment is a plurality of rollers including at least a first set of powered rollers and a second set of powered rollers, the first set of powered rollers being separated from the second set of powered rollers by a set of non-powered rollers; a connecting end configured to pivot relative to the front end of the terminal conveyor segment; 21. An extensible conveyor system according to any one of claims 17 to 20, comprising:

22. 1. An extensible conveyor system, comprising: a plurality of conveyor segments ganged together in a telescoping configuration in which the individual conveyor segments at least partially overlap one another; a conveyor extension / retraction system operatively coupled to at least one of the conveyor segments and configured to control extension and retraction of the extendable conveyor system by controlling movement of the conveyor segments relative to one another; A sensor system, a control system in electrical communication with the conveyor extension / retraction system and the sensor system, the control system comprising: obtaining a first distance between a front end of the conveyor system and at least one object positioned in front of the conveyor system from the sensor system; determining that the first distance is less than a first predetermined distance; responsive to the first distance being less than the first predetermined distance, controlling a conveyor extension / retraction system to move a conveyor segment to increase the distance from the at least one object; 1. An extensible conveyor system configured to perform operations including:

23. the plurality of conveyor segments comprising a base conveyor segment configured to receive loads from a gravity chute, a terminal conveyor segment, and one or more intermediate conveyor segments disposed between the base conveyor segment and the terminal conveyor segment; the base conveyor segment of the plurality of conveyor segments includes a load stop configured to raise and lower in response to control signals from the control system; the one or more intermediate conveyor segments each comprise an independently controllable conveyor belt; The front conveyor segment is a plurality of rollers including at least a first set of powered rollers and a second set of powered rollers, the first set of powered rollers being separated from the second set of powered rollers by a set of non-powered rollers; a connecting end configured to pivot relative to the front end of the terminal conveyor segment; 20. The extensible conveyor system of claim 19, comprising:

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