Conveyor module

Abstract

A conveyor module comprising: a rotatable portion having one or more conveying elements mounted thereon, each conveying element having a plurality of engagement members configured to engage with a surface of an object to be conveyed in a first direction via rotation of the rotatable portion, each engagement member further being configured for free rotation on the conveying element in a second direction that is orthogonal to the first direction; a driving mechanism configured to rotate the rotatable portion such that the engagement members cause movement of an engaged object in the first direction; and a control mechanism configured to control rotation of the rotatable portion via the driving mechanism; wherein the rotatable portion defines an internal cavity, and the driving mechanism is at least partly housed within the cavity.

Description

[0001] CONVEYOR MODULE

[0002] Field of the Invention

[0003] The present invention relates to a conveyor module for facilitating movement of a plurality of objects within an object transport system.

[0004] Background

[0005] Sorting systems, for example for package sorting systems, typically include a conveying system which is able to receive packages and route them to their destination. The conveying system includes a transporting surface, such as a conveyor belt or a system of cooperating wheels, on which the package rests and is moved about by a central control system. The transporting surfaces can take a number of different forms, as follows.

[0006] A first example conveying system includes a conveyor belt ring having multiple feed-in and feed-out paths attached to the main ring. Packages are conveyed to the central ring via the feed-in conveying paths and are transported round the ring until each package reaches its designated fee-out conveyor path. A problem with this system is that the conveying system is a generally large, fixed system of conveyor belts and so flexibility of the conveying paths is very limited. Furthermore, these systems are typically too large and expensive to be accessible to small and medium sized facilities. These systems are not able to easily adjust their functionality or configuration.

[0007] A second example conveying system includes a shuttle robot system in which carrier robots move around a floor to collect and distribute packages around different locations on the floor. However, this system is only able to move packages in two dimensions. Further, a limited number of carrier robots operate at a given time and so the number of packages being transported at a given time is also limited. In addition, carrier robots on the other hand are designed to carry objects of fixed size, thus being inefficient in situations where there is large variability in size of the objects that need to be handled.

[0008] A third example conveying system includes transportation layer for the transportation of packages and a storage layer for storage of packages. A robot moves packages through the transportation layer to its desired location on the storage layer. The packages are moved in containers which are designed to fit the transportation layer. However, due to the use of containers to transport the packages, there is a limit of the size of the package that can be transported through the system within the container. Additionally, using containers of a fixed size is an inefficient use of space if small packages are being handled.

[0009] Some conveying systems include conveyor belts that can move parcels in all directions, known as omnidirectional conveyor belts. The conveyor belt is controlled by a control system that sends commands to a driving system. The systems often include multiple floor segments, each floor segment having multiple omnidirectional wheels arranged within the segment. The omnidirectional wheels in each segment are connected by wires to the control system. In some cases, the segments can be lifted up out of the floor to inspect the wiring. These systems are capable of high throughput but generally do not have high precision.

[0010] Traditional e-commerce automation solutions are big, bulky, expensive, typically lacking ease of scalability and / or having restrictions with regards to exploitation of space in all three dimensions. Additionally, many of the solutions do not allow for high flexibility in run-time, with their functionality parameters often set in stone by the specific hardware configuration, leaving little room for on-demand operation adjustment and optimization.

[0011] It would be desirable to have a flexible, modular hardware system that allows for operation in at least two dimensions, and preferably in three dimensions, powered by software that allows for on demand adjustment and optimization of functionality. Summary

[0012] In accordance with a first aspect, there is provided a conveyor module comprising: a rotatable portion having one or more conveying elements mounted thereon, each conveying element having a plurality of engagement members configured to engage with a surface of an object to be conveyed in a first direction via rotation of the rotatable portion, each engagement member further being configured for free rotation on the conveying element in a second direction that is orthogonal to the first direction; a driving mechanism configured to rotate the rotatable portion such that the engagement members cause movement of an engaged object in the first direction; and a control mechanism configured to control rotation of the rotatable portion via the driving mechanism; wherein the rotatable portion defines an internal cavity and the driving mechanism is at least partly housed within the cavity.

[0013] By housing the driving mechanism at least partially within the cavity, a size of the conveyor module can be reduced. In particular, since the driving mechanism is not fully located outside of the rotatable portion, it shares a substantial amount of the footprint of the rotatable portion, thereby reducing a space that would otherwise be occupied by the driving mechanism. Additionally, locating the driving mechanism (e.g., a motor) within the rotatable portion may also permit coaxiality of the motor and rotatable portion without significantly increasing the size of the conveyor module. In addition to permitting removal of a drive train, typically comprising gears or belts, it also removes the off axis loading that these components introduce. Further, it allows for a reduction in height compared to a solution placing the motor below the rotatable portion.

[0014] Preferably, at least a major portion of the driving mechanism is housed within the cavity. The term “major portion” may be understood as meaning a majority of the driving mechanism, for example more than 50% of the driving mechanism. Accordingly, most of the driving mechanism is housed within the cavity defined by the rotatable portion. It is preferable that all of the driving mechanism is housed within the cavity. Preferably, the driving mechanism comprises an electric motor configured to directly provide a rotational force to the rotatable portion, and the conveyor module further comprises: a retaining sleeve configured to receive and retain the motor in place whilst the motor provides the rotational force to the rotatable portion; wherein the retaining sleeve is configured to fit within the cavity defined by the rotatable portion. This structure of the retaining sleeve may be compatible with motors with gearboxes, for example commercial off the shelf components, thereby improving the ease of setup and maintenance of the conveyor module. The phrase “directly provide a rotational force” may be understood as the motor interacting (i.e., providing the rotational force) with the rotatable portion without any intermediate components. Advantageously, the motor can directly engage with the rotatable portion, thereby reducing any slackness in the system. Further advantageously, the motor can be located within the retaining sleeve, which may advantageously provide a means for stabilising the motor whilst it provides the rotational force to the rotatable portion.

[0015] In some embodiments, the motor comprises a first retaining means; the retaining sleeve comprises a second retaining means; and the first retaining means and the second retaining means are configured to interact to facilitate securing of the motor in place. The phrase “interact to facilitate securing of the motor” may be understood as meaning that the first retaining means and the second retaining means can be used to assist in appropriately positioning the motor within the retaining sleeve. Advantageously, assembly of the conveyor module may be easier.

[0016] In some embodiments, the first retaining means is a retaining abutment extending radially from a lateral external surface of the motor and the second retaining means is at least one retaining groove longitudinally extending along an internal retaining surface of the retaining sleeve. In this way, the motor may be positioned such that the retaining abutment is engaged with the retaining groove, and the motor may be moved into the retaining sleeve whilst always being secured. Preferably, the at least one retaining groove comprises a plurality of retaining grooves circumferentially distributed about a retaining surface of the retaining sleeve. The “retaining surface” may be an interior surface of the retaining sleeve. In this way, the orientation of motor is less important when assembling the conveyor module, because the motor may be positioned to engage with any of the plurality of retaining grooves. That is, the motor may be positioned within the retaining sleeve at any rotational orientation. Advantageously, assembly of the conveyor module may be even easier.

[0017] Preferably, the internal cavity of the rotatable portion is cylindrical, and the retaining sleeve is cylindrical such that the rotatable portion and the retaining sleeve are complementary. The phrase “the rotatable portion and the retaining sleeve are complementary” may be understood as the rotatable portion and the retaining sleeve being shaped such that the retaining sleeve is able to seamlessly fit within the rotatable portion. Advantageously, easy of assembly may be improved.

[0018] In some embodiments, the rotatable portion comprises a cylindrical hub configured to support the conveying elements and provide an internal cavity to accommodate the driving mechanism. The cylindrical hub may advantageously provide a means for stabilising the conveying elements during rotation, whilst also providing a separation between the rotatable portion and the driving mechanism, such that rotatable portion is able to rotate freely with respect to the driving mechanism.

[0019] Preferably, cylindrical hub is configured to be rotated by the driving mechanism. Since the cylindrical hub supports the conveying elements, rotation of the cylindrical hub confers a corresponding rotation to the conveying elements. This may further improve the compactness of the conveyor module, because the driving mechanism can interact with the component in which it is housed to drive rotation of the rotatable portion. Preferably, the driving mechanism comprises a drive shaft having a geometrically shaped cross-section, and wherein the cylindrical hub of the rotatable portion comprises a closed end portion having a drive shaft aperture that is configured (e.g., keyed) to receive and thereby engage the drive shaft (e.g., a distal end of the drive shaft) such that rotation of the drive shaft drives rotation of the cylindrical hub. The geometrically shaped cross-section of the shaft drive shaft may comprise a polygon shape, such as a cruciform, triangular, or square shape.

[0020] Preferably, the rotatable portion is configured to be mounted on the retaining sleeve via a bearing component that is housed within the rotatable portion. In this way, when the driving mechanism is located within the internal cavity, the bearing component allows the rotatable portion to freely rotate without encouraging the driving mechanism to also rotate.

[0021] The cylindrical hub may comprise a first securing means configured to facilitate securing of the conveying elements to the cylindrical hub. The phrase “facilitate securing of the conveying elements to the cylindrical hub” may be understood as meaning that the first securing means can be used to assist in appropriately positioning the conveying elements on the cylindrical hub. Advantageously, the conveyor module may be more easily assembled.

[0022] In some embodiments, the first securing means comprises at least one protrusion on the external surface of the cylindrical hub. In this way, the at least one protrusion may interact with a corresponding securing means of the conveying elements.

[0023] Preferably, each conveying element comprises a second securing means configured to engage with the first securing means on the cylindrical hub. Advantageously, the conveyor module may be more easily assembled.

[0024] In some embodiments, the second securing means comprises at least one indent located on an inner circumferential surface of the conveying element, wherein the at least one indent is shaped to complement the at least one protrusion. In this way, the conveying element can be sleeved onto a component having a suitable protrusion for engaging with the indent. For example, when the conveyor module comprises a cylindrical hub having at least one protrusion, the conveying element can easily be sleeved onto the cylindrical hub by engaging the protrusion with the indent. Advantageously, ease of assembly of the conveyor module may be improved.

[0025] Preferably, the at least one conveying element comprises at least a pair of conveying elements mounted on the rotatable portion such that the engagement members do not coincide along a longitudinal axis. That is, the conveying elements are arranged such that the engagement members of the pair of conveying elements are offset from one another. In this way, a consistent engagement surface is provided about a circumference of a conveying unit comprising the pair of conveying elements. Advantageously, a package is more likely to be engaged and conveyed by the conveying elements.

[0026] Preferably, the conveyor module further comprises an end plate arranged to prevent longitudinal movement of the conveying elements on the rotatable portion. In this way, movement of the conveying elements is restricted to rotational movement. Advantageously, the conveyor module is more stable.

[0027] Preferably, the conveyor module further comprises a housing having an opening through which a portion of each conveying element projects. The housing may act as a full enclosure which isolates the internal components from water and dust, whilst still allowing the conveying elements to function appropriately.

[0028] In some embodiments, at least one edge of the opening parallel to a direction of force of the at least one conveying element comprises a raised (or ramped) portion configured to guide a package to the at least one conveying element. The “direction of force” may be understood as a tangential direction of the rotation of the conveying elements. The protrusion may thus be adjacent to a face of the conveying element proximate this edge. Since the conveying elements project through the opening, a package urged towards the conveyor module may initially contact the face of the conveying element proximate the edge of the opening. The raised portion facilitates movement of said package to, for example, a moveable segment of an omnidirectional wheel. Advantageously, packages, particularly small packages with small footprints (e.g., less than 200 mm by 200 mm), packages with significantly non-planar bottom faces, and soft packages may be assisted in reaching the conveying elements.

[0029] In some embodiments, the raised portion comprises a curved surface. This curved surface may advantageously guide the package to the at least one conveying element whilst reducing a risk of damaging the package.

[0030] Preferably, the housing comprises: an upper housing arranged to at least partially enclose the conveying element; a lower housing arranged to enclose at least part of the driving mechanism; and a locking mechanism configured to secure the first and second housing parts together. In this way, the housing may be easily assembled, thereby further improving the ease of assembly of the conveyor module.

[0031] Preferably, the rotatable portion is further configured to have a bearing element mounted thereon, and wherein the upper housing and lower housing each have a complementing arch portion that are together arranged to accommodate said bearing element. In this way, the rotatable portion can be suitable houses within the housing whilst being able to freely rotate with respect to the housing. Advantageously, the conveyor module can be more compact.

[0032] In some embodiments, the locking mechanism is configured as a snap-fit mechanism. In this way, the lower housing and the upper housing can be connected easily, further facilitating the ease of assembly of the conveyor module.

[0033] Preferably, the locking mechanism comprises a plurality of snap-fit connectors.

[0034] Advantageously, the housing may be more securely connected. Preferably, the lower housing comprises a connector slot configured to receive (or accommodate) the control mechanism. In this way, the control mechanism may be securely held within the connector slot in a particular orientation. Advantageously, securely holding the control mechanism in a particular orientation may improve the ease of connection with a control system.

[0035] Preferably, the connector slot comprises a first slot and a second slot that is at a different orientation to the first slot. In this way, an orientation at which the control mechanism is held may be modified by placing the control mechanism within the first slot or the second slot. Advantageously, the conveyor module may be installed at different orientations in a control system depending on the slot used.

[0036] Preferably, the first and second slots are arranged orthogonally. In this way, a plurality of conveyor modules may be installed in a control system at a 90 degree offset from one another. Advantageously, an alternating or chess-board-like pattern of conveyor modules may be easily arranged.

[0037] Preferably, wherein the control mechanism is flexibly connected to the driving mechanism such that the control mechanism can be orientated in either of the first or second slots. In this way, the control mechanism may be oriented in a range of different orientations. Advantageously, such a flexible connection may improve the ease of connection between the conveyor module and a control system.

[0038] In some embodiments, the housing comprises a lip configured to support a length of elastically deformable material. The lip may otherwise be considered to be a stepped portion. The material may be wrapped about the lip and may act to provide a tight fit, thereby preventing unwanted lateral movement, between the housing and a framework when the conveyor module is installed in the framework. Advantageously, a stable electrical connection may be ensured, and damage to the conveyor module may be reduced. The material may be moulded onto the housing, for example through a two-shot moulding process, which may improve the cost and longevity of the conveyor module at large production quantities. Preferably, the lower housing is configured to provide an opening on an underside of the housing. The opening may communicate with a passageway that extends completely through the conveyor module. The passageway may allow water, dust, or other debris to pass through the conveyor module to the opening so that water and / or debris does not build up within the conveyor module.

[0039] Preferably, the lower housing comprises curved side walls arranged to converge towards each other. For example, the lower housing may comprise curved side walls that match a curvature of the conveying elements. The curved side walls, along with the rotational motion of the rotatable portion, may encourage debris, dust and water to exit the conveyor module via the opening on the underside of the housing.

[0040] The curved side walls may be shaped so as to create a constant spacing between the side walls and the rotatable portion. This may prevent larger pieces of debris from entering the conveyor module and getting lodged between the side walls and the rotatable portion.

[0041] Preferably, the control mechanism comprises a printed circuit board (PCB). A PCB may facilitate electrical connections without the need for wires. This may facilitate easy assembly of the conveyor module. In some examples, the printed circuit board may be arranged to extend from the conveyor module, preferably arranged to extend externally from the conveyor module.

[0042] In accordance with a second aspect, there is provided a conveyor element comprising a conveying hub having a plurality of fixed segments that are spaced around an outer circumference of the conveying hub with engagement members rotatably mounted therebetween such that the engagement members freely rotate. The conveying hub may advantageously provide a means for easily assembling the rotatable portion of the conveyor module, thereby further improving the ease of assembly of the conveyor module. Preferably, each fixed segment comprises a pair of cavities positioned on opposing sides of the fixed segment and each engagement member comprises an axle about which an outer surface of the engagement member can rotate, wherein free ends of the axle are positionable inside respective cavities of adjacent fixed segments. In this way, the moveable segments may easily be installed on the conveying hub, thereby further improving the ease of assembly of the conveyor module.

[0043] Preferably, the conveying element further comprises a second securing means configured to facilitate securing of the conveyor element to a cylindrical hub. Advantageously, the conveyor module may be more easily assembled.

[0044] In some embodiments, the second securing means comprises at least one indent located on an inner circumferential surface of the conveying hub. In this way, the conveying element can easily be sleeved onto the cylindrical hub by engaging the protrusion with the indent. Advantageously, ease of assembly of the conveyor module may be improved.

[0045] Preferably, the conveying element is an omnidirectional wheel. This provides active driven movement in a first and second direction, the first and second directions opposite to each other for example forwards and reverse directions. The omnidirectional wheel also provides passive movement in a third and fourth direction, the third and fourth direction opposite to each other and perpendicular to the first and second directions for example left and right directions. Omnidirectional wheels provide a convenient mechanism for providing motion in multiple directions, including perpendicular directions, which reduces the overall number of components present in the conveyor module.

[0046] Preferably, each omnidirectional wheel comprises a plurality of fixed segments and moveable segments, wherein the plurality of fixed segments and moveable segments form an outer circumference of the omnidirectional wheel. The moveable segments advantageously provide a surface for facilitating passive movement, whilst the fixed segments advantageously provide an engagement surface for providing active driven movement. The moveable segments may comprise an axle about which an outer surface of the moveable segment can freely rotate. The outer surface may be provided by a sleeve having an inner plastic portion and an outer elastomer portion, the inner plastic portion surrounding the axle, and the outer elastomer portion providing the outer surface of the moveable segment. The outer elastomer portion may be customised depending on the environment and / or package used. The hardness of the elastomer portion may be varied depending on the environment and / or package. The surface roughness of the elastomer part may also be varied. The elastomer portion may also comprise a profiled surface.

[0047] Brief Description of Drawings

[0048] Embodiments of the present invention will now be described by way of example only with reference to the accompany drawings in which:

[0049] Figure 1a shows a perspective view of a conveyor module;

[0050] Figure 1 b shows a bottom-up view of a conveyor module;

[0051] Figure 2 shows an exploded view of a conveyor module;

[0052] Figure 3 shows an exploded view of a conveyor module;

[0053] Figure 4 shows an exploded view of a rotatable portion of a conveyor module;

[0054] Figure 5 shows a perspective view of a conveying frame;

[0055] Figure 6a shows a perspective view of a conveying system;

[0056] Figure 6b shows a bottom-up view of a conveying system;

[0057] Figure 6c shows a perspective view of a conveying system; Figure 6d shows a bottom-up view of a conveying system;

[0058] Figure 7a shows an exploded view of a control assembly;

[0059] Figure 7b shows an exploded view of a control assembly;

[0060] Figure 8a shows a perspective view of a conveyor module prior to insertion into a control module;

[0061] Figure 8b shows a perspective view of a conveyor module after insertion into a control module;

[0062] Figure 8c shows a cross-sectional view of a conveyor module after insertion into a control module;

[0063] Figure 8d shows a cross-sectional view of a conveyor module after insertion into a control module; and

[0064] Figure 9 shows a schematic view of conveyor modules and an object.

[0065] Detailed Description

[0066] The present disclosure relates to a connection assembly for electrically connecting a plurality of conveyor modules to form a conveying system.

[0067] In the following description, a package will be used as an example of a type of object that may be moved using the conveying system. Generally, the conveying system comprises a plurality of conveyor modules and a conveying frame. Each conveying module comprises at least one rotatable element having an engagement surface that is configured to engage with a surface of a package. Each conveying module also has a driving mechanism configured to rotate the at least one rotatable element. In this way, rotation of the at least one rotatable element causes rotation of the engagement surface and thereby effects movement of the package on the engagement surface. A control mechanism of the conveying module is configured to control rotation of the rotatable element via the driving mechanism, and communicate with a control system which is generally external to the conveyor module. The conveying frame comprises a plurality of apertures. Each aperture is configured to receive a conveyor module so as to form an array of conveyor modules. Together, the array of conveyor modules provide a substantially planar surface for conveying packages. Each conveyor module is configured to be releasably mounted within an aperture of the conveying frame. By mounting a conveyor module within an aperture, an electrical connection between the conveyor module and the control system is established, thus facilitating electrical communication between the control system and the mounted conveyor module.

[0068] In use, a package resting on the engagement surface of the conveyor module is moved across the substantially planar surface created, through rotation of the rotatable elements so that the package is moved from an engagement surface of one conveyor module to an engagement surface of an adjacent conveyor module. This has the effect that the package is moved across the substantially planar surface.

[0069] The particular path travelled by the package across the substantially planar surface is determined and controlled by a main communication and control system, which may be referred to as a planning system. This planning system tracks and plans the movement of a package across the substantially planar surface.

[0070] Further details of the conveying system and the planning system will now be described.

[0071] Looking first at the conveyor module, Figure 1a shows a perspective view of an exemplary conveyor module 2, Figure 1 b shows a bottom-up view of the conveyor module 2, Figure 2 shows an exploded view of the conveyor module 2, and Figure 3 shows another exploded view of the conveyor module 2. The conveyor module 2 may be referred to as a motorised wheel system (MWS).

[0072] Generally, the conveyor module 2 is a singular unit that includes at least one conveying element in the form of actuated conveying elements 4. The at least one conveying element comprises at least a pair of conveying elements 4 mounted on a rotatable portion such that the conveying elements do not coincide along a longitudinal axis of the conveyor module. In the present example, the at least one conveyor module 2 comprises two pairs of conveying elements 4, and an end plate 10, although this number is not limiting. These conveying elements 4 allow a force to be applied on a package in one direction while also allowing a package to passively roll over the conveying elements 4 in the perpendicular direction.

[0073] In more detail, the conveyor module 2 comprises a rotatable portion 6 having one or more conveying elements 4 mounted thereon, each conveying element 4 having a plurality of engagement members configured to engage with a surface of an object to be conveyed in a first direction via rotation of the rotatable portion 6. Each engagement member is further configured for free rotation on the conveying element in a second direction that is orthogonal to the first direction. As discussed above, the one or more conveying elements is implemented as five conveying elements 4 in the present example.

[0074] Figure 4 shows an exploded view of the rotatable portion 6 of the conveyor module 2. The rotatable portion 6 comprises a cylindrical hub 8 configured to support the conveying elements (i.e. , the conveying elements 4) and provide an internal cavity to accommodate a driving mechanism. The cylindrical hub 8 is cylindrical in shape, having a cross-section corresponding to a shape of the conveying elements 4.

[0075] The cylindrical hub 8 comprises a first securing means arranged to facilitate securing of the conveying elements (i.e., the conveying elements 4) to the cylindrical hub 8. In the illustrated embodiment, the first securing means comprises at least one protrusion 8a on the external surface of the cylindrical hub 8. More particularly, the first securing means comprises a plurality of protrusions 8a distributed about an outer circumferential surface of the cylindrical hub 8, in the present example taking the form of a series of longitudinally extending ribs 8a. These ribs 8a facilitate securing of the conveying elements 4 to the cylindrical hub 8, as will be discussed further below. Alternatively, the first securing means could comprise at least one (typically a plurality of) indents (not shown) distributed about the outer circumferential surface of the cylindrical hub 8.

[0076] Each conveying element 4 comprises a second retaining means configured to engage with the first retaining means on the cylindrical hub 8, as will be discussed further below.

[0077] Turning now to the conveying elements 4, each conveying element 4 is an omnidirectional wheel comprising a plurality of fixed segments 4a and moveable segments 4b. The plurality of fixed segments 4a and moveable segments 4b form the outer circumference of each conveying element 4. In particular, the fixed segments 4a and moveable segments 4b are arranged around each conveying element 4 such that they are spaced apart from each and so that they alternate with each other. In other words, a fixed segment 4a is circumferentially adjacent (i.e. located between) two moveable segments 4b, and similarly a moveable segment 4b is circumferentially adjacent (i.e. located between) two fixed segments 4a.

[0078] With reference to Figure 4, each conveying element 4 comprises a conveying hub 4c having a plurality of fixed segments (the fixed segments 4a) that are spaced around an outer circumference of the conveying hub 4c with engagement members (the moveable segments 4b) rotatably mounted therebetween such that the engagement members freely rotate. The conveying hub 4c is circular in shape. The conveying hub 4c comprises a plurality of radially extending protrusions 4a that provide the fixed segments 4a of the conveying element 4. Circumferentially adjacent each protrusion 4a is a depression 4d configured (or shaped) to accommodate one of the moveable segments 4b. Each protrusion 4a comprises a pair of cavities 4e positioned on opposing sides of the protrusion 4a. Each moveable segment 4b comprises an axle 4f, about which an outer surface 4g of the moveable segment 4b can rotate (e.g., using bearing components (not shown)). The free ends of the axle 4f are positionable inside respective cavities 4e of adjacent protrusions 4a so that the moveable segments 4b can be located between adjacent fixed segments 4a.

[0079] As discussed above, each conveying element 4 comprises a second securing means configured to engage with the first securing means on the cylindrical hub 8. The second securing means comprises at least one indent located on an inner circumferential surface of the conveying element 4, wherein the at least one indent is shaped to complement the at least one protrusion 8a. That is, the at least one indent is shaped so as to accommodate a corresponding protrusion 8a. In this example, the conveying hub 4c comprises the second securing means in the form of at least one indent 4g located on an inner circumferential surface of the conveying hub 4c. In this way, the indent 4g and protrusion 8a engage in a splined coupling manner. The at least one indent 4g comprises a plurality of indents 4g distributed about an inner circumferential surface of the conveying hub 4c, in the present example taking the form of a series of longitudinally extending indents 4g. These indents 4g facilitate securing or locking of the conveying elements 4 to the cylindrical hub 8, because the conveying hub 4c can be sleeved onto the cylindrical hub 8 in such a manner that the ribs 8a of the cylindrical hub 8 are located within corresponding indents 4g of the conveying hub 4c. It will be appreciated that the second securing means could comprise at least one (typically a plurality of) protrusion (not shown) distributed about the inner circumferential surface of the conveying hub 4c. Such embodiments are suitable for use with a cylindrical hub 8 having indents distributed about the outer circumferential surface.

[0080] The end plate 10 is arranged to prevent longitudinal movement of the conveying elements 4 on the rotatable portion. In other words, the end plate 10 is arranged to prevent longitudinal movement of the omnidirectional wheels across a first end of the cylindrical hub 8, so as to further secure the omnidirectional wheels position and improve stability of the conveyor module 2. The end plate 10 also functions as a conveying element because it comprises fixed segments 4b and moveable segments 4d. Similar to the omnidirectional wheels discussed above, the end plate 10 comprises a conveying hub 10b comprising a plurality of radially extending protrusions 10d that provide the fixed segments 4b. The conveying hub 10b and the conveying hub 4c of an adjacent conveying element 4 contact one another whilst leaving a gap for the moveable segments 4d to rotate freely.

[0081] The end plate 10 is secured to a closed end 8b of the cylindrical hub 8 via a fastener. In the illustrated embodiment, the fastener is implemented as a pair of screws 12, a pair of apertures 10a located on the end plate 10, and a pair of corresponding screw holes 8c located on the closed end 8b. Each screw 12 can be inserted through a respective aperture 10a and aligned with a respective screw hole 8c for fastening.

[0082] The conveying hub 10b comprises a projection 10c arranged to support a bearing element 28. The bearing element 28 facilitates securing of the rotatable portion 6 with a housing 22 (discussed further below).

[0083] The cylindrical hub 8 further comprises a retaining means arranged to prevent movement of the conveying elements 4 across a second end of the cylindrical hub 8. The retaining means is implemented as a retaining plate 8d arranged to block the conveying elements 4 from moving off a second end of the cylindrical hub 8. In particular, the retaining plate 8d is located proximate (i.e. , at) a second face (not shown) of the cylindrical hub 8, the second face opposing the closed end 8b. The retaining plate 8d comprises a plurality of protrusions 8e and a plurality of curved surfaces 8f. The protrusions 8e are arranged to align with corresponding protrusions 4a of a conveying element 4 adjacent the retaining plate 8d. These protrusions 8e comprise a curved surface to facilitate movement of a package when said package comes into contact with the protrusions 8e. The curved surfaces 8f are each arranged to align with respective moveable segments 4b. A gap is present between each curved surface 8f and the corresponding moveable segment 4b, so that movement of the moveable segment 4b is not inhibited. The curved surface 8f provides a protective shell for the corresponding moveable segment 4b. The cylindrical hub 8 is dimensioned so as to accommodate at least one conveying element 4 (in the present example, 5 conveying elements 4). Accordingly, a length of the cylindrical hub is sufficient to support the at least one conveying element 4. The length of the cylindrical hub 8 is preferably configured to minimise a gap between adjacent conveying elements 4, and to minimise a gap between the end plate 10 and the conveying element 4 adjacent the end plate 10. Most preferably, the length of the cylindrical hub 8 is such that the conveying hubs 4c are in contact with adjacent conveying hubs 4c.

[0084] The rotatable portion 6 is configured to be rotated by the driving mechanism. In particular, the cylindrical hub 8 is configured to be rotated by the driving mechanism. The cylindrical hub 8 comprises a drive shaft aperture 8g. In particular, the cylindrical hub 8 comprises the closed end 8b having the drive shaft aperture 8g that is configured (i.e., keyed) to receive and thereby engage a distal end of a rotating member (e.g., a drive shaft 16c of a motor 16, as discussed further below), such that rotation of the rotating member drives rotation fo the cylindrical hub 8. That is, the drive shaft aperture 8g is arranged to receive the drive shaft 16c when the drive shaft 16c is inserted into the drive shaft aperture 8g. The drive shaft aperture 8g comprises geometrically shaped (in this case, square) cross-section to provide a suitable surface for the drive shaft 16c to drive the rotatable portion 6.

[0085] To assemble the rotatable portion 6, the moveable segments 4b of a particular conveying element 4 are fitted to the conveying hub 4c by positioning the free ends of the axle 4f in the appropriate cavities 4e of adjacent protrusions 4a. The conveying hub 4c of each conveying element 4 is sleeved onto the cylindrical hub 8, for example by sliding the conveying hub 4c along the cylindrical hub 8 with the first securing means interacting with the second securing means (i.e., with the indents 4g lined up with corresponding ribs 8a). The conveying hubs 4c are positioned on the cylindrical hub 8 such that they are each in contact with at least one adjacent conveying hub 4c. Additionally, the conveying elements are arranged such that the moveable segments 4f of an adjacent pair of conveying elements 4 do not coincide along the longitudinal axis of the conveyor module 2. That is, the moveable segments 4f (and by extension, the fixed segments 4e) are offset. When all of the conveying hubs 4c are positioned on the cylindrical hub 8, the end plate 10 is secured to the closed end 8b of the cylindrical hub by screwing the screws 12 into the corresponding screw holes 8c on the closed end 8b. Since the conveying elements 4 are mechanically coupled to the cylindrical hub 8 via the first and second securing means (i.e. , the ribs 8a and the indents 4g), rotation of the cylindrical hub 8 causes corresponding rotation of the conveying elements 4.

[0086] With reference to Figure 2, which shows an assembled rotatable portion 6, the rotatable portion 6 comprises an internal cavity 8h. More particularly, the cylindrical hub 8 comprises the internal cavity 8h. The internal cavity 8h is configured to accommodate a driving mechanism.

[0087] The driving mechanism comprises a motor 16 (e.g., a DC motor) configured to provide a rotational force to the rotatable portion 6. The motor 16 comprises a rotating member (a drive shaft 16c) extending from a first side of the motor 16. In use, the drive shaft 16c is located within the drive shaft aperture 8g, such that rotation of the drive shaft 16c causes a corresponding rotation of the rotatable portion 6. The drive shaft 16c comprises a geometrically shaped (in this case, square) cross-section, so that the side surfaces of the drive shaft 16c can apply a force to the side surfaces of the drive shaft aperture 8g.

[0088] The motor 16 comprises a first retaining means arranged to facilitate securing of the motor 16 in place. In the present example, the first retaining means is a retaining abutment 16a (typically a pair of diametrically opposing retaining abutments 16a) extending radially from a lateral external surface 16b of the motor 16. Thus, the retaining abutment 16a extends along a lateral axis of the motor 16. In the present example, the motor 16 is cylindrical in shape and as such, the lateral external surface 16b is the curved surface that wraps around the cylinder between the two circular ends. The precise location of the retaining abutment 16a on the lateral external surface 16b of the motor 16 does not matter. It will be appreciated that alternative motor shapes may be suitable. For example, the motor 16 could have a rectangular casing, in which case the retaining abutment 16a is located on a side surface.

[0089] The conveyor module 2 further comprises a retaining sleeve 20 arranged to retain the motor 16 in place whist the motor 16 provides the rotational force to the rotatable portion 6. The retaining sleeve 20 is configured to fit within the rotatable portion 6. More particularly, the retaining sleeve 20 is shaped so as to fit within the cylindrical hub 8. In use, the retaining sleeve 20 is placed within the internal cavity 8h of the cylindrical hub 8.

[0090] The retaining sleeve 20 comprises a retaining cavity 20a (see Figure 2) bounded by an internal retaining surface 20b (the internal retaining surface 20b being an internal surface of the retaining sleeve 20).

[0091] The retaining sleeve 20 also comprises a second retaining means arranged to interact with the first retaining means of the motor 16 to facilitate securing of the motor in place. In the present example, the second retaining means is at least one retaining groove 20c longitudinally extending along the internal retaining surface 20b of the retaining sleeve 20. The retaining groove 20c is arranged to receive the retaining abutment 16a of the motor 16 and allow the motor 16 to move along the longitudinal axis, whilst preventing rotational movement of the motor 16. In the illustrated embodiment, the at least one retaining groove 20c comprises a plurality of retaining grooves 20c circumferentially distributed about the internal retaining surface 20b of the retaining sleeve 20. These circumferentially distributed retaining grooves 20c facilitate an easier insertion of the motor 16 into the retaining sleeve 20. In particular, the rotational orientation of the motor 16 is less important, because the motor 16 can be inserted such that the retaining abutment 16a engages with any of the retaining grooves 20c. One the motor 16 has been placed within the retaining sleeve 20, the retaining sleeve 20 prevents any sideways movement of the motor 16. The retaining sleeve also helps protect the motor 16 from dust and damage due to external factors. To assemble the driving mechanism, the motor 16 is inserted into the retaining sleeve 20 such that the retaining abutment 16a engages with one of the retaining grooves 20c. The motor 16 is moved into the retaining sleeve 20 (more particularly, the retaining cavity 20a) until the motor 16 is completely encompassed by the retaining sleeve 20.

[0092] The retaining sleeve 20 further comprises a retaining flange 20d arranged to retain the bearing component (i.e., the ball bearing assembly 14). The retaining flange 20d extends from a first end of the retaining sleeve 20. The retaining flange 20d also provides the function of retaining the retaining sleeve 20 together with the rotatable portion 6 when assembled with a housing or casing (discussed further below). To achieve this function, the retaining flange 20d is shaped to correspond to the shape of the casing, such that the retaining flange 20d contacts the casing to prevent movement of the retaining sleeve 20 and rotatable portion 6. The retaining flange 20d comprises an indent 20e arranged to provide space for the control mechanism.

[0093] The internal cavity 8h is also configured to accommodate a bearing component configured to couple the cylindrical hub 8 with the driving mechanism, such that the rotatable portion 6 is able to rotate freely with respect to the driving mechanism. In the present embodiment, the bearing component is implemented as a ball bearing assembly 14. The ball bearing assembly 14 is arranged to separate the driving mechanism from an interior surface 8i of the cylindrical hub 8 bounding the internal cavity 8h, such that there is no direct contact between the driving mechanism and the cylindrical hub 8, and the rotatable portion 6 is able to rotate freely whilst the driving mechanism remains stationary. To enable positioning of the ball bearing assembly 14, the cylindrical hub 8 comprises a groove 8j dimensioned to fit the ball bearing assembly 14, so that the bearing component can be housed or accommodated by the groove 8j. The rotatable portion 6 is configured to be mounted on the retaining sleeve 20 via the bearing component that is housed within the rotatable portion 6. To assemble the driving mechanism with the rotatable portion 6, the ball bearing assembly 14 is positioned within the groove 8j of the cylindrical hub 8. The driving mechanism is inserted into the internal cavity 8h of the cylindrical hub 8, such that the driving mechanism fits within the rotatable portion, until the drive shaft 16c engages the drive shaft aperture 8g. In this configuration, the retaining sleeve 20 is encompassed by the cylindrical hub 8, and the ball bearing assembly 14 separates the retaining sleeve 20 from the interior surface 8i of the cylindrical hub 8. Since the drive shaft aperture 8g is located on the cylindrical hub 8, which is mechanically coupled to the conveying elements 4, rotational motion of the drive shaft 16c causes rotation of the cylindrical hub 8 with the conveying elements 4 (i.e. , rotation of the rotatable portion 6). The rotatable portion 6 is able to rotate freely with respect to the driving mechanism due to the presence of the bearing component. Since the drive shaft 16c directly engages the drive shaft aperture 8g, slack in the motor is reduced, which in turn reduces backlash. The driving mechanism may comprise an additional threaded fastening consisting of a countersunk screw.

[0094] The conveyor module further comprises a control mechanism 18. The control mechanism 18 is flexibly connected to the driving mechanism such that the control mechanism can be oriented in different configurations. The control mechanism is a printed circuit board (PCB) 18. The PCB 18 is flexibly connected to a connection point 16d of the motor 16 arranged to receive wires 17 arranged to facilitate communication between the motor 16 and the PCB connector 18. The connection point 16d is located on a second end 16e of the motor 16. The wires 17 are flexible, which allows for the PCB connector 18 to be oriented in any configuration. For example, as shown in Figures 2 and 3, the PCB connector 18 is arranged perpendicular to the lateral external surface 16b, but the PCB connector 18 could feasibly be arranged in any other orientation, such as being parallel with the lateral external surface 16b.

[0095] As shown in Figure 2, the conveyor module 2 further comprises a housing 22, made up of a lower housing 24, and an upper housing 26. The housing 22 also comprises an engagement or locking mechanism configured to secure the upper and lower housing together. In the present example, the engagement mechanism is configured as a snap-fit engagement mechanism. The engagement mechanism comprises a first engagement portion 22a and a second engagement portion 22b. The lower housing 24 comprises the first engagement portion 22a and the upper housing 26 comprises the second engagement portion 22b. The first engagement portion 22a is an aperture 22a and the second engagement portion 22b is a flexible hook 22b. The upper housing 26 can be mechanically connected with the lower housing 24 by applying a downwards force to the upper housing 26, such that the flexible hook 22b engages with the aperture 22a. It will be appreciated that the first engagement portion 22a could be the flexible hook and the second engagement portion 22b could be aperture. In the illustrated example, the locking mechanism comprises a plurality of snap-fit connectors, such that there is a plurality of first engagement portions 22a and second engagement portions 22b.

[0096] The upper housing 26 also comprises an opening 26b through which a portion of each of the conveying elements 4 protrudes, as shown in Figure 1.

[0097] The upper housing 26 also comprises two ramped or raised portions 26c that each extend away from the upper housing 26. In the illustrated example, the raised portions 26c are manufactured together with the upper housing 26, such that the raised portions 26c and the upper housing 26 form a unified whole. The raised portions 26c extend from sides 26d of the opening 26b. The sides 26d from which the raised portions 26c extend are parallel to the direction of force applied by the conveying elements 4 (i.e., the direction of rotation of the conveying elements 4). Thus, a package that is passively rolling over the conveying elements 4 (i.e., moving along a direction perpendicular to the direction of rotation of the conveying elements 4) will contact one of the raised portions 26c before contacting one of the omnidirectional wheels.

[0098] With reference to one of the raised portions 26c, the raised portion 26c is configured to guide the package to the conveying elements 4. In particular, the raised portion 26c is shaped so as to guide, or facilitate movement of, the package to the conveying elements 4. More particularly, the raised portion 26c comprises a surface that increases in height from a side proximate an edge of the upper housing 26 to the side 26d of the opening 26b. For example, the illustrated raised portion 26c comprises a convex curved surface, the convex curved surface curving outwards from the side 26d from which the raised portion 26c extends. It will be appreciated that the raised portion 26c is not limited to having a convex curved surface and may instead comprise a flat surface that is angled such that a height of the protrusion increases from the from side proximate an edge of the upper housing 26 to the side 26d of the opening 26b. The height of the raised portion 26c at the side 26d of the opening 26b is such that the raised portion 26c guides the package to contact a moveable segment 4b of the conveying elements 4.

[0099] As a package is moved towards the conveyor module 2, it typically contacts the raised portion 26c at some point along the surface of the raised portion 26c. The surface of the raised portion 26c guides the package upwards to a height such that the package contacts the moveable segment of one of the conveying elements 4, which passively rotates perpendicular to the driven direction of the conveying element 4, causing sideways motion of the package along the conveyor module 2. Thus, the package is able to seamlessly move along the conveyor module 2. Without this raised portion 26c (i.e., if the upper housing 26 was substantially flat), the package would initially contact a side of one of the conveying elements 4, which could inhibit movement of the package. The raised portion 26c is of particular use when transporting smaller packages, in particular packages that have a height that is less than the amount by which the conveying elements 4 protrude through the aperture 26a. For example, the raised portion 26c is of particular use when transporting packages having front face area of 200 mm by 200 mm. The raised portion 26c is also of particular use with soft packages that significantly deform under their own weight, and packages with a significantly off-centre or high centre of mass relative to the centre of area of the package face. The upper housing 26 further comprises a perimeter slot 26f located towards a corner of the upper housing 26. The perimeter slot 26f may allow debris that might otherwise collect on top of the upper housing 26 to fall through the perimeter slot 26f under the force of gravity.

[0100] The lower housing 24 is shaped to accommodate the retaining sleeve 20. As discussed above, the retaining flange 20d of the retaining sleeve 20 is shaped to correspond to the shape of the lower housing 24. More particularly, the retaining flange 20d is shaped so as to contact interior side walls of the lower housing 24.

[0101] A lower end of the lower housing 24 comprises a connector slot, as shown in Figure 1 b, configured to receive or accommodate the control mechanism 18 (i.e. , the PCB 18). The connector slot is configured to securely accommodate or receive the control mechanism 18 in different orientations. In particular, the connector slot comprises a first slot 24b and a second slot 24c that is at a different orientation to the first slot 24b. More particularly, the first and second slots are arranged orthogonally, such that the second slot 24c is at a 90-degree rotation from the first slot 24b. The first slot 24b and the second slot 24c facilitate insertion of the conveyor modules 2 into a conveying frame 40 in an alternating, or chess-board- like, pattern, as discussed further below. As discussed above, the control mechanism 18 is flexibly connected to the driving mechanism such that the control mechanism can be oriented in either the first slot 24b or the second slot 24c.

[0102] The housing 22 further comprises a lip 22c or stepped portion 22c configured to receive or support a length elastically deformable material. In the present example, the lip 22c is located on the lower housing 24, below the first engagement portion 22a. The material is also flexible so that it can be deformed to engage with the lip 22c. Examples of suitable materials include foam or rubber. The material wrapped about the lower housing 24 below the lip 22c and acts to provide a tight fit between the housing 22 of the conveyor module 2 and the plates of a framework 44 when the conveyor module 2 has been positioned within an aperture 42 of the framework, as discussed further below. The material fills in any space between the housing 22 and the plates, preventing lateral movement of the conveyor module 2 in the aperture 42. Preventing unwanted lateral movement is important for ensuring a stable electrical connection and preventing damage of components. The material also serves as a vibration damping component, reducing the vibrations experienced by the conveyor module 2, which in turn significantly reduces noise.

[0103] As illustrated in Figure 1 b, the housing 22 of the conveyor module 2 is configured to provide an opening 30 on the underside of the housing 22. In particular, the lower housing is configured to provide the opening 30 on the underside of the housing 22. The opening 30 provides a terminus for a passageway which extends into the main body of the conveyor module 2 to a chamber in which the conveying elements 4 are located to allow them to rotate freely.

[0104] The chamber is a cavity bound by the lower housing 24 and the upper housing 26. The lower housing 24 has curved side walls 24d arranged to converge towards each other, as can be seen in Figure 2. These curved side walls 24d generally match the curvature of the conveying elements 4. These sloped or curved side walls 24d encourage dust and water to exit the housing 22 rather than remain at the bottom of the housing 22. A gap is present between the side walls 24d and the conveying elements 4. This gap helps provide a fluid connection between the opening 26b in the upper housing 26 of the conveyor module 2 and the opening 30. The opening 30 acts as a water and dust drainage system, allowing dust and water which enters the opening 26b to flow through the chamber and passageway, and out of the opening 30 via an opening. In use, the passageway of the conveyor module 2 will be substantially vertical. This has the advantage that any debris collected in the chamber is able to flow downwards through the passageway, under the action of gravity, and out the opening in the opening 30. This avoids debris, in particular water and dust, building up within the chamber, or space, which surrounds the conveying elements 4 which could affect rotational movement of the wheels 4. The conveyor module 2 can therefore be thought of as comprising a through passageway which extends between the opening at the top of the conveyor module 2 (i.e. the opening 26b in the upper housing 26) and a second opening at the base of the conveyor module (i.e. an opening 30a of the opening 30). The conveying elements 4 are located at least partially within this through passageway.

[0105] The upper housing 26 and lower housing 24 each have a complementing arch portion 26e, 24e that are together arranged to accommodate the bearing element 28. The arch portions 26e, 24e allows the rotatable portion 6 together with the bearing element 28 to be securely fitted within the housing 22 without restricting rotational motion of the rotatable portion 6. Thus, the rotatable portion 6 is configured to have the bearing element 28 mounted thereon, wherein the upper housing and lower housing each have a complementing arch portion that are together arranged to accommodate said bearing component 28. These arch portions 26e, 24e allow the rotatable portion 6 to be securely fitted within the housing 22 without restricting rotational motion of the rotatable portion 6.

[0106] To assemble the conveyor module 2, the driving mechanism and the rotatable portion 6 are assembled as discussed above. The bearing element 28 is positioned on the projection 10c. The driving mechanism together with the rotatable portion 6 (now including the bearing element 28) are positioned within the lower housing 24. The control mechanism 18 (i.e. , the PCB connector 18) is arranged in a suitable orientation within the connector slot 24a. The upper housing 26 is placed on top of the lower housing 24, such that the bearing element 28 is located within the arch portions 26e, 24e. The engagement mechanism is used to secure the upper housing 26 with the lower housing 24.

[0107] The portion of outer circumference of each conveying element 4 which protrudes through the opening 26b in the upper housing 26 forms part of an engagement surface. The engagement surface is the part of the conveyor module 2 onto which a package is placed, and which causes movement of the package through movement of the conveying elements 4.

[0108] The fixed segments 4a fixedly rotate with the sub-wheel main body (i.e. they rotate in the direction the conveying element 4 is driven by a motor) causing forward and backward motion. During driven motion of the conveying element 4, the moveable segments 4b will also help effect forward and reverse motion of a package on the engagement surface. Additionally, the moveable segments 4b are able to passively rotate perpendicular to the driven direction causing sideways motion.

[0109] As discussed above, the conveyor module 2 comprises a control mechanism 18 which takes the form of a printed circuit board (PCB). The control mechanism 18 is connected to the motor 16 via a connection point 16d on the motor which provides an electrical interface between the motor 16 and the control mechanism 18. The control mechanism 18 controls the rotation of the conveying elements 4 via the motor 16 and gears 18.

[0110] The control mechanism 18 is also arranged to communicate with a control system that is external to the conveyor module 2, typically part of the conveying frame. In this way, the control mechanism 18 can receive commands from the control system and control the motor 16 accordingly. This will be explained in more detail later.

[0111] Turning now to Figure 5, a perspective view of an exemplary conveying frame 40 is shown in the form of a metal grid frame. The conveying frame 40 comprises a plurality of apertures 42, regularly arranged in a grid-like manner across the conveying frame 40. The apertures 42 of the conveying frame 40 are each for receiving a conveyor module 2, forming an array of conveyor modules 2 that together form a conveying surface for transporting packages received on this surface. The conveying frame 40 therefore acts as a support structure for holding many conveying modules 2 together in order to form a transport surface over which packages can be transported.

[0112] The conveying frame 40 comprises a framework 44. The framework 44 comprises two support plates 46, positioned substantially parallel to each other and spaced apart from each other. The support plates 46 are located adjacent and parallel to two side edges of the framework 44. The support plates 46 are made of carbon steel in order that these support plates 46 are sufficiently strong to be able to withstand the weight of the conveying system. The framework also comprises a plurality of primary inner plates 48, positioned substantially parallel to each other and spaced apart from each other. The primary inner plates 48 are generally perpendicular to the support plates 46, and extend across the middle area of the framework. The support plates 46 may be made of aluminium.

[0113] A plurality of connector plates 50 are positioned substantially parallel to each other and spaced apart from each other, acting to separate the plurality of inner plates 48 into a number of sub-groups. The connector plates 50 are parallel to the inner plates 48 and perpendicular to the support plates 46. The connector plates 50 may be made of aluminium. Each connector plate 50 is arranged to support a plurality of connection assemblies 52, extending away from the framework 44 underneath the framework 44, as discussed further below.

[0114] In order to complete the grid-like framework 44, a plurality of secondary inner plates 54 are positioned substantially parallel to the support plates 46, extending across the inner area of the framework 44. The secondary inner plates 54 are perpendicular to the primary inner plates 48 and the connector plates 50. The secondary inner plates 54 may be made of aluminium.

[0115] Finally, four edging plates 56 are placed around the outer edge of the framework 44 forming the outer boundary of the framework 44. The edging plates 56 may be made of aluminium.

[0116] All the plates of the framework are connected together using a plurality of slots within each plate. Thus, one plate is slotted into another plate forming an intersection. In particular, the plates are arranged to slot into each other under the action of gravity, and so the framework 44 can be held together under the action of gravity rather than physical fixing components. In the example shown in Figure 5, the constructed framework 44 forms a grid having 14 x 14 apertures 42, where each aperture 42 is a square of size 83 mm x 83 mm. However, alternative framework sizes are also possible. A control system 60 is arranged to communicate with a main control system (not shown) as well as each conveyor module 2. With reference to Figures 6a to 6d, the control system 60 comprises a plurality of connection assemblies 52 that are configured to facilitate a direct (“plug and socket”) physical electrical connection of a plurality of conveyor modules 2 to a control system, for example to allow them to be individually controlled and / or supplied with power as described above.

[0117] The connection assemblies 52 provide an electrical connection to the conveyor modules 2 (more particularly, the control mechanism 18), such that the control mechanism 18 of the conveyor module 2 (which controls rotation of the conveying element 4) is able to receive a control signal from the connection assembly 52 to which it is connected, which is itself arranged to communication electrically with a separate main control system and / or receive power from a power supply.

[0118] Advantageously, the connection assemblies 52 provides a direct electrical connection for providing the control signal to the conveyor module 2, while reducing the risk of potential damage to the connection assemblies 52, in particular PCBs of the connection assembly 52, by limiting exposure of the PCBs to the external environment.

[0119] Generally, as shown in Figures 7a and 7b, which show exploded views of the connection assembly 52, each connection assembly 52 comprises a housing comprising a upper housing part 54 and a lower housing part 56, which are arranged to at least partially house a plurality of electrical components. Specifically, the upper and lower housing parts are arranged to at least partially house a printed circuit board (PCB) unit 58 (or PCB 58) arranged to provide the control signal to a connected conveyor module 2.

[0120] In this way, the PCB unit 58 can be considered as being at least partially encapsulated by the upper and lower housing parts 54, 56, and hence the housing. In use, the upper housing part 54 is located above the lower housing part 56 and so the upper housing part 54 can also be referred to as an “upper” housing part and the lower housing part 56 can also be referred to as a “lower” housing part.

[0121] The upper and lower housing parts 54, 56 are arranged to be attached together in order to form the housing. In the example shown, the upper and lower housing parts 54, 56 are attached together using an interlocking hook arrangement. For example, the lower housing part 56 comprises a plurality of hooked portions 56a extending away from the main body of the lower housing part 56, which is an upwards extension when the connection assembly 52 is in use. In the illustrated example, there are four hooked portions 56a. Two hooked portions 56a extend from each longitudinal edge of the lower housing part 56, each hooked portion 56a being proximate a corner of the lower housing part 56 (more particularly, at a displacement from each corner of the lower housing part 56). The upper housing part 54 comprises corresponding hooked portions (not shown) sized and shaped to cooperate or engage with the hooked portions 56a of the lower housing part 56. These hooked portions are located in protective cavities 54a located at complementary positions to the hooked portions 56a of the lower housing part 56. That is, the protective cavities 54a are located at points of the upper housing part 54 that align with the hooked portions 56a when assembled. This interlocking hook arrangement facilitates easy assembly of the connection assembly 52, because the upper and lower housing parts 54, 56 can be assembled in a “snap-fit” manner.

[0122] It will be appreciated that any other suitable arrangement for attaching the upper and lower housing parts 54, 56 can be used.

[0123] The upper housing part 54 comprises a plurality of connection slots 54b. Each connection slot 54b is arranged to receive at least part of the control mechanism 18 of a conveyor module 2 and facilitate electrical connection between the control mechanism 18 and the PCB unit 58. Each connection slot 54b is aligned along the same axis. In particular, each connection slot 54b is aligned along a longitudinal axis of the connection assembly 52. Each connection slot 54b is located on a surface of a respective enclosure (e.g., a PCI connector enclosure 54c) protruding from a surface of the upper housing part 54 (i.e., an upper surface of the upper housing part 54 in use). Each PCI enclosure 54c is configured to enclose an electrical connection point of the PCB unit 58 (i.e., a PCI connector 58a), such that when the control mechanism 18 of a conveyor module 2 is inserted into the slot 54b, the control mechanism 18 forms an electrical connection with the PCI connector 58a and, by extension, the PCB unit 58, as will be discussed further below. The connection slot 54b and PCI connector enclosure 54c may be considered a socket configured to establish an electrical connection with an electrical connector of a conveyor module such that electrical communication is established between the conveyor module and at least one of the electrical connectors.

[0124] Each connection slot 54b (and corresponding PCI connector enclosure 54c) is located towards a distal end of the housing. That is, the connection slots 54b are not located proximate a centre of the housing. In particular, four connection slots 54b and PCI connector enclosures 54c are located at each end of the upper housing part 54. This arrangement of PCI connector enclosures 54c (and PCI connectors 58a) allows for four conveyor modules 2 to be connected to the PCB unit 58 at each end of the connection assembly 52. This is clearly illustrated in Figure 6b, which shows a partially assembled conveyance system, where it can be seen that four conveyor modules 2 are connected to one end of a connection assembly 52. As discussed above, the orientation of a control mechanism 18 of a conveyor module 2 can be configured by placing the control mechanism in the first slot 24b or the second slot 24c, which is at a 90 degree rotation from the first slot 24b.

[0125] Since the connection slots 54b are aligned (i.e., they are in a parallel orientation), after insertion into connection slots 54b, conveyor modules 2 having a control mechanism 18 in the first slot 25b will be at a 90 degree rotational offset to conveyor modules 2 having a control mechanism 18 in the second slot 25c. Thus, an alternating, or chess-board-like, pattern of conveyor modules 2 can be achieved by inserting conveyor modules 2 adjacent conveyor modules 2 that have a control mechanism in a different slot 25b, 25c. Notably, this can be implemented with all of the control assemblies being aligned along the same axis.

[0126] The housing further comprises a frame engagement means arranged to facilitate attachment of the connection assembly 52 to the conveying frame 40. In the illustrated embodiment, the upper housing part 54 comprises the frame engagement means. The frame engagement means comprises a plurality of frame engagement elements 54d, each arranged to engage with the conveying frame 40. More particularly, the frame engagement elements 54d are arranged to engage the support plates 46 of the framework 44. In the present example, the frame engagement elements 54d each comprise a hooking member 54e and a stabilising wall 54f facing the hooking member 54e. Both the hooking member 54e and the stabilising wall 54f protrude from the upper surface of the upper housing part 54.

[0127] The upper housing part 54 further comprises a sloped or chamfered perimeter portion 54g that facilitates draining of debris or fluids. The upper housing part 54 also comprises a locating protrusion 54g extending from an upper surface of the upper housing part 54. The locating protrusion 54g is configured to align with a corresponding indent (not shown) of the framework 44. During assembly, the connection assembly 52 is aligned such that the protrusion 54g is aligned with the indent of the framework. Thus, the upper housing part 54 can only be positioned in a correct manner.

[0128] In the present example, the support plates 46 comprise apertures (not shown) configured to align with the hooking members 54e when assembled. In this way, the upper housing part 54 (and by extension, the connection assembly 52) can be engaged or secured to the support plates 46 by aligning the hooking members 54e with respective apertures and moving the conveyor module 52 upwards. As the conveyor module 52 moves upwards, a protruding side of the hooking member 54e contacts the support plate 46, causing the hooking member 54e to move from a first position (at which the hooking member 54e is biased) to a second position until the hooking member 54e is vertically in line with the aperture, at which point the hooking member 54e returns to the first position and engages the aperture. The stabilising wall 54f prevents movement along a longitudinal axis of the framework 44. Attachment of the conveyor module 2 to the framework 44 can therefore be achieved via a “snap-fit” means, without requiring

[0129] The apertures of the support plates 46 are positioned on either side of the intersecting primary plates 48, such that two opposing frame engagement elements 54d are separated by a primary plate 48. In this way, lateral movement of the conveyor module 2 can be prevented, and the conveyor module 2 is securely positioned and attached to the framework 44.

[0130] The housing (more particularly, the lower housing part 56) comprises a slot 56b for accommodating a control line 62. More particularly, the lower housing part 56 comprises two opposing slots 56b positioned on side walls of the lower housing part 56 approximately centrally along a longitudinal axis of the lower housing part 56, although it will be appreciated that the slots 56b may be positioned elsewhere.

[0131] The control line 62 is configured to provide an electrical connection between control modules 58b of adjacent PCB units 58 (i.e., PCB units 58 of adjacent connection assemblies 52) and a central control unit (not shown), such that a row of control assemblies (e.g., as shown in Figure 7a) can be controlled by the central control unit (not shown). The control line 62 also provides an electrical connection between the adjacent PCB units 58 and a power supply unit, such that the control line 62 functions as a power input for each connection assembly 52. The central control unit may be connected to the power supply unit such that the control signals and power signals are both provided via the control line 62. The control line 62 comprises a plurality of cables, including a control signal cable and a power cable.

[0132] The lower housing part 56 also comprises an opening 56c configured to allow one or more components of the PCB unit 58 to traverse the lower housing part 56. In other words, the opening 56c provides a space for components of the PCB unit 58 that protrude from a lower side (when in use) of the PCB unit 58 to occupy. For example, the connection assembly 52 (more particularly, the PCB unit 58) comprises an alert means 58c, for example in the form of a plurality of lightemitting diodes (LEDs) 58c, that protrudes from the lower side of the PCB unit 58, and a capacitor 58d that protrudes from the lower side of the PCB unit 58.

[0133] The alert means 58c is configured to provide a status indication of the PCB unit 58. For example, the plurality of LEDs 58c are configured to emit light when there is a problem with the PCB unit 58, such as the PCB unit 58 being incorrectly connected to an adjacent PCB unit 58 or the control unit. The plurality of LEDs 58c are each configured to provide a status indication in response to distinct types of fault. In the present example, there are four LEDs 58c. Thus, each LED 58c, and / or combination of LEDs 58c can provide a respective indication.

[0134] The connection assembly 52 also comprises a cap 64 configured to enclose and protect the components of the PCB unit 58 that protrude from the lower side of the PCB unit 58. The cap 64 is attachable to the lower housing part 56. In particular, the cap 64 comprises hooks 64a that are configured to engage corresponding slots 56d located on an underside of the lower housing part 56. Since the slots 56c are located on side walls of the lower housing part 56, and the cap 64 engages with the underside of the lower housing part 56, the cap 64 does not interfere with the control line 62.

[0135] When the cap 64 is attached to the lower housing part 56, the components, e.g., the capacitor 58d, protruding from the lower side of the PCB unit 58 occupy an inner space of the cap 64. The cap 64 is made of a translucent material so that light emitted by the LEDs 58c is visible through the cap 64. In this way, the status of the PCB unit 58 can be determined without having to dismantle the connection assembly 52.

[0136] The cap 64 comprises a generally sloped floor so as to encourage debris, dust, and water towards a lower cavity 64b of the cap 64. The lower cavity 64b comprises a plurality of apertures for allowing said debris, dust and water to leave the cap. The lower cavity 64b is positioned to align with the capacitor 58d so as to provide a space for accommodating the capacitor 58d. In this way, the plurality of apertures also serves the purpose of providing airflow to the capacitor 58d so as to facilitate heat dissipation, thereby reducing the risk of overheating.

[0137] The cap 64 also comprises a plurality of LED channels 64c, each being configured to receive and accommodate a respective LED 58c. The LED channels 64c provide a pathway for light emitted by the LEDs 58c to escape the cap 64, to ensure that light emitted by the LEDs is visible from outside of the cap 64.

[0138] To assemble the connection assembly 52, the PCB unit 58 is appropriately aligned with the lower housing part 56, such that the control module 58b of the PCB unit 58 is aligned with the slots 56b of the lower housing part 56 and the LED 58c extends through the opening 56c. The control line 62 is either pre-connected to the control module 58b or is connected to the control module 58b after the PCB unit 58 is located is positioned in the lower housing part 56. If the control line 62 is pre-connected to the control module 58b, a free end of the control line 62 is fed through the appropriate slot 56b from inside the lower housing part 56 to outside the lower housing part 56. Otherwise, the free end of the control line 62 is fed through the appropriate slot 56b from outside the lower housing part 56 to connect the control line 62 to the control module 58b. Next, the cap 64 is connected to the lower housing part 56 by positioning the hooks 64a of the cap 64 within the corresponding slots 56d of the lower housing part 56. Finally, the upper housing part 54 is positioned such that the PCI connector enclosures 54c align with the respective PCI connectors 58a, and the upper housing part 54 is moved such that the hooked portions 56a engage with the corresponding protective cavities 54a. Thus, assembly can be achieved in a “snap-fit” manner, without requiring the use of components such as fasteners. It will be appreciated that this assembly process is by way of example, and an alternative order of assembly may be envisaged.

[0139] After the connection assembly 52 has been assembled, it can be attached to the framework 44 using the frame engagement means. In particular, the connection assembly 52 is positioned such that two opposing frame engagement elements 54d are separated by a primary plate 48 and a support plate 46 is between the hooking member 54e and the stabilising wall 54f. The connection assembly can then by moved upwards so that the hooking member 54e engages the aperture of the support plate. Thus, the connection assembly 52 can be connected to the framework 44 in a “snap-fit” manner, without requiring the use of components such as fasteners.

[0140] As shown in Figure 6d, each connection assembly 52 can be placed to cover eight apertures 42 of the framework 44. That is, the connection assembly 52 can be centrally placed in a group of eight apertures. The configuration of the connection slots 54b on a connection assembly 52 is such that there are eight connection slots 54b arranged in groups of four, and each group of four is proximate a respective distal end of the connection assembly 52. This configuration of connection slots 54b allows the connection assembly 52 to take up less space. It will be appreciated that the size of the apertures 42 are for illustration purposes only, and that it is preferable that the apertures 42 have a substantially square shape, as shown in Figures 6a to 6c.

[0141] As mentioned previously, each conveyor module 2 is designed to be inserted into an aperture 42 in the conveying frame 40, as shown in Figures 6a to 6 in order to form a transporting surface made up of multiple conveyor modules 2. Since each conveyor module 2 is identical, forming the transporting surface using multiple, identical conveyor modules 2 reduces overall production costs. In addition, since all the conveying elements 4 within each conveyor module 2 are pointing in the same direction, and each conveyor module 2 has only one motor 16 to drive the wheels 4, each conveyor module 2 is relatively cheap to produce.

[0142] In particular, the conveyor module 2 is designed to be easily inserted into an aperture and removed from the aperture 42. In other words, there are no fixed or permanent connections between the conveyor module 2 and the conveying frame 40. Instead, the conveyor module 2 can be inserted into an aperture 42 when it is need and subsequently removed from the aperture 42 either when it is not needed or for replacement or repair. In this way, the conveyor module 2 can be thought of as being releasably mounted within the aperture 42 rather than fixedly mounted within the aperture 42. The ability to insert and remove the conveyor module 2 as and when needed may be referred to as “Plug and play”.

[0143] The conveyor module 2 is designed such that when the conveyor module 2 is inserted into an aperture 42 of the conveying frame 40, the control mechanism 18 of the conveyor module 2 will automatically connect with the control system 60, in particular the PCB unit 58, of the conveying frame 40. This therefore has the effect that when the conveyor module 2 is inserted into an aperture 42 of the conveying frame 40, the control mechanism 18 of the conveyor module 2 will automatically connect with the main control system, via the connection with the control system 60 of the conveying frame 40.

[0144] Automatically establishing an electrical connection between the conveying module 2 and the conveying frame 40 upon insertion of the conveyor module 2 into the conveying frame 40 means that an electrical connection is automatically established between the conveying module 2 and the main control system upon insertion of the conveyor module 2 into the conveying frame 40.

[0145] Each PCB unit 58 on the underside of the conveying frame 40 is connected to a plurality of conveyor modules 2 above the PCB unit 58 as well as being connected to the main power supply and control systems. In this way, each conveyor module 2 is connected to the main power supply and control system via the PCB units 52 of the conveying frame 40.

[0146] Due to the design of the conveyor module 2, and the provision of a large PCB unit 58 for connection and power supply on the underside of the conveying frame 40, each conveyor module 2 can be simply “dropped” into an aperture 42 of the conveying frame 40 and the conveyor module 2 will connect its own control mechanism, in the form of a PCB, to the central control system. This “plug and play” mounting system makes it possible to change a conveyor module 2 very quickly should the existing one malfunction, thus decreasing the cost of maintenance. A number of features which facilitate the plug and play solution will now be discussed.

[0147] As can be seen in at least Figures 8a to 8d, the control mechanism 18 (i.e., the PCB 18) comprises a portion 18a which extends beyond the housing 22 of the conveyor module 2. The opening 30 also extends beyond the main housing 22 of the conveyor module 2.

[0148] When the conveyor module 2 is inserted into the aperture 42, the extending portion 18a of the control mechanism 18 is arranged to be inserted into the slot 54c in the connection assemblies 52, as can be seen in Figures 8a to 8d. In particular, each extending portion 18a of the control mechanism 18 of the conveyor module 2 is received by an electrical connector (e.g., a PCI connector) 58a on the PCB unit 58 of the conveying frame 40. The extending portion 18a slots into the female PCI connector 58a which extends upwards from the PCB unit 58 mounted below the connection assemblies 52 and extends towards the conveyor module 2. When the conveyor module 2 is inserted into the aperture 42, the extending portion 18a slides into the PCI connector 58a on the PCB unit 58, thus connecting the control mechanism 18 of the conveyor module 2 to the control system 60 of the conveying frame 40.

[0149] The use of a control mechanism 18 in the form of a PCB on the conveyor module 2 and a corresponding PCB unit 58 and PCI connector 58a on the conveying frame 40 provides the ability to control and power each conveyor module 2 independently from each other. The use of PCBs rather than a wire-based system results in a more compact system and a quicker assembly process. Furthermore, maintenance of both the conveyor module 2 and the conveying frame 40 is much simpler because the conveyor module 2 can be simply lifted out of its corresponding aperture 42 in the conveying frame 40, without the need to undo lots of wiring. Figure 6a shows a conveying frame 40 filled with multiple conveyor modules 2 to form a transporting or conveying surface. The conveyor modules 2 are inserted into the conveying frame 40 in an alternating, or chess-board-like, pattern. By alternating we mean that when looking at the conveying frame 40 from above, the conveying elements 4 in a conveyor module 2 alternate between being arranged in a forwards-backwards driven direction and a left-right drive direction. The driven direction of the conveying elements 4 within a conveyor module 2 may be considered as a longitudinal axis of the conveyor module 2. The alternating arrangement of conveyor modules 2 therefore means that the longitudinal axis of the plurality of conveyor modules 2 alternates between being aligned at 0 degrees and aligned at 90 degrees, the angles of alignment being defined in relation to the conveying frame 40 when viewed from above. Thus, the omnidirectional wheels that are aligned at 0 degrees may be considered as being orientated up-and-down along the conveying frame 40 and the conveying elements 4 that are aligned at 90 degrees may be considered as being orientated left-and-right across the conveying frame 40.

[0150] As discussed above, the connector slot facilitates this alternating arrangement of conveyor modules. In particular, the control mechanism 18 can be inserted into the first slot 24b or the second slot 24c, the sub-cavities being aligned perpendicularly. Depending on which sub-cavity the control mechanism occupies, the general orientation of the conveyor module after insertion into the connection assembly is either aligned at 0 degrees or aligned at 90 degrees.

[0151] The conveying elements 4 allow objects to be pushed forward and backward by the wheel 4, as is the case with any other wheeled device. However, the moveable segments of the wheels 4 allow objects to passively roll left and right over the wheel 4.

[0152] As a result of the use of conveying elements 4 in the conveyor modules 2, the alternating pattern of conveyor modules 2 in the conveying frame 40 can freely move any object in any direction, provided that the object is in contact with at least two conveying elements 4 that are aligned 90 degrees in relationship to each other.

[0153] Since each conveyor module 2 can provide a driven force in one direction, when many conveyor modules 2 are arranged together, with a 90 degrees rotation alternating back and forth between adjacent conveyor modules 2, the resulting transporting surface can apply a driven force in both the x and y directions and any sum of these. For example, movement in the x direction can be achieved by only driving conveying elements 4 that “point” in the x direction and diagonal movement can be achieved by turning on all conveying elements 4 under an object. Thus, not all conveyor modules 2 need to be driven at any given time. Instead only the conveyor modules that are needed to cause movement of a package are activated. This is illustrated in Figure 9.

[0154] Figure 9 shows two outlines A1 , A2 with represent two packages on a conveying surface. One set of squares B can apply horizontal movement (left and right across the page) while the other set of squares C in the alternating pattern can apply vertical movement (up and down along the page). The first package A1 is moved in a horizontal direction by the driven horizontal squares B, and moving passively over the vertical squares C. The second package A2 is moved in a diagonal directions as a result of the sum of the driven forces applies by both squares B and C.

[0155] The conveying frame 40 essentially acts as an omnidirectional drive, capable of controlling the conveying elements 4 of each conveyor module 2 independently from each other. That is, the movement of the conveying elements 4 of any one conveyor module 2 is independent from the movement of the conveying elements 4 of any other conveyor module 2. In other words, the conveying elements 4 do not all need to be active and in motion at the same time; only the wheels necessary to effect movement of a package need to be driven at any given time. This allows for precise and individual control of packages on the transporting surface. The particular arrangement of conveyor modules 2 in the conveying frame 40 to form the alternating grid-like pattern means that the space between adjacent (adjacent in both the vertical and horizontal direction) conveyor modules 2 is relatively small, and so the distance between conveying elements 4 is also small. This means that there is a relatively high density of conveying elements 4 over the entire transporting surface. This leads to high movement precision as a package does not need to travel a great distance before its movement can be adjusted e.g. its direction of travel changed. Additionally, a relatively high density of conveyor modules 2, with a corresponding small distance between conveying elements 4, means that smaller packages can be moved around over the transporting surface.

[0156] Particular control of the conveying elements 4 to effect particular movement of a package on the transporting surface is ultimately undertaken by the main control system, which sends commands to the control mechanism 18 via the control system 60 of the conveying frame 40.

[0157] The control system forms part of an overall planning system. Generally, the planning system is the system which controls the movement of packages through the conveying system to ensure they reach their end destination.

[0158] The planning system includes an information acquisition system, a processing system, and a main control system. The information acquisition system is arranged to obtain package information from the package, wherein the package information comprises a destination location of the package. The processing system is configured to determine a route of the package from the scanning location to the destination location. The main control system is configured to communicate with the previously described conveying system, wherein the main control system is configured to control the driving mechanism of the conveyor module such that the package is moved across the substantially planar surface along the determined path from the scanning location to the destination location through rotation of the conveying elements. Further details will be provided in the following. In order to determine an end destination of each package, each package first needs to be entered into the planning system. Once the package has been entered into the system, information associated with the package can be retrieved, for examples the package ID and its end destination, and these can be used by the planning system to plan a route for the package to travel across the transporting surface to its end destination.

[0159] Thus, in order for the planning system to know what to do with each individual package, the package needs to be identified and matched with the package in the database provided by a customer. This is done by obtaining information about the package using the acquisition system. In some examples, the acquisition system takes the form of a scanning system. In this case, the scanning system scans a barcode on the package and searches for the code in the database provided by the customer.

[0160] In particular, when a new package is placed on to the system, by placing the package on the transporting surface at a starting location, it will be driven, or moved, to a scanning area by the conveying elements 4 which make up the transporting surface. Once the package reaches the scanning area, the barcode on the package is scanned. This may be done using any suitable imaging apparatus such as a barcode scanner or a camera.

[0161] The scanning system comprises a plurality of scanning apparatus, positioned at different locations and pointing in different directions. This allows the scanning system to identify and scan a barcode anywhere on the package. In particular, in the scanning area, scanning apparatus will be located above the scanning area and pointing below, in order to capture barcodes on the top of packages. Scanning apparatus will also be positioned around a horizontal perimeter and pointing inwards to the centre of the area defined by this perimeter, in order to capture barcodes on the sides of the package. Some scanning apparatus will be positioned on the transporting surface and pointing upwards, in order to capture barcodes that are on the underside of a package. Once the barcode has been located and scanned, the planning system will then search through a database of packages provided by the customer and find the code matching the one from the barcode.

[0162] While a scanning system has been provided as an example of an information acquisition system, other systems may also be used. For example, in some cases the planning system may receive information about a new package from an external source. In this case, the information acquisition system may be a processing or computing device arranged to receive information about a package in order to identify the package and match with the package in the database provided by a customer.

[0163] After the package has been identified, the planning system can also look up the end destination of the package, using the database, so that the planning system is able to plan operations and movement of the package accordingly.

[0164] The movements of the package are determined by the processing system. The processing system includes an observation system, for observing the package and its movements, and a planning system, for determining the route the package takes across the transporting surface.

[0165] In general, the planning system uses a machine learning algorithm to determine the movement steps for all packages in the system. This has the advantage that the algorithm will optimize itself for every deployed system, taking into account the physical setup of the system (e.g. floor geometry, number of floors), the operation pattern, the number of other packages being moved, and the size and shape of the packages.

[0166] The observation system comprises a plurality of video cameras which are able to detect and track the packages as they move across the transporting surface. The plurality of video cameras are placed above the transporting surface, looking down at the transporting surface. The transporting surface of the overall system will generally be made up of multiple conveying frames located next to each other, in order to build up the shape of the desired overall transporting surface. In general there are several cameras above each transport module. The video stream from the video cameras is used by a software algorithm to look at the stream from the cameras and detect and continuously track packages in the feed.

[0167] The observation system and planning system work together, as the processing system, to route a package across the transporting surface, avoiding other packages and obstacles, to its end destination. The planning system plans a movement sequence for a package and this sequence is executed by sending appropriate commands to the conveyor modules 2 to control movement of the conveying elements 4. The planned movement sequences are determined by the mode of operation. One example mode of operation is referred to as “Sequencing”, where packages are moved around until they are sitting on the transporting surface in a desired order / sequence. This operation may be carried out before packages are taken out of the system one by one and placed in a truck so that the order of placement in the truck matches the order of unloading when the truck is driving through a delivery route.

[0168] The main control system is a general software system that uses observation data from the observation system to control the movement of packages. The control system takes in as input the desired state of each package (position and rotation) and produces a set of control commands that move the package toward its desired state. While doing this, the control system uses the run time data from the observation system in order check for errors in movement trajectory and produce adjustment commands as and when is necessary.

[0169] Each movement command is first expressed in a vector form [linear velocity, angular velocity] where each vector represents the linear and angular velocities that the package should have during the specific time step. Then, a vector field is created for each package that will, when applied as commands to the conveyor modules 2, result in the desired linear and angular velocities. Finally, the vector field is only applied to the conveyor modules 2 directly beneath the package (here, the observation data is again used to determine which conveyor modules 2 are beneath each package).

[0170] Finally, because each conveying element 4 can only produce a horizontal or vertical force field element, the control signal sent to each conveyor module 2 represents only the vector component of the field element that is parallel to the direction of the conveying elements 4 on that particular conveyor module 2. For example, if a uniform vector field that is to be applied is [2,1], (meaning 2 in the horizontal direction and 1 in the vertical direction), a control signal of 2 is sent to all conveyor units 2 that can apply force in the horizontal direction and a control signal of 1 is sent to all conveyor units 2 that can apply force in the vertical direction. In the end, this number of the control signal is converted to actual RPM (so 2 may represent maximum RPM in clockwise direction, 1 may represent 50% of maximum RPM in clockwise direction and -2 may represent maximum RPM in counter clockwise direction).

[0171] The general steps of operating the planning system will now be briefly described.

[0172] Firstly, a package is placed on the transporting surface. This is generally done at a start location on the transporting surface. The package is then immediately imaged and detected by the observation system in order to enter the package into the overall system. The detected package is then assigned an ID so that the package can be identified and tracked within the system. The IDs are assigned so that no two packages on the transporting surface at the same time have the same ID. A “package instance” is created which contains relevant information about the package, for example its current location and its dimensions. The planning system is informed about the new package and a command to move the package is produced. The first movement command is typically to send the package to the scanning area so that the scanning system can identify the end destination of the package, using the barcode, and the planning system can subsequently plan movement of the package accordingly. As the package moves along the transporting surface the observation system tracks the package by using the positional information from previous time frame captured by the video cameras and comparing it to the positional information in the current time frame. Positional information used to track the package along the transporting system include xy-coordinates, the dimensions of the package, and the orientation of the package on the transport surface.

[0173] A number of assumptions are used to match detections from a current frame with packages identified in a previous frame, as follows: i) A package could not have moved an unreasonable distance between two frames (time between two frames is typically in the range of 1 / 20 of a second). ii) A package could not have changed its angle an unreasonable amount between two frames. iii) A package has the same dimensions throughout its lifetime. iv) The package’s movement vector correlates with the movement command given, which means that it is highly unlikely that the package has moved 1 cm to the right if it was given the command to moved 1 cm to the left.

[0174] As already discussed, the physical surface of the transport surface has a chess board-like pattern that makes detection of packages easier and more precise. This is due to the fact that the planning system knows about the chess board pattern, what it looks like, and that this pattern is the same all the time and everywhere on the surface. Therefore, detecting objects on the surface having this pattern becomes easier because the system can use the regularity of the pattern to better detect objects on the surface.

[0175] In summary, the planning system comprises hardware and software aspect. The hardware primarily consists of multiple conveying frames, each having a surface that can move packages freely in all directions. This surface may be referred to as an omnidirectional conveyor belt. Optionally, the hardware may include multiple elevator modules to move the transporting surface up and down. Several conveying frames can be stacked on top of one another with elevator modules connecting the different floors together. Both the conveyor module and the transport module are designed such that they can be stacked together in all directions, thus allowing for formation of systems that can cover any surface area and have an arbitrary number of floors. Packages can then move freely on each floor using the conveyor module(s) and between floors using the elevator module(s). An overarching software system uses video cameras to detect and track packages. It also plans the movement of the packages and implements the appropriate movement controlling routines and procedures.

[0176] The planning system is a modular omnidirectional conveyor belt system capable of moving packages freely, in some cases in three dimensions. The system has the ability to perform complex sortation, storage, retrieval, and other sequences of operations with many packages simultaneously in parallel (parallel execution of operations in the same space).

Claims

Claims1 . A conveyor module comprising: a rotatable portion having one or more conveying elements mounted thereon, each conveying element having a plurality of engagement members configured to engage with a surface of an object to be conveyed in a first direction via rotation of the rotatable portion, each engagement member further being configured for free rotation on the conveying element in a second direction that is orthogonal to the first direction; a driving mechanism configured to rotate the rotatable portion such that the engagement members cause movement of an engaged object in the first direction; and a control mechanism configured to control rotation of the rotatable portion via the driving mechanism; wherein the rotatable portion defines an internal cavity, and the driving mechanism is at least partly housed within the cavity.

2. The conveyor module of claim 1 , wherein the driving mechanism comprises an electric motor configured to directly provide a rotational force to the rotatable portion, and the conveyor module further comprises: a retaining sleeve configured to receive and retain the motor in place whilst the motor provides the rotational force to the rotatable portion; wherein the retaining sleeve is configured to fit within the cavity defined by the rotatable portion.

3. The conveyor module of claim 2, wherein: the motor comprises a first retaining means; the retaining sleeve comprises a second retaining means; and the first retaining means and the second retaining means are configured to interact to facilitate securing of the motor in place.

4. The conveyor module of claim 3, wherein the first retaining means is a retaining abutment extending radially from a lateral external surface of the motorand the second retaining means is at least one retaining groove longitudinally extending along an internal retaining surface of the retaining sleeve.

5. The conveyor module of claim 4, wherein the at least one retaining groove comprises a plurality of retaining grooves circumferentially distributed about a retaining surface of the retaining sleeve.

6. The conveyor module of any of claims 2 to 5, wherein the internal cavity of the rotatable portion is cylindrical, and the retaining sleeve is cylindrical such that the rotatable portion and the retaining sleeve are complementary.

7. The conveyor module of any preceding claim, wherein the rotatable portion comprises a cylindrical hub configured to support the conveying elements and provide an internal cavity to accommodate the driving mechanism.

8. The conveyor module of claim 7, wherein the cylindrical hub is configured to be rotated by the driving mechanism.

9. The conveyor module of claim 7 or 8, wherein the driving mechanism comprises a drive shaft having a geometrically shaped cross-section, and wherein the cylindrical hub of the rotatable portion comprises a closed end portion having a drive shaft aperture that is configured to receive and thereby engage the drive shaft such that rotation of the drive shaft drives rotation of the cylindrical hub.

10. The conveyor module of any of claims 7 to 9, wherein the rotatable portion is configured to be mounted on the retaining sleeve via a bearing component that is housed within the rotatable portion.11 . The conveyor module of any of claims 7 to 10, wherein the cylindrical hub comprises a first securing means configured to facilitate securing of the conveying elements to the cylindrical hub.

12. The conveyor module of claim 11 , wherein the first securing means comprises at least one protrusion on the external surface of the cylindrical hub.

13. The conveyor module of claim 11 or 12, wherein each conveying element comprises a second securing means configured to engage with the first securing means on the cylindrical hub.

14. The conveyor module of claim 13, wherein the second securing means comprises at least one indent located on an inner circumferential surface of the conveying element, wherein the at least one indent is shaped to complement the at least one protrusion.

15. The conveyor module of any preceding claim, wherein the at least one conveying element comprises at least a pair of conveying elements mounted on the rotatable portion such that the engagement members do not coincide along a longitudinal axis.

16. The conveying module of any preceding claim, further comprising an end plate arranged to prevent longitudinal movement of the conveying elements on the rotatable portion.

17. The conveyor module of any preceding claim, further comprising a housing having an opening through which a portion of each rotatable portion projects.

18. The conveyor module of claim 17, wherein at least one edge of the opening parallel to the first direction comprises a raised portion configured to guide a package to the at least one conveying element.

19. The conveyor module of 18, wherein the raised portion comprises a curved surface.

20. The conveying system of any of claims 17 to 19, wherein the housing comprises: an upper housing arranged to at least partially enclose the conveying element; a lower housing arranged to at least partially enclose the driving mechanism; and a locking mechanism configured to secure the upper and lower housing together.21 . The conveying module of claim 20, wherein the rotatable portion is further configured to have a bearing element mounted thereon, and wherein the upper housing and lower housing each have a complementing arch portion that are together arranged to accommodate said bearing component.

22. The conveyor module of claim 20 or claim 21 , wherein the locking mechanism is configured as a snap-fit mechanism.

23. The conveyor module of claim 22, wherein the locking mechanism comprises a plurality of snap-fit connectors.

24. The conveyor module of any of claims 20 to 23, wherein the lower housing comprises a connector slot configured to receive the control mechanism.

25. The conveyor module of claim 24, wherein the connector slot comprises a first slot and a second slot that is at a different orientation to the first slot.

26. The conveyor module of claim 25, wherein the first and second slots are arranged orthogonally.

27. The conveyor module of claim 26, wherein the control mechanism is flexibly connected to the driving mechanism such that the control mechanism can be orientated in either of the first or second slots.

28. The conveyor module of any of claims 17 to 27, wherein the housing comprises a lip configured to support a length of elastically deformable material.

29. The conveyor module of any of claims 17 to 28, wherein the lower housing is configured to provide an opening on an underside of the housing.

30. The conveyor module of claim 29, wherein the lower housing comprises curved side walls arranged to converge towards each other.

31. The conveyor module of any preceding claim, wherein the control mechanism comprises a printed circuit board (PCB).

32. A conveyor element for a conveyor module, the conveyor element comprising a conveying hub having a plurality of fixed segments that are spaced around an outer circumference of the conveying hub with engagement members rotatably mounted therebetween such that the engagement members freely rotate.

33. They conveyor element of claim 32, wherein each fixed segment comprises a pair of cavities positioned on opposing sides of the fixed segment and each engagement member comprises an axle about which an outer surface of the engagement member can rotate, wherein free ends of the axle are positionable inside respective cavities of adjacent fixed segments.

34. The conveyor element of claim 32 or claim 33, wherein the conveying hub further comprises a second securing means configured to facilitate securing of the conveyor element to a cylindrical hub.

35. The conveyor element of claim 34, wherein the second securing means comprises at least one indent located on an inner circumferential surface of the conveying hub.

36. The conveyor element of any of claims 32 to 35, wherein the at least one conveying element comprises an omnidirectional wheel.

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