Sorting module for a sorting conveyor

Abstract

A sorting module for a sorting conveyor includes a flexible conveying mat for moving a product in multiple directions. The sorting module includes a frame comprising a top plate and a bottom plate. Drivers at each edge between the top plate and bottom plate selectively drive the flexible conveying mat in a longitudinal direction or a lateral direction relative to an input conveying section.

Description

[0001] SORTING MODULE FOR A SORTING CONVEYOR

[0002] RELATED APPLICATIONS

[0003] The present application claims priority to US Provisional Patent Application No. 63 / 769,888, filed March 11, 2025 and entitled "Sorting Module for a Sorting Conveyor", the contents of which are herein incorporated by reference.

[0004] BACKGROUND OF THE INVENTION

[0005] The invention relates generally to sorting conveyors and more particularly to a sorting conveyor capable of moving in multiple directions for the purpose of conveying a package, product, or other conveyed item (each an "article") to a desired location.

[0006] A drawback of currently available conveyor systems is the difficulty in sorting articles. Prior systems deliver a large number of articles to a high-speed sorting machine, which sorts articles for transport within the conveyor system. A more desirable method is a grid sorter capable of routing articles from a starting location to an ending destination within a conveyor system. However, a grid sorter requires a reliable conveyor that can direct articles in a plurality of directions.

[0007] SUMMARY OF THE INVENTION

[0008] A sorting module in a conveying system is capable of directing articles in a plurality of directions, specifically, forward, backward, left, and right. Thus, the disclosed sorting module enables the creation of a grid sorter that can transport a package from one of a plurality of input locations to one of a plurality of output locations. A sorting module in the sorting conveyor includes a top plate, a bottom plate, and drivers at each edge between the top plate and bottom plate. The drivers selectively drive a flexible conveying mat in a longitudinal direction or a lateral direction relative to an input conveying section.

[0009] According to one aspect, a sorting module comprises a frame including a bottom plate and a top plate above the bottom plate, a drive assembly and a flexible conveying mat driven by the drive assembly for receiving and conveying a product. The drive assembly is mounted between the top plate and the bottom plate. The drive assembly comprises a first drive roller at a first side edge of the frame and rotatable about a first axis, a second drive roller at a second side edge of the frame, the second drive roller rotatable about a secondaxis perpendicular to the first axis, a third drive roller at a third side edge of the frame, the third drive roller rotatable about a third axis parallel to the first axis, and a fourth drive roller at a fourth side edge of the frame, the fourth drive roller rotatable about a fourth axis parallel to the second axis. The flexible conveying mat is flexible in a longitudinal and lateral direction. The first drive roller selectively rotates to transition the flexible conveying mat over the first side edge to an interior space between a bottom plate and a bottom support. The second drive roller selectively rotates to transition the flexible conveying mat over the second side edge to the interior space. The third drive roller selectively rotates to transition the flexible conveying mat over the third side edge to the interior space and the fourth drive roller selectively rotates to transition the flexible conveying mat over the fourth side edge to the interior space.

[0010] BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an isometric view of a sorting conveyor including a sorting module as a product is transferred onto a flexible conveying mat on the sorting module from a first conveyor segment according to an embodiment;

[0011] FIG. 2 shows the sorting conveyor of FIG. 1 as the flexible conveying mat moves to the middle of the sorting module;

[0012] FIG. 3 shows the sorting conveyor of FIG. 1 as the flexible conveying mat discharges product onto a second conveyor segment in line with the first conveyor segment;

[0013] FIG. 4 shows the sorting conveyor of FIG. 1 as the flexible conveying mat discharges product onto a third conveyor segment perpendicular to the first and second conveyor segments;

[0014] FIG. 5 shows the sorting conveyor of FIG. 1 as the flexible conveying mat discharges product onto a fourth conveyor segment opposite the third conveyor segment;

[0015] FIG. 6 is an isometric view of a sorting module including a flexible conveying mat according to an embodiment;

[0016] FIG. 7 shows the sorting module of FIG. 6 without the flexible conveying mat; FIG. 8 shows the sorting module of FIG. 7 with a top plate removed;

[0017] FIG. 9 is a side cross-sectional view of the sorting module of FIG.6;FIG. 10 shows the sorting module of FIG. 6 as the flexible conveying mat travels in a first direction over a front roller;

[0018] FIG. 11 shows the sorting module of FIG. 6 as the flexible conveying mate travels in a second direction perpendicular to the first direction and over a side roller;

[0019] FIG. 12 is an isometric view of a drive roller suitable for driving a flexible conveying mat;

[0020] FIG. 13 is a detailed view of a center portion of the drive roller of FIG. 12;

[0021] FIG. 14 is an isometric view of a sorting module according to another embodiment; FIG. 15 shows the sorting module of FIG. 14 with the flexible sorting mat removed; FIG. 16 is an isometric view of the drive roller of the sorting module of FIG. 14; FIG. 17 is a detailed view of a portion of the drive roller of FIG. 16;

[0022] FIG. 18 is an isometric view of the base of the drive roller of FIG. 16;

[0023] FIG. 19 is an end view of the base of FIG. 18;

[0024] FIG. 20 is an isometric top view of a portion of a flexible conveying mat comprising hingedly connected tiles according to an embodiment;

[0025] FIG. 21 is a bottom view of the portion of FIG. 20;

[0026] FIG. 22 is an isometric top view of an individual tile of the portion of FIG. 20;

[0027] FIG. 23 is a bottom view of the tile of FIG. 22;

[0028] FIG. 24 shows three interconnected tiles of the embodiment of FIG. 20;

[0029] FIG. 25 is a bottom view of the three interconnected tiles of FIG. 24;

[0030] FIG. 26 shows a portion of a flexible conveying mat formed of a plurality of tiles of FIG. 22 as the mat bends around a drive roller;

[0031] FIG. 27 is a side view of the drive roller and flexible conveying mat portion of FIG.

[0032] 26;

[0033] FIG. 28 is an isometric top view of a portion of a flexible conveying mat comprising connected tiles according to another embodiment;

[0034] FIG. 29 is a bottom view of the portion of FIG. 28;

[0035] FIG. 30 is an isometric top view of an individual tile of the portion of FIG. 28;

[0036] FIG. 31 is a bottom view of the individual tile of FIG. 30;

[0037] FIG. 32 is an isometric bottom view of portion of a flexible conveying mat comprising a plurality of tiles including snap-in magnets;FIG. 33 shows the portion of FIG. 32 with the magnets removed;

[0038] FIG. 34 is a sectional view of a tile of the portion of FIG. 32 showing the snap-fit of a magnet in the tile;

[0039] FIG. 35 is an isometric view of a drive roller for a sorter module including snap-in magnets according to an embodiment;

[0040] FIG. 36 is a cutaway view of the drive roller of FIG. 35;

[0041] FIG. 37 is a bottom view of a modular tile including a square recess for seating a magnet according to another embodiment;

[0042] FIG. 38 a bottom view of a modular tile including a countersunk recess for seating a magnet according to another embodiment;

[0043] FIG. 39 shows a portion of a flexible conveying mat using a plurality of octagonal tiles according to another embodiment;

[0044] FIG. 40 is a bottom view of the portion of FIG. 39;

[0045] FIG. 41 is a is a bottom view of the portion of FIG. 40 with covers removed;

[0046] FIG. 42 shows the portion of FIG. 39 bending longitudinally;

[0047] FIG. 43 is an isometric top view of a modular tile suitable for forming a flexible conveying mat according to another embodiment;

[0048] FIG. 44 is a bottom view of the modular tile of FIG.43;

[0049] FIG. 45 shows a plurality of modular tiles of FIG.43 flexibly joined together to form a flexible conveying mat;

[0050] FIG. 46 is a bottom view of a portion of a flexible conveying mat including drive pegs according to another embodiment;

[0051] FIG. 47 is a bottom view of a modular tile in the portion of FIG. 46;

[0052] FIG. 48 is a top view of a modular tile suitable for forming a flexible conveying mat and including a friction pad on a top conveying surface;

[0053] FIG. 49 is an isometric view of a drive roller suitable for driving a flexible conveying mat with drive pegs;

[0054] FIG. 50 is a side view of the drive roller of FIG. 49 driving a flexible conveying mat; FIG. 51 is a bottom view of a portion of a flexible conveying mat with multiple drive pegs per tile according to another embodiment;FIG. 52 is an isometric view of a sorting module for driving a flexible conveying mat having drive pegs according to another embodiment;

[0055] FIG. 53 is a detailed view of a corner region of the sorting module of FIG. 52;

[0056] FIG. 54 is a cross-sectional view of the corner region of FIG. 53;

[0057] FIG. 55 is a detailed view of a corner region of a sorting module according to another embodiment;

[0058] FIG. 56 is an isometric view of a finger plate of the sorting module of FIG. 55;

[0059] FIG. 57 is an isometric view of a sorting module including an edge driven flexible conveying mat according to another embodiment;

[0060] FIG. 58 shows the sorting module of FIG. 57 with the flexible conveying mat removed;

[0061] FIG. 59 shows the sorting module of FIG. 58 with a top plate removed;

[0062] FIG. 60 is a top view of the embodiment of FIG.59; and

[0063] FIG. 61 shows the sorting module of FIG. 60 as it moves the flexible conveying mat in a first direction.

[0064] DETAILED DESCRIPTION OF THE INVENTION

[0065] A grid sorter comprises a plurality of conveyor sections having one or more intersections. At each intersection there is a sorting module configured to send conveyed articles to a desired conveyor section. The invention will be described relative to certain illustrative embodiments, though those skilled in the art will recognize that the invention is not limited to the illustrative embodiments.

[0066] Referring to FIG. 1, a sorting conveyor 10 comprises a plurality of conveyor segments intersecting at a multi-directional sorting module 100. Product 14 conveyed on a first conveyor segment 12a can be transferred to another conveyor segment 12b, 12c or 12d, or back to the conveyor segment 12a, by the sorting module 100. From the first conveyor segment 12a, product 14 is transferred onto a flexible conveying mat 170, which moves into position on a top surface the sorting module 100 to receive the product 14. The flexible conveying mat 170 then moves to the center of the top surface of the sorting module 100, as shown in FIG. 2. When the flexible conveying mat 170 is on top of the sorting module 100,the flexible conveying mat 170 may be propelled as desired toward any of conveyor segments 12a— 12d to discharge product onto a selected conveyor segment.

[0067] In one option, the flexible conveying mat 170 can continue the forward movement of the product 14 and pass the product onto a second conveyor segment 12b in line with the first conveyor segment, as shown in FIG. 3. As it transfers the product 14, the flexible conveying mat 170 bends around a front edge of the sorting module 100 and passes to an interior space in the sorting module 100. The flexible conveying mat 170 can then return to the top of the sorting module (via the front edge or another edge) to receive and transfer another product. In another option, shown in FIG. 4, the flexible conveying mat 170 diverts a product 16 laterally to a third conveyor segment 12c that is perpendicular to the first and second conveyor segments 12a, 12b, bending around a second edge of the sorting module 100 into the interior space below the conveying surface before returning to the top to receive and transfer another product. The flexible conveying mat 170 can bend in both the lateral and longitudinal direction to allow diversion of the product laterally or transfer longitudinally. In another option, shown in FIG. 5, a flexible conveying mat 170 can divert a product 18 to a fourth conveyor segment 12d extending opposite the third conveyor segment 12c, bending around a third edge of the sorting module into the area below the top surface before returning to the top. The flexible conveying mat 170 preferably returns to the top of the sorting module 100 as a product is transferred from a conveyor segment onto the flexible conveying mat 170. The sorting module 100 may include multiple flexible conveying mats 170 that cooperate to convey and transfer product, with one conveying mat below the conveying surface when another is above the conveying surface.

[0068] Referring to FIGS. 6 — 9, an illustrative sorting module 100 for a sorting conveyor includes a frame 110, a drive assembly 130 and a flexible conveying mat 170 for receiving and moving a product, as directed by the drive assembly.

[0069] The illustrative frame 110 includes a low-friction top plate 111 forming a top surface for supporting the flexible conveying mat 170, a bottom plate 112 and an intermediate plate 113. The illustrative sorting module 100 is square to form four sides that interface with conveyor segments 12a— 12d, but the invention is not so limited.

[0070] The illustrative drive assembly 130 comprises mat driver at each side edge of the frame, between the top plate 111 and the intermediate plate 113, for engaging and movingthe flexible conveying mat 170 in a selected direction. The illustrative mat driver comprises drive rollers 131a, 131b, 131c, 131d rotatably mounted between the top plate 111 and the intermediate plate 113 at each side edge. Each roller is configured to rotate about an axis corresponding to the associated side edge. Rollers 131a and 131b are parallel to each other and rollers 131c and 131d are perpendicular to rollers 131a, 131b and parallel to each other to form a square shape, but the invention is not limited to a square shape. The drive assembly can alternatively have a rectangular or other shape. The top plate 111 and intermediate plate 113 both extend to and interface with each drive roller, and the flexible conveying mat 170 is sized and configured to extend to all of the drive rollers when centered on the top plate 111, so that it is always in contact and engaged with at least one drive roller. When a trailing edge of the flexible conveying mat 170 passes onto the top plate 111 from a first drive roller, the front edge of the flexible conveying mat 170 is already engaged with and driven by an opposing drive roller. Each drive roller 131 can be rotatably mounted between opposing stanchions 114 extending up from the bottom plate 112 or other support structure. The illustrative stanchions 114 also support the top plate 111 at the corners.

[0071] As shown in FIG. 8, each drive roller 131a, 131b, 131c, 131d is driven by an associated motor 133a, 133b, 133c, 133d and timing belt 132a, 132b, 132c, 132d. Each motor is supported by the intermediate plate 113. In another embodiment, opposing pairs of rollers can be synchronized and driven by a single motor. Other suitable means for mounting and driving the drive rollers can be used. The drive rollers 131a-d coordinate to move the flexible conveying mat 170 in a longitudinal direction Y, as shown in FIG. 10 or lateral direction X, as shown in FIG. 11, and can divert the flexible conveying mat 170 by 90° in either direction, if desired. The conveying mat 170 passes below the top plate to an intermediate space 115 between the intermediate plate 113 and bottom plate 112, shown in FIG. 9, and can return to the top plate 111.

[0072] In an illustrative embodiment, the drive rollers 131a-d magnetically drive the flexible conveying mat 170. The drive rollers 131a— d include an array of magnets and the flexible conveying mat is embedded with a corresponding matrix of magnets or magnetic targets attracted to the drive roller magnets, but the invention is not so limited. In an embodiment, each drive roller comprises N rows of magnets, each row distributed about the periphery of the roller, and the flexible conveying mat 170 comprises a matrix of NxN magnets matchingsthe spacing of the drive roller magnets and flexible in both a lateral and longitudinal direction. Other suitable means for driving the flexible conveying mat 170 in different directions may be used.

[0073] As shown in FIGS. 12 and 13, in one embodiment, each drive roller 131 comprises a pulley base 134 upon which a series of spaced apart rings 135 with embedded magnets 136 are mounted. A central toothed ring 137 engages a corresponding timing belt 132 to drive the drive roller 131. Alternatively, each drive roller 131 may be motorized or driven through another suitable means. Any suitable means for driving the drive rollers may be used.

[0074] The flexible conveying mat 170 includes a matrix of magnets that engage and move with the embedded magnets on the driver rollers as the engaged drive roller rotates. The mat magnet array matches the spacing of the magnets 136 in the drive rollers 131, so that when the mat is in a top central position, magnets at each edge of the mat are top dead center over the drive rollers. The conveying mat magnets engage the activated drive roller, while the non-activated drive rollers are rotated so that the magnets therein are not in line with the conveyor mat magnets, allowing the conveying mat to slide transversely over the non-activated drive rollers.

[0075] When drive rollers 131a, 131b rotate in a first direction, the flexible conveying mat 170 moves forward longitudinally towards conveyor segment 12b. When the drive rollers 131a, 131b rotate in a second, opposite direction the flexible conveying mat 170 moves backwards longitudinally towards conveyor segment 12a. When the second set of drive rollers 131c, 131d rotate in a first direction, the flexible conveying mat moves laterally in a first direction towards conveyor segment 12c. When the second set of drive rollers 131c, 131 d rotate in an opposite direction, the flexible conveying mat moves laterally in a second direction towards conveyor segment 12d. The drive rollers also coordinate to pull the flexible conveying mat 170 from below the top plate 111 after transferring a product to a conveyor segment to prepare the flexible conveying mat to receive another product for transfer. The flexible conveying mat is capable of bending in both the lateral and longitudinal directions to allow the mat to reverse around the drive rollers. The flexible conveying mat magnets disengage from an engaged drive roller after the magnet passes onto the top plate 111 or into the area between the intermediate plate 113 and bottom plate112. The flexible conveying mat can have any suitable embodiment and be formed of any suitable material.

[0076] FIGS. 14 and 15 show another embodiment of a sorting module 200 suitable for directing a product in a lateral and— or longitudinal direction. The sorting module 200 includes a flexible conveying mat 270 comprising a plurality of flexibly connected modular tiles 271 capable of flexing both laterally and longitudinally relative to each other to allow the flexible conveying mat to reverse around drive rollers at different orientations. Any suitable means for flexibly connecting the modular tiles 271 to form an array can be used. Each tile 271 includes a magnet on or embedded in a bottom surface that attracts to and moves with a magnet on a drive roller 231 of the sorting module. In the embodiment of FIGS. 14 and 15, a drive roller 231 at each edge of the sorting module 200 comprises a cylindrical base with slots for receiving a row of magnets. A first set of parallel drive rollers 231a, 231b can drive the flexible conveying mat in a first direction and a second direction opposite the first direction. A second set of parallel drive rollers 231c, 231 d can drive the flexible conveying mat in a third direction perpendicular to the first and second directions and a fourth direction opposite the third direction (and also perpendicular to the first and second directions).The driver rollers 231 extend up from a bottom surface 212 and are supported by supports at the corners of the bottom surface 212 by stanchions 214, which also support a low friction top surface 211. The low friction top surface 211 extends between the drive rollers 231 and supports the flexible conveying mat 270. As the flexible conveying mat 270 travels over a drive roller to offload a product onto an interfacing conveyor segment, the flexible conveying mat 270 passes into an intermediate area between the bottom plate and an intermediate plate of the sorting module 200.

[0077] The modular tiles 271 can be formed of injection-molded plastic, but the invention is not so limited.

[0078] FIGS. 16 — 19 show an embodiment of a drive roller 231 for driving a flexible conveying mat suitable for use in the sorting module 200 of FIGS. 14 and 15. The illustrative drive roller 231 comprises an extruded base 233 with longitudinally-extending slots 235 in the peripheral surface for receiving magnetic inserts. Magnets 236 for engaging and moving magnets in an associated flexible conveying mat are housed in the slots 235 to match the spacing of magnets in the flexible conveying mat. Each illustrative magnet 236 issandwiched between two metal buffering blocks 237, with rubber blocks 238 between each magnet-buffering block combination to improve friction, as well as reduce wear and noise. The metal buffering blocks may be formed of steel and the extruded base may be formed of aluminum, but the invention is not so limited.

[0079] As shown in FIG. 19, the illustrative base 233 has a basic shape of a 14-sided polygon to facilitate engagement and disengagement of the magnets, but the invention is not so limited.

[0080] Referring to FIGS. 20—21, a flexible conveying mat 270 can comprise a plurality of hingedly connected modular tiles 271. Each modular tile 271, shown in FIGS. 22 and 23, includes a body 273 forming from a top conveying surface 279 that is preferably square in shape. Connecting elements extend from the edges of the body 273 for connecting the tile 271 to adjacent tiles. A first set of connecting elements extends from a first edge and includes a closed hinge element 276 and an open hinge element 277 with a latching ridge 278. A second set of connecting elements extends from a second edge intersecting and perpendicular to the first edge, also including a closed hinge element 282 and an open hinge element 283 with a latching ridge 284. Third and fourth sets of connecting elements 385, 386 include closed hinge elements. To assemble the flexible conveying mat 270, the tiles 271 are arranged adjacent to each other in a selected grid patterns, such that hinge elements interleave and the side edges of the bodies abut to form a substantially continuous surface. Then, rodlets 290 (shown in FIG. 21) are inserted into aligned hinge elements in lateral and longitudinal positions to hingedly connect the tiles together. Each rodlet 290 includes a groove that engages a latching ridge 278, 284 in an open hinge element to secure the rodlet in a hinge passageway. As shown in FIGS. 24 and 25, when assembled, the tiles 271 can flex in both a lateral and longitudinal direction relative to each other.

[0081] The bottom surface 274 of at least some of the tiles includes a recess 280 for seating a magnet. The magnet can be retained using an adhesive, a locking mechanism, a snap fit or other suitable means. The illustrative bottom surface 274 has a concave shape formed by intersecting circles to facilitate movement of the tile over the curved surface of a drive roller in both a lateral and longitudinal direction, with the recess 280 in the middle and nadir.In another embodiment, a flexible conveying mat can comprise a sheet of flexible material, such as fabric, rubber, plastic and combinations thereof, in which a matrix of magnets is embedded.

[0082] In another embodiment, rodlets connecting tiles with hinges on multiple edges can contain magnets for driving a flexible conveying mat formed of such hingedly connected tiles.

[0083] Referring to FIGS. 26 and 27, an embodiment of a drive roller 331 for a flexible conveying mat 270 in a sorting module can include recesses 333 in a drive surface 335 for receiving magnets to drive the flexible conveying mat 270. The bottom surface of the tiles 271 allows the mat to wrap around the drive roller 331 as shown, or move laterally relative to the drive roller.

[0084] FIGS.28—29 show another embodiment of a flexible conveying mat 370 formed using hingedly connected tiles 371, shown individually in FIGS. 30 and 31. The illustrative flexible conveying mat 370 includes interleaved tiles 371 that can bend both laterally and longitudinally relative to each other. Each tile 371 includes a body with four perpendicular side edges, a top conveying surface 379 and an opposite bottom surface 374 for seating a magnet. A first set of connecting elements 375 extends from a first edge and includes aligned hooks forming open hinges. A second set of connecting elements 376 extends from a second edge intersecting and perpendicular to the first edge and also includes hooks forming open hinges. Third and fourth sets of connecting elements 377, 378 extend from third and fourth edges and include aligned, shaped protrusions with an integrated shaft 372 extending between. The illustrative shaft 372 is configured to fit into the openings of the hooks of a mating set of connecting elements 375 or 376 to connect two tiles together.

[0085] The bottom surface 374 of a tile can be shaped and configured to mount a magnet. The illustrative bottom surface 374 includes a recess 380 for seating a magnet, but the invention is not so limited.

[0086] Any suitable means for connecting a plurality of modular tiles to form a flexible conveying mat may be used, and any suitable means for integrated magnets into such a flexible conveying mat may be used.

[0087] A modular tile for a flexible conveying mat may mount a magnet on a bottom surface through any suitable means, including, but not limited to, adhesives, a snap-fit connection,overmolding and mechanical locking means. For example, as shown in FIGS. 32—34 a recess 533 on a bottom surface of a modular tile 571 in a flexible conveying mat 570 may include flexible arms 580 that engage a groove 591 on a magnet 590 to latch the magnet 590 in place relative to the tile.

[0088] As shown in FIGS. 35 and 36, a drive roller 631 for magnetically driving a flexible conveying mat can include embedded magnets 680 retained through a snap fit connection. The illustrative drive roller 631, which has a polygonal shape, includes recesses 633 in alternating faces of the periphery for receiving magnets 680 that engage and drive magnets in an associated flexible conveying mat. Each magnet 680 includes a peripheral groove 681 that receives a latching protrusion 634 within a recess 633 to integrate the magnet 680 to the drive roller 631.

[0089] As shown in FIG. 37, a modular tile 771 used to make a flexible conveying mat can include a square recess 733 for seating a magnet to drive the flexible conveying mat. In another embodiment, shown in FIG. 38, a modular tile 871 used to make a flexible conveying mat can include a countersunk recess 833 for seating an annular magnet 880.

[0090] Referring to FIGS. 39—42, in another embodiment, a flexible conveying mat 970 for receiving product from a first conveyor segment and transferring product to a second conveyor segment, which may be aligned or angled relative to the first conveyor segment, comprises a plurality of octagonal-shaped tiles 971 with magnets 980 embedded within the tile. The tiles 971 are connected to each other via anchored rods 973 to form an array of magnets and an upper conveying surface. Each tile 971 includes four anchored rods connecting the tile to another tile in the array while enabling flexing of the tiles laterally and longitudinally relative to each other. Each anchored rod 973 extends through an opening 978 in a side of a tile to and through an opening in a side of an adjacent tile, as shown in FIG. 41. Other forms of flexible connectors may be used to flexibly connect tiles to form a flexible conveying mat, and the tiles can have any suitable shape, such as square and round and are not limited to the illustrative octagonal shape.

[0091] For example, as shown in FIG.43 — 45, a modular magnetic tile 1071 for a flexible conveying mat can comprise a base with a top conveying surface 1079, an opposite bottom surface 1074 in which a magnet is embedded, and four side walls to form a square-shaped magnetic tile. A first side wall includes a latch 1075, comprising two expanding flexible armsextending from the first side wall, each arm terminating in an outward-extending detent. A second side wall adjacent and perpendicular to the first side wall also includes a latch 1076 comprising two expanding flexible arms and outward-extending detents. A third side wall opposite the first side wall and adjacent to the second side wall includes an opening 1077 configured to receive a latch of an adjacent modular magnetic tile 1071, as shown in FIG.45. A fourth side wall also includes an opening 1078 configured to receive and engage a latch of an adjacent modular magnetic tile. The bottom surface 1074 may include a recess 1079 for seating a magnet through any suitable means, as described above.

[0092] When latched, the tiles 1071 can bend relative to each other in both a lateral and longitudinal direction. A plurality of modular magnetic tiles 1071 can latch together to form a flexible conveying mat 1070 for a sorting module, as shown in FIG.45.

[0093] A flexible conveying mat for a sorting module having drivers at four edges can be driven by the drivers through any suitable means and is not limited to the magnetic drives described above. For example, in another embodiment, shown in FIGS. 46—47, a flexible conveying mat 1170 can comprise a plurality of hingedly connected square tiles 1171, each including a drive peg 1172 extending down from a bottom surface for engaging a drive roller at a side of a sorting module. Each tile comprises a square body with hinges 1176 extending from each side edge for connecting to adjacent tiles in the mat. Rodlets 1190 extending through interleaved hinge elements join adjacent tiles so that the tiles can be longitudinally and laterally relative to each other. The rodlets 1190 can be retained through any suitable means, including a latching detent 1191, but the invention is not so limited.

[0094] Tiles that form edges of the flexible conveying mat can have shaped leading edges to facilitate engagement with an associated drive roller.

[0095] In one embodiment, shown in FIG.48, a positive drive tile 1181 for a flexible conveying mat can include a friction top surface 1182 to facilitate conveyance.

[0096] FIG. 49 shows a drive ring suitable for engaging drive teeth on a flexible conveying mat to drive the flexible conveying mat in a selected direction. The drive ring 1131 comprises a hub 1132 for mounting the drive ring in series with a plurality of other drive rings on a shaft at a side edge of a sorting module. The drive ring 1131 includes a plurality of drive teeth 1133 distributed about a periphery 1134 for engaging drive pegs 1172 on a flexible conveying mat 1170, as shown in FIG. 50.In another embodiment, shown in FIG. 51, a positive drive tile 1271 for a flexible conveying mat 1270 can include multiple drive pegs 1272 per tile, with associated drive rollers at edges of an associated sorting module configured to engage the drive pegs to move the flexible conveying mat.

[0097] FIG. 52 shows an embodiment of a sorting module 300 suitable for use with a positive drive flexible conveying mat, such as the flexible conveying mat 1070 of FIG. 46. The sorting module 300 includes a bottom support plate 312 supporting drive structure and a top plate 311 forming a top support surface for the flexible conveying mat. The illustrative top plate 311 includes an intersecting matrix of grooves 313 for accommodating the drive pegs 1172 of the flexible conveying mat 1070. The matrix of grooves 313 can be omitted or have any suitable configuration to accommodate any structure on the bottom of a flexible conveying mat.

[0098] The drive structure at the side edges of the sorting module 300 comprises a pulley 1120 at each edge of the sorting module between the top plate 311 and bottom plate 312. The pulley 1120 includes a series of toothed drive rings 1131 for engaging and driving a flexible conveyor mat 1070. The rings 1131 are spaced on the pulley 1120 to match the spacing of the magnets on the flexibly conveying mat 1070. Each pulley 1120 is driven by a motor housed between the top plate 311 and an intermediate plate (not shown) above the bottom plate 312.

[0099] At each corner, the sorting module 300 includes a hold down device 340, shown in detail in FIGS. 53 and 54. The hold down device 340 guides the edges of the flexible conveying mat 1070 as the mat traverses an edge of the module into an intermediate space between the bottom plate 312 and intermediate plate. The edges of the flexible conveying mat 1070 may include inserts 1080 having curved top surfaces. As shown in FIG. 54, as the flexible conveying mat 1070 curves around a ring 1131, the curved surfaces of the inserts 1080 form a circle. The curved inner surface of the hold down device 340 presses against the curved surfaces of the inserts 1080 to ensure proper engagement between the rings 1131 and mat 1070.

[0100] In another embodiment, shown in FIG. 55, a sorting module 400 can include finger plates 440 to guide the transition of a flexible conveying mat 1370 around drive edges of the sorting modules. An illustrative finger plate, shown in FIG. 56, comprises an L-shaped base 441 with a plurality of extensions 442. The base could alternatively have a T-shaped base, oranother suitable shape suitable for interfacing back-to-back sorting modules. Each extension 442 has two perpendicular outer sides 443, 444 and a curved inner surface 445. The tips of each extension 442 extend over the top conveying surface of the flexible conveying mat 1370. As shown, the tiles 1371 can include friction pads or other shaped top surfaces that form channels for receiving the tips. The inner surface 445 can guide the flexible conveyor mat 1370 as it transitions over a side edge of the sorting module 400 and ensure proper engagement between the tiles 1371 and driver.

[0101] Referring to FIGS. 57—61, in another embodiment, a sorting module 500 for a sorting conveyor comprises drivers that drive the edges of a flexible conveying mat 1470 to move the flexible conveying mat in different directions. The sorting module 500 includes a frame including a bottom plate 512, a top support plate 511 and side walls 514 that extend at right angles to form a square, intersecting at corners. The top support plate includes openings 516 at edges interfacing the side walls 514 to expose a driving belt 532 housed within the frame. Each driving belt 532 includes a series of magnets 533 for driving an associated flexible conveying mat 1470. The flexible conveying mat 1470 comprises a flexible body with magnets or magnetic targets disposed at the edges to match the spacing of the magnets 533 in the timing belt. Paired driving belts selectively drive the flexible conveying mat 1470 by engaging the mat magnets with the belt magnets to push the flexible conveying mat 1470 in a selected direction, as shown in FIG. 61. Non-driving belts can be relaxed and disengaged, while the active driving belts can be taut to engage the flexible conveying mat 1470.

[0102] In an embodiment, the flexible conveying mat 1470 can automatically find a home position, which can be on the top surface 511 and— or an intermediate space below the bottom plate 512. A target can be used to help find a home position.

[0103] In an exemplary embodiment, modular magnetic tiles forming a flexible conveying mat may be made of injection-molded thermoplastic. One of skill in the art will understand that other materials may be used, for example, portions of the foregoing may be made of non-magnetic metals or other suitable materials.

[0104] In addition, any suitable pattern of modular magnetic tiles may be used to create a flexible conveying mat.

[0105] Other forms of connectors may be used as means for flexibly connecting tiles. For example, a flexible conveying mat may be manufactured by co-molding or otherwiseattaching a flexible piece of fabric to serve as living hinge. Additionally, a combination of different plastics may be used to achieve desired flexibility.

[0106] The foregoing description of the embodiments of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and modifications and variations are possible in light of the above teachings or may be acquired from practice of the invention. The embodiments were chosen and described in order to explain the principles of the invention and its practical application to enable one skilled in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated.

[0107] This invention is susceptible to considerable variation in its practice. Therefore, the foregoing description is not intended to limit, and should not be construed as limiting, the invention to the particular exemplifications presented hereinabove. Rather, what is intended to be covered is as set forth in the ensuing claims and the equivalents thereof as permitted as a matter of law.

Claims

What is claimed is:

1. A sorting module comprising:a frame including a bottom plate and a top plate above the bottom plate;a drive assembly mounted between the top plate and the bottom plate, the drive assembly comprisinga first drive roller at a first side edge of the frame and rotatable about a first axis, a second drive roller at a second side edge of the frame, the second drive roller rotatable about a second axis perpendicular to the first axis, a third drive roller at a third side edge of the frame, the third drive roller rotatable about a third axis parallel to the first axis, anda fourth drive roller at a fourth side edge of the frame, the fourth drive roller rotatable about a fourth axis parallel to the second axis; anda flexible conveying mat for receiving and conveying a product, the flexible conveying mat flexible in a longitudinal and lateral direction, wherein the first drive roller selectively rotates to transition the flexible conveying mat over the first side edge between the top plate and an interior space between the top plate and bottom plate, the second drive roller selectively rotates to transition the flexible conveying mat over the second side edge between the top plate and the interior space, the third drive roller selectively rotates to transition the flexible conveying mat over the third side edge between the top plate and the interior space and the fourth drive roller selectively rotates to transition the flexible conveying mat over the fourth side edge between the top plate and the interior space.

2. The sorting module of claim 1, wherein each side edge interfaces with a conveyor segment of a sorting conveyor system.

3. The sorting module of claim 1, wherein each drive roller includes a series of magnets and the flexible conveying mat includes a matrix of magnets configured to engage the drive roller magnets.

4. The sorting module of claim 3, wherein the flexible conveying mat comprises a plurality of hingedly connected tiles including embedded magnets.

5. The sorting module of claim 4, wherein each tile comprises a body forming a square top surface, a plurality of closed hinge elements extending from sides of the body and a plurality of open hooks extending from sides of the body, and a plurality of rodlets inserted into aligned hinge elements and open hooks.

6. The sorting module of claim 4, wherein each tile comprises a body forming a square top surface, a first set of connecting elements extending from a first edge of the body including aligned hooks forming open hinge, a second set of connecting elements extending from a second edge intersecting and perpendicular to the first edge and also includes hooks forming open hinges, a third set of connecting elements extending from a third edge and including aligned, shaped protrusions with an integrated shaft extending therebetween and a fourth set of connecting elements extending from a fourth edge and including aligned, shaped protrusions with an integrated shaft extending between.

7. The sorting module of claim 4, wherein each hingedly connected tile includes a recess in a bottom surface for seating a magnet.

8. The sorting module of claim 7, wherein the recess includes a flexible arm that engages a groove on the magnet for latching the magnet to the tile.

9. The sorting module of claim 4, wherein each tile includes an opening in a first side for receiving an anchored rod to connect the rile to an adjacent tile in the flexible conveying mat.

10. The sorting module of claim 4, wherein each tile includes a latch comprising expanding flexible arms extending from a first side of the tile.

11. The sorting module of claim 3, wherein each drive roller comprises a pulley base, a series of spaced apart rings with magnets mounted about the periphery of each ring and a central toothed ring for engaging a timing belt to drive the drive roller.

12. The sorting module of claim 3, wherein each drive roller comprises an extruded base with longitudinally-extending slots and magnets inserted and seated in the slots.

13. The sorting module of claim 12, wherein each magnet is sandwiched between two metal buffering blocks, with rubber blocks between successive metal buffering blocks.

14. The sorting module of claim 1, wherein the flexible conveying mat comprises a plurality of hingedly connected tiles, each tile including a drive peg configured to engage a drive recess on a drive roller.

15. The sorting module of claim 1, further comprising a plurality of hold down devices at each corner of the frame for guiding the flexible conveying mat around a roller.

16. The sorting module of claim 1, further comprising a plurality of finger plates for guiding the flexible conveying mat around drive edges of the sorting modules.

17. The sorting module of claim 16, wherein each finger plate comprises an L-shaped base with a plurality of extensions, each extension having two perpendicular outer sides and a curved inner surface.

18. The sorting module of claim 1, wherein each drive roller drives a driving belt extending along an edge of the frame and including a series of magnets for driving the flexible conveying mat.

19. The sorting module of claim 18, wherein the top plate has openings at side edges to expose the driving belts.

20. The sorting module of claim 18, wherein the flexible conveying mat comprises a flexible body with magnets at edge of the body to match the spacing of the magnets in the timing belt.

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