System and method for controlling an accumulation conveyor

A material handling system, comprising:

• an accumulation conveyor comprising:
• a plurality of zones comprising at least a first zone, a second zone, and a third zone, wherein the first zone is upstream of the second zone, wherein the second zone is upstream of the third zone;
• a plurality of sensors, comprising at least a first sensor, a second sensor, and a third sensor;
• wherein the first sensor is located at an exit portion of the first zone, the second sensor is located at an exit portion of the second zone, and the third sensor is located at an exit portion of the third zone;
• and
• a plurality of control modules comprising at least a first control module, a second control module, and a third control module, wherein the first control module is communicably coupled with the first sensor, the first zone, and second control module, wherein the second control module is communicably coupled with the second sensor, the second zone, and third control module, wherein the third control module is communicably, coupled with the third sensor and the third zone,
• wherein the second control module is configured to:
• receive a third feedback signal from the third control module, wherein the third feedback signal indicates that the third sensor in the third zone is blocked;
• set a second drive assembly associated with the second zone to a disengaged state;
• receive a first signal from the first control module associated with the first zone, wherein the first signal indicates whether a first article has an irregular boundary or a second article has a regular boundary exits from the first zone;
• control the second drive assembly and a second brake assembly associated with the second zone based on the indication of the exit of the one of the first article or the second article from the first zone by the first signal received from the first control module, wherein the second drive assembly and the second brake assembly perform a first set of operations for the first article and a second set of operations for the second article;
• and
• a main controller communicably coupled with the accumulation conveyor to perform operations to receive data indicating conditions for each zone of the plurality of zones.