Range sensing conveyor package management system for measuring and controlling density of parcels on a conveyor

A range sensing photo eye array apparatus for measuring and controlling the density of parcels on a conveyor, comprising:

• a feed conveyor and a receiving conveyor each one having independent drive motors;
• said feed conveyor including a range sensing field of measurement at a distal discharge end adjacent said receiving conveyor
• said receiving conveyor including a range sensing field of measurement at a distal receiving end adjacent said feed conveyor;
• a range sensing photo eye array having a virtual encoder and a signal generating and detecting means extending across the surface of said feed conveyor field of measurement and said receiving conveyor field of measurement;
• computer means for calculating percentage of desired occupancy of said receiving conveyor and percentage of actual occupancy of said receiving conveyor;
• a programmable logic controller for controlling said conveyor speed and movement based upon signals received from said photo eye array identifying gaps between packages on said receiving conveyor of sufficient space for insertion of an additional package from said feeding conveyor.

A method of measuring and controlling density of articles on a conveyor using programmable logic controller,, comprising the steps of:

• selecting a transition zone between a feed conveyor and a receiving conveyor each one having independent drive means;
• selecting a range sensing field of measurement of said selected transition zone, said range sensing field of measurement including a range sensing photo eye array in communication with a virtual encoder and a signal generating and detecting means extending across said selected transition zone;
• determining a percentage of an actual occupancy of a feed conveyor occupancy defined zone;
• determining a percentage of actual occupancy of a receiving conveyor occupancy defined zone;
• calculating a feed conveyor density of articles on said feed conveyor as a percentage of said feed conveyor occupancy and calculating a receiving conveyor density of articles on said receiving conveyor as a percentage of said receiving conveyor density of said articles in said transition zone with computer means;
• selecting a percentage of a desired occupancy of said receiving conveyor after a merger of said articles from said feeding conveyor to said receiving conveyor;
• feeding said articles from said feed conveyor at a selected rate of speed to said receiving conveyor occupancy defined zone;
• merging said articles at said conveyor area of said transition zone between said feed conveyor and said receiving conveyor and adjusting conveyor speed ratios proportioned according to ratio of desired density to current density to increase the density or volume of articles in a selected area of the receiving conveyor;
• and
• controlling said conveyor speed and movement with said computer means based upon signals received from said range sensing photo eye array identifying gaps between said articles on said receiving conveyor of sufficient space for insertion of additional articles from said feed conveyor.

A range sensing apparatus for measuring and controlling the density of articles on a conveyor, comprising:

• a feed conveyor and a receiving conveyor each one having independent drive motors;
• said feed conveyor including a range sensing field of measurement at a distal discharge end adjacent said receiving conveyor;
• said receiving conveyor including a range sensing field of measurement at a distal receiving end adjacent said feed conveyor;
• a range sensing device having a virtual encoder and a signal generating and detecting means extending across the surface of said feed conveyor field of measurement and said receiving conveyor field of measurement;
• computer means for calculating percentage of desired occupancy of said receiving conveyor and percentage of actual occupancy of said receiving conveyor;
• a programmable logic controller for controlling a conveyor speed and movement based upon signals received from said range sensing detection device identifying gaps between packages on said receiving conveyor of sufficient space for insertion of an additional package from said feeding conveyor.

A range sensing photo eye array apparatus for measuring and controlling the density of articles on a conveyor, comprising:

• a feed conveyor and a receiving conveyor each one having independent drive motors;
• said feed conveyor including a range sensing field of measurement at a distal discharge end adjacent said receiving conveyor;
• said receiving conveyor including a range sensing field of measurement at a distal receiving end adjacent said feed conveyor;
• at least one range sensing photo eye array having a virtual encoder and a signal generating and detecting means extending across the surface of said feed conveyor field of measurement and said receiving conveyor field of measurement;
• computer means for calculating percentage of desired occupancy of said receiving conveyor and percentage of actual occupancy of said receiving conveyor;
• a programmable logic controller for controlling a conveyor speed and movement based upon signals received from said range sensing detection device identifying gaps between packages on said receiving conveyor of sufficient space for insertion of an additional package from said feeding conveyor.