Conveyor load tracking system

A method for tracking a plurality of loads on a conveyor, comprising:

• providing a conveyor configured to move the loads in a travel direction relative to an entrance of the conveyor, the conveyor including a plurality of segments arranged in end to end relationship with one another in the travel direction, the plurality of segments including at least a first segment and a second segment;
• providing a first sensor located between the first and second segments;
• associating a frontward load of the loads with a frontward load data record;
• associating the frontward load data record with a frontward load location record encompassing the first segment of the conveyor and encompassing frontward load expected travel distances of the load of the frontward load data record in the travel direction along the first segment after associated conveyor travel distances;
• associating a middle load of the loads with a middle load data record, wherein the middle load is located upstream of the frontward load;
• associating the middle load data record with a middle load location record encompassing the first segment of the conveyor and encompassing second expected load travel distances of the load of the middle load data record in the travel direction along the first segment after associated conveyor travel distances;
• associating a rearward load of the loads with a rearward load data record, wherein the rearward load is located upstream of the middle load;
• associating the rearward load data record with a rearward load location record encompassing the first segment of the conveyor and encompassing third expected load travel distances of the load of the rearward load data record in the travel direction along the first segment after associated conveyor travel distances;
• detecting the frontward load entering the second segment with the first sensor in accordance with the frontward load expected travel distance of the frontward load location record;
• detecting a presence of an unknown load of the loads entering the second segment with the first sensor outside of the second expected load travel distances of the middle load location record, and creating a new data record associated with the unknown load;
• associating the new data record with a new location record encompassing the second segment of the conveyor and encompassing new expected load travel distances of the unknown load of the new data record in the travel direction along the second segment after associated conveyor travel distances;
• detecting with the first sensor that the middle load is not present at the first sensor at the second expected travel distance associated with the first sensor;
• detecting the rearward load entering the second segment with the first sensor in accordance with the third expected load travel distance of the rearward load location record;
• disassociating the middle load data record from the middle load location record and pairing the middle load data record with the new data record such that the middle load of the middle load data record is tracked with the new location record of the new data record.

A system for conveying and tracking loads, comprising:

• a conveyor having an entrance and configured to move the loads in a travel direction;
• the conveyor having a plurality of segments arranged in end to end relationship with one another;
• a first sensor located between the first and second segments;
• a controller configured to execute the following steps;
• associate a designated load of the loads with a designated load data record;
• associate the designated load data record with a designated load location record encompassing the first segment of the conveyor and encompassing designated load expected travel distances of the designated load in the travel direction along the first segment after associated conveyor travel distances;
• detect a presence of an unknown load of the loads entering the second segment with the first sensor outside of the designated load expected travel distances of the designated load location record, and create a new data record associated with the unknown load;
• associate the new data record with a new location record encompassing the second segment of the conveyor and encompassing new expected load travel distances of the unknown load of the new data record in the travel direction along the second segment after associated conveyor travel distances;
• detect with the first sensor that the designated load is not present at the first sensor at the first expected travel distance associated with the first sensor;
• and
• disassociate the designated load data record from the designated load location record and pair the designated load data record with the new data record such that the designated load of the designated load data record is tracked with the new location record of the new data record.