Parcel distribution control

A method for controlling parcel distribution on a conveyor belt system, the method comprising:

• receiving parcel data from a set of sensors on the conveyor belt system, wherein for each zone in the conveyor belt system, the set of sensors comprises a cross sensor detecting across an entire conveyor width, a right sensor detecting a first lateral portion, and a left sensor detecting a second lateral portion;
• analyzing the parcel data to determine a volume of parcels in each zone of the conveyor belt system by calculating parcel width based on determining which sensors of the cross sensor, right sensor, and left sensor are simultaneously blocked by each parcel, calculating parcel length by multiplying sensor blocking duration by conveyor belt speed, creating a three-dimensional virtual box volume measurement from the width and length calculations, and assigning volume density ratings to each zone based on comparing the virtual box volume to threshold values;
• and
• adjusting a speed of individual conveyor belts independently of each other based on the analyzed parcel data to maintain optimal parcel distribution in the conveyor belt system, wherein the adjusting of the speed comprises comparing volume density ratings between each zone and its immediately adjacent upstream and downstream zones, when a zone has a HEAVY volume density rating and an adjacent zone has a LIGHT volume density rating, temporarily adjusting conveyor belt speeds for a duration of less than one second to transfer parcel volume from the HEAVY zone to the LIGHT zone, and repeating the volume determination and speed adjustment in a continuous feedback loop to disperse concentrated parcel volumes across zones without establishing predetermined fixed spacing between parcels.

A computer-readable storage medium comprising computer-executable instructions that when executed cause a processor of a computing device to:

• receive parcel data from a set of sensors on a plurality of operatively connected individual conveyor belts in a conveyor belt system, wherein the sensors comprise, for each conveyor belt zone, a cross sensor detecting full width, a right sensor detecting a right portion, and a left sensor detecting a left portion;
• analyze the parcel data to determine a volume of parcels in each zone of the conveyor belts by determining a width measurement for each parcel based on a pattern of which of the cross sensor, right sensor, and left sensor detect the parcel, determining a length measurement for each parcel based on sensor blocking duration and belt speed, calculating a virtual box volume using the width and length measurements, and categorizing each zone as having HEAVY, NORMAL, or LIGHT volume density based on the virtual box volume;
• and
• adjust a speed of individual conveyor belts independently of each other based on the analyzed parcel data to maintain optimal parcel distribution in the conveyor belt system, wherein adjusting the speed comprises implementing a look-ahead and look-behind control algorithm that compares volume density of each zone with its adjacent zones, dispersing concentrated volumes by temporarily speeding up or slowing down individual conveyor belts for periods less than one second when volume density differences exist between adjacent zones, and continuously monitoring and adjusting to prevent parcel backup and overcrowding rather than achieving predetermined pitch spacing.