Methods and apparatus for controlling conveyor zones

A control system for an accumulating conveyor having a plurality of independently driven zones, the system comprising:

• an input/output module comprising:
• an input configured to receive a first article detection signal from a first article detection sensor for a first zone in an accumulating conveyor, the first zone comprising a plurality of rollers selectively rotatable in unison by a drive mechanism;
• an input configured to receive a second article detection signal from a second article detection sensor in a second zone of the accumulating conveyor, the second zone comprising a plurality of rollers rotatable in unison by a single drive mechanism;
• an output configured to provide a first actuation signal to cause selective rotation of the rollers of the first zone of the conveyor;
• and
• an output configured provide a second actuation signal to cause selective rotation of the rollers of the second zone of the conveyor;
• a control module in communication with the input/output module to receive the first and second article detection signals, wherein the control module is configured to control the first and second actuation signals using the status of the first and second article detection signals.

A method for controlling two or more conveyor zones using a single control module, the method comprising:

• receiving in a control module at least one signal from another control module for controlling the operation of the control module;
• using a circuit in the control module to control a first actuation signal for selectively powering or stopping a first conveyor zone in response to the at least one signal;
• and
• using the circuit in the control module to control a second actuation signal for selectively powering or stopping a second conveyor zone in response to the at least one signal.

A control module for controlling at least one zone of a conveyor, comprising:

• an input configured to receive an article detection signal from a zone of a conveyor;
• an output configured to provide an actuation signal for control of a zone of the conveyor;
• a user input device configured to receive an input from a user representing the speed at which the conveyor will run;
• and
• a control circuit configured to utilize the article detection signal and the user input to set the actuation signal.