Conveyors including sensors for detecting error conditions associated with products traveling on the conveyors

A method for sorting and tracking products at a product distribution facility, the method comprising:

• providing a plurality of interconnected conveyors configured to move the products;
• providing a first sensor positioned proximate a product advancement surface of at least one of the conveyors and configured to detect at least one identifying characteristic of at least one product moving on the product advancement surface;
• providing a second sensor positioned proximate the product advancement surface and configured to detect at least one physical characteristic of the at least one product moving on the product advancement surface;
• providing a plurality of transfer nodes interconnecting the plurality of conveyors, each of the transfer nodes configured to permit transfer of the at least one product from the product advancement surface of the at least one of the conveyors to the product advancement surface of another one of the conveyors;
• providing an electronic database storing inventory management data including:
• data indicating predefined identifying characteristic and physical characteristic information associated with the at least one product, the predefined identifying characteristic and physical characteristic information corresponding to the at least one product when in a new condition and undamaged;
• and
• data indicating actual identifying characteristic information associated with the at least one product, the actual identifying characteristic information corresponding to the at least one product when detected by the first sensor during movement of the at least one product along the product advancement surface;
• data indicating actual physical characteristic information associated with the at least one product, the actual physical characteristic information corresponding to the at least one product when detected by the second sensor during movement of the at least one product along the product advancement surface;
• and
• providing a processor-based electronic inventory management device in communication with the first and second sensors and the electronic database, the electronic inventory management device being configured obtain the inventory management data stored in the electronic database and, based on the obtained inventory management data, to:
• compare the data indicating the actual identifying characteristic information associated with the at least one product detected by the first sensor during movement on the product advancement surface to the data indicating the predefined identifying characteristic information associated with the at least one product in order to determine an identity of the at least one product detected by the first sensor;
• compare the data indicating the actual physical characteristic information associated with the at least one product detected by the second sensor during movement on the product advancement surface to the data indicating the predefined physical characteristic information associated with the at least one product in order to verify that the identity of the at least one product and that the condition of the at least one product detected by the second sensor is new and undamaged;
• and
• redirect movement of the at least one product detected by the first and second sensors on the product advancement surface of the at least one of the conveyors from the product advancement surface of the at least one of the conveyors to the product advancement surface of the another one the conveyors via at least one of the transfer nodes in response to a determination, by the electronic inventory management device, that a verification of the identity of the at least one product failed or that the at least one product is not in a new condition or is in a damaged condition.