Networked motorized drive roller conveyor

A motorized drive roller conveyor comprising:

• an upstream zone and a downstream zone, each zone including a drive roller, an idler roller that is driven by the drive roller, and a sensor;
• and
• a card that controls the upstream zone and the downstream zone;
• wherein the card measures a gap between a first item on the conveyor and a second item on the conveyor by beginning a counter when a trailing edge of the first item passes the sensor of the upstream zone and stopping the counter when a leading edge of the second item passes the sensor of the upstream zone to generate a measured counter value;
• wherein at least one of the plurality of networked cards is configured for the user to input a desired gap between consecutive items on the conveyor and to convert the desired gap into a desired counter value;
• and
• wherein if the first item is stopped in the downstream zone, the card of the upstream zone causes the drive roller of the upstream zone to advance the second item into the downstream zone for a distance derived from the counter value before stopping movement of the second item.

A method for controlling a gap between items on a motorized drive roller conveyor comprising the steps of:

• converting an inputted desired gap between consecutive items on the conveyor to a desired counter value;
• detecting a trailing edge of a first item at a predetermined location in a first zone on a conveyor system;
• beginning a counter once the trailing edge of the first item passes the predetermined location;
• stopping the counter upon the first occurrence of the following:
• (i) a leading edge of a second item is detected at the predetermined location;
• or
• (ii) the first item is stopped in a downstream zone adjacent the first zone;
• and
• generating a measured counter value.