US-12617622-B2 - Conveyor assembly and method of using the same

Abstract

Various embodiments are directed to a conveyor assembly and method of using the same. In various embodiments, a conveyor assembly comprises a plurality of rollers configured to facilitate transportation of an object on a conveyor surface, the plurality of rollers comprising a first drive roller operable to rotate in a first rotational direction to cause a movement of the conveyance surface in a conveyance direction; and a second roller configured for rotation in a second rotational direction opposite the first rotational direction to generate a counterforce that opposes the movement of the conveyor surface in the conveyance direction; and a controller configured to control the first drive roller and a secondary motor operable to drive rotation of the second roller in the second rotational direction to stop the movement of the conveyor surface such that the object disposed thereon is stopped at a stop position defined within the conveyor zone.

Inventors

• Venkatesh Raikar
• Saravanan Sadasivan
• Sourabh PAINJANE

Assignees

• INTELLIGRATED HEADQUARTERS, LLC

Dates

Publication Date

20260505

Application Date

20231130

Priority Date

20221220

Claims (19)

1. 1 . A conveyor assembly configured for transporting an object along a transportation path, the conveyor assembly comprising: a plurality of rollers configured to facilitate transportation of the object disposed on a conveyor surface through a conveyor zone, wherein the plurality of rollers comprises: a first drive roller selectively operable to rotate in a first rotational direction to cause a movement of the conveyor surface in a conveyance direction to move the object along the transportation path defined within the conveyor zone; and a second roller configured to be selectively rotated in a second rotational direction opposite the first rotational direction in order to generate a counterforce that opposes the movement of the conveyor surface in the conveyance direction; and a controller configured to generate one or more control signals configured to control the first drive roller and a secondary motor operable to drive rotation of the second roller in the second rotational direction; wherein the conveyor assembly is configured to execute a stopping operation by stopping a first rotation of the first drive roller and initiating a second rotation of the second roller in the second rotational direction at substantially same time to stop the movement of the conveyor surface such that the object disposed thereon is stopped at a stop position defined within the conveyor zone.
2. 2 . The conveyor assembly of claim 1 , wherein the conveyor surface is defined by a conveyor belt disposed within the conveyor zone, the conveyor belt being engaged with at least a portion of the plurality of rollers such that the first rotation of the first drive roller causes a first force to be imparted on the conveyor belt in a first linear direction and the second rotation of the second roller causes the counterforce to be imparted on the conveyor belt in a second linear direction opposite the first linear direction.
3. 3 . The conveyor assembly of claim 1 , further comprising one or more sensor elements configured to capture sensor data associated with one or more of the object disposed on the conveyor surface and an operational configuration defined by the conveyor surface within the conveyor zone.
4. 4 . The conveyor assembly of claim 3 , wherein the one or more sensor elements are configured to capture the sensor data comprising one or more of object speed data, object position data, object weight data, object size data, and conveyor angle data.
5. 5 . The conveyor assembly of claim 4 , wherein the controller is configured to determine an inertial force associated with the object based at least in part on the sensor data.
6. 6 . The conveyor assembly of claim 5 , wherein the controller is further configured to: compare the inertial force to a threshold inertial force; and upon determining that the inertial force is greater than the threshold inertial force, selectively operate the second roller.
7. 7 . The conveyor assembly of claim 1 , wherein the plurality of rollers includes a second drive roller operably connected to the second roller, and wherein the second drive roller is communicably connected to the controller such that the controller is configured to cause the second roller to selectively rotate by selectively operating the second drive roller.
8. 8 . The conveyor assembly of claim 1 , wherein the second roller is operably connected to an external motor assembly that is communicably connected to the controller such that the controller is configured to selectively rotate the second roller by selectively operating the external motor assembly.
9. 9 . The conveyor assembly of claim 1 , wherein the conveyor assembly is further configured to execute the stopping operation by initiating a third rotation of the first drive roller in the first rotational direction to impart a balancing force on the conveyor surface that is at least substantially equal and opposite to the counterforce.
10. 10 . The conveyor assembly of claim 1 , wherein the conveyor assembly is configured such that as the first drive roller is being operated to rotate in the first rotational direction, the second roller embodies a free-rotating idler roller such that the movement of the conveyor surface in the conveyance direction causes the second roller to rotate in the first rotational direction.
11. 11 . The conveyor assembly of claim 10 , wherein the one or more control signals generated by the controller comprises a second motor activation signal configured to initiate an operation of the secondary motor such that the second roller embodies a slave roller controlled by the operation of the secondary motor during at least a portion of stopping operation.
12. 12 . The conveyor assembly of claim 1 , wherein the first drive roller comprises an internal brake assembly, wherein the controller is configured to control the internal brake assembly of the first drive roller; and wherein executing the stopping operation comprises activating the internal brake assembly defined by the first drive roller to at least substantially stop the first drive roller from rotating in the first rotational direction.
13. 13 . The conveyor assembly of claim 1 , wherein the plurality of rollers further comprises a first slave roller engaged with at least a portion of a conveyor belt defining the conveyor surface, the first slave roller being operably connected to the first drive roller such that rotation of the first drive roller in the first rotational direction results in a corresponding rotation of the first slave roller in the first rotational direction.
14. 14 . The conveyor assembly of claim 13 , wherein the second roller defines a second slave roller operably connected to one of a second drive motor and an external motor assembly, the second slave roller being engaged with at least a second portion of the conveyor belt.
15. 15 . A method of operating a conveyor assembly, the method comprising: operating a first drive roller to cause a movement of a conveyor surface in a conveyance direction, wherein the conveyor surface is configured to move in the conveyance direction in order to transport an object disposed thereon along a transportation path defined within a conveyor zone; and initiating a stopping operation to stop the movement of the conveyor surface in the conveyance direction by causing a second roller engaged with a conveyor belt to rotate in a second rotational direction so as to at least partially counteract inertial forces associated with the object; wherein the second roller is operated such that the object disposed on the conveyor surface are stopped at a stop position defined within the conveyor zone.
16. 16 . The method of claim 15 , further comprising capturing sensor data associated with one or more of an operational configuration defined by the conveyor surface within the conveyor zone and the object disposed on the conveyor surface.
17. 17 . The method of claim 16 , wherein the sensor data captured by one or more sensor elements comprises one or more of object speed data, object weight data, object size data, and conveyor angle data.
18. 18 . The method of claim 16 , further comprising determining an inertial force associated with the object based at least in part on the sensor data.
19. 19 . The method of claim 18 , further comprising: comparing the inertial force associated with the object to a threshold inertial force; and upon determining that the inertial force is greater than the threshold inertial force, selectively operating a secondary motor to cause the second roller to rotate in the second rotational direction opposing the movement of the conveyor surface to stop the movement of the conveyor surface such that the object disposed thereon is stopped within the conveyor zone.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This application claims priority pursuant to 35 U.S.C. 119(a) to Indian Application No. 202211073869, filed Dec. 20, 2022, which application is incorporated herein by reference in its entirety. FIELD OF THE INVENTION Example embodiments of the present invention relates generally to a material handling system for handling items, and, more particularly, to motorized rollers for use in controlling a conveyor a surface within conveyor assembly. BACKGROUND Conveyor systems and assemblies may be used in industrial manufacturing and packing applications, for example, to facilitate the transportation of a large number of objects to a desired destination within a factory or a warehouse. These conveyor systems and assemblies often utilize one or more motorized drive rollers to drive movement of a conveyor surface upon which the objects are disposed to transport the objects along a transportation path defined by the conveyor assembly. Many conveyor assemblies are plagued by technical challenges and limitations. Through applied effort, ingenuity, and innovation, the problems identified herein have been solved by developing solutions that are included in embodiments of the present disclosure, many examples of which are described in detail herein. BRIEF SUMMARY Various embodiments are directed to a conveyor assembly and method of using the same. In various embodiments, a conveyor assembly configured for transporting an object along a transportation path may comprise a plurality of rollers configured to facilitate transportation of an object disposed on a conveyor surface through a conveyor zone, wherein the plurality of rollers comprises: a first drive roller selectively operable to rotate in a first rotational direction to cause a movement of the conveyance surface in a conveyance direction to move the object along a transportation path defined within the conveyor zone; and a second roller configured to be selectively rotated in a second rotational direction opposite the first rotational direction in order to generate a counterforce that opposes the movement of the conveyor surface in the conveyance direction; and a controller configured to generate one or more control signals configured to control the first drive roller and a secondary motor operable to drive rotation of the second roller in the second rotational direction; wherein the conveyor assembly is configured to execute a stopping operation by selectively causing the second roller to rotate in the second rotational direction to stop the movement of the conveyor surface such that the object disposed thereon is stopped at a stop position defined within the conveyor zone. In various embodiments, the conveyor surface may be defined by a conveyor belt disposed within the conveyor zone, the conveyor belt being engaged with at least a portion of the plurality of rollers such that a first rotation of the first drive roller causes a first force to be imparted on the conveyor belt in a first linear direction and a second rotation of the second roller causes the counterforce to be imparted on the conveyor belt in a second linear direction opposite the first linear direction. In various embodiments, the conveyor assembly may further comprise one or more sensor elements configured to capture sensor data associated with one or more of the object disposed on the conveyor surface and an operational configuration defined by the conveyor surface within conveyor zone. In certain embodiments, the one or more sensor elements may be configured to capture sensor data comprising one or more of object speed data, object position data, object weight data, object size data, and conveyor angle data. In certain embodiments, the controller may be configured to determine an inertial force associated with the object based at least in part on the sensor data. In certain embodiments, the controller may be further configured to compare the inertial force to a threshold inertial force; and, upon determining that the initial force is greater than the threshold inertial force, selectively operate the second roller. In various embodiments, the plurality of rollers may include a second drive roller operably connected to the second roller, and wherein the second drive roller is communicably connected to the controller such that the controller is configured to cause the second roller to selectively rotate by selectively operating the second drive roller. In various embodiments, the second roller may be operably connected to an external motor assembly that is communicably connected to the controller such that the controller is configured to selectively rotate the second roller by selectively operating the external motor. In various embodiments, the conveyor assembly may be configured to execute the stopping operation by stopping a first rotation of the first drive roller and initiating a second rotation of the second roller in the second rotational direction at su