U.S. patent number 3,786,939 [Application Number 05/298,873] was granted by the patent office on 1974-01-22 for method and apparatus for sorting articles on a conveyor utilizing a shift register and a time varying code control mechanism.
This patent grant is currently assigned to Rapistan, Incorporated. Invention is credited to Daniel L. Fowler, James D. Habegger, Andrew B. Huttula, James T. Schrader.
United States Patent |
3,786,939 |
Habegger , et al. |
January 22, 1974 |
METHOD AND APPARATUS FOR SORTING ARTICLES ON A CONVEYOR UTILIZING A
SHIFT REGISTER AND A TIME VARYING CODE CONTROL MECHANISM
Abstract
A sorting conveyor is divided into discrete discharge zones each
assigned a unique zone identification code and each including one
or more discharge locations having one or two discharge chutes
aligned therewith and assigned a chute identification code. Each
article inducted onto the conveyor is assigned a digital code a
portion of the bits of which correspond to the code assigned to a
chute within a zone. The article code is applied to a shift
register memory and shifted in synchronism with the conveyor
movement to be applied to a zone control circuit during a timer
interval corresponding to the entry of the article into the
discharge zone. A code generator synchronized with the conveyor
movement produces a time varying code repeated for each zone time
interval and which is compared with a location code assigned to
each discharge location and uniquely identifying the position on a
discharge chute within a discharge zone. An article diverter is
actuated to discharge an article onto a discharge chute when the
zone and chute codes coincide with the article code and the
location code assigned to a discharge chute corresponds to the
generated time varying code.
Inventors: |
Habegger; James D.
(Middleville, MI), Huttula; Andrew B. (Grand Rapids, MI),
Fowler; Daniel L. (Kentwood, MI), Schrader; James T.
(Grand Rapids, MI) |
Assignee: |
Rapistan, Incorporated (Grand
Rapids, MI)
|
Family
ID: |
23152336 |
Appl.
No.: |
05/298,873 |
Filed: |
October 19, 1972 |
Current U.S.
Class: |
198/349.95 |
Current CPC
Class: |
B65G
47/506 (20130101) |
Current International
Class: |
B65G
47/50 (20060101); B65g 043/00 () |
Field of
Search: |
;214/11R,11A,11C,152,60
;198/38 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Forlenza; Gerald M.
Assistant Examiner: Johnson; R. B.
Attorney, Agent or Firm: Peter P. Price et al.
Claims
The embodiments of the invention in which an exclusive property or
privilege is claimed are defined as follows.
1. A method of diverting articles from a sorting conveyor onto a
desired discharge chute comprising the steps of:
segmenting a sorting conveyor into a plurality of discharge zones
along the length of the conveyor each having at least one discharge
location for a discharge chute;
providing an article code for each article inducted onto said
conveyor which uniquely identifies a discharge zone and chute
therein;
storing article codes provided as articles are inducted onto the
conveyor in a memory circuit having a plurality of output terminals
each associated with one of the discharge zones;
shifting the article codes within said memory in timed relationship
to the conveyor movement to successive output terminals associated
with associated successive discharge zones through which an article
is traveling;
generating a repetitive time varying code in timed relationship to
the conveyor movement and having a period corresponding to the
movement of an article through a discharge zone;
comparing the article code at the output terminals of said memory
means with a zone code assigned each discharge zone;
comparing the time generated code with a location code assigned
each discharge location; and
diverting an article from said conveyor onto a discharge chute upon
the coincident correspondence of the zone identification code with
the article identification code and the location code with the time
varying code.
2. The method of claim 1 and including the steps of:
segmenting the article code into a zone identification code and a
chute identification code;
comparing the zone code with the zone identification code;
comparing the chute code with the chute identification code;
and
diverting an article only when the compared codes coincide.
3. The method of claim 2 wherein the last named comparing step
comprises the step of decoding the chute identification code
present at the output terminals of said memory circuit by a
decoding circuit having preassigned chute identification codes
therein which program the decoding circuit to respond to a
correspondingly coded chute within a discharge zone.
4. In a sorting conveyor system divided into a plurality of
discharge zones each including one or more discharge locations for
a discharge chute, a control system for actuating a diverter for a
discharge chute when an article inducted onto said conveyor is
aligned with the desired chute comprising:
means for providing an article code uniquely identifying a
discharge zone and chute to which said article is to be
diverted;
memory means synchronized with said conveyor movement for receiving
said article code and transferring said code to sequential output
terminals of said memory in synchronism with the movement of said
conveyor through discharge zones;
means for providing a zone code uniquely identifying each zone
within said conveyor system;
first comparator means associated with each discharge zone and
coupled to an output terminal of said memory means associated with
a discharge zone and to said zone code providing means associated
with the same zone for comparing at least a portion of the article
code at the memory output terminal with the zone code;
means for generating a time varying code in timed relationship to
said conveyor movement;
means for supplying a chute location code for each discharge chute
within said system;
second comparator means associated with each discharge chute for
comparing said time varying code with said chute location code and
for generating an output signal in response to the coincident
detection thereof; and
circuit means coupled to said first and second comparators and
responsive to signals therefrom for actuating a chute diverter when
an article is aligned with said discharge chute as indicated by the
coincidence of said codes.
5. The system as defined in claim 4 wherein said means for
generating a time varying code comprises:
a tachometer coupled to said conveyor for developing electrical
tachometer output signals whose frequency is related to the speed
of said conveyor; and
a code generating circuit coupled to said tachometer output signals
for providing a multiple bit output code comprising signals which
are integer submultiples of the frequency of said tachometer output
signals.
6. The system as defined in claim 5 wherein said code generating
circuit further develops clock pulses having a period of occurrence
corresponding to the movement of an article through a discharge
zone and which are applied to said memory means to shift said
article codes to sequential output terminals thereof.
7. The system as defined in claim 4 wherein said circuit means
includes decoding means associated with each discharge zone and
coupled to said output terminals of said memory means to detect a
chute code included in said article code for a chute of a discharge
zone and coupled to said first comparator and enabled by an output
signal therefrom to actuate a chute diverter only when the chute
code is detected by said decoding means.
8. The system as defined in claim 4 wherein said memory means
comprises a shift register memory.
9. The system as defined in claim 4 wherein said means for
providing a zone code comprises a digital code switch for each
discharge zone.
10. The system as defined in claim 4 wherein said means for
supplying a chute location code comprises a digital code switch for
each discharge chute.
11. A sorting conveyor divided into a plurality of discharge zones
each having one or more discharge locations for discharge chutes
for a control system comprising:
means for providing an article code identifying a discharge zone
and chute at which an article is to be discharged;
means for providing a repetitive time varying code related to the
conveyor movement and uniquely identifying each discharge location
within a zone; and
circuit means receiving said article code and said time varying
code in timed relationship to the movement of said conveyor to
divert an article at a discharge chute identified by said article
code and at a location identified by said time varying code.
12. The system as defined in claim 11 wherein said time varying
code is initiated as an article enters a zone and repeated as an
article passes through successive zones.
13. The system as defined in claim 12 wherein each discharge zone
is assigned a zone code uniquely identifying the zone and
corresponding to the zone identification portion of an article code
as an article enters and travels within the zone.
14. The system as defined in claim 13 wherein said circuit means
comprises:
memory storing article codes accompanying articles as they are
inducted onto said conveyor;
means for shifting said article codes to sequential output
terminals of said memory associated with said zones and in
synchronization with the conveyor movement;
comparator means for comparing the assigned zone code and zone
identification portion of the article code, and the time varying
code and the location code assigned a chute; and
control means coupled to said comparator means for actuating a
chute diverter to divert an article into the desired discharge
chute as it aligns therewith as indicated by the coincidence
between the respective codes.
15. In a conveyor system comprising a sorting conveyor divided into
a plurality of discrete discharge zones each including one or more
discharge locations each capable of having one or more discharge
chutes associated therewith, a control system for discharging
articles onto predetermined discharge chutes during a zone period
in which said article is aligned with said predetermined chute by
actuating a chute diverter, said control system comprising:
means for generating an article code uniquely identifying a
discharge zone and chute of said conveyor;
memory means coupled to said generating means and including a
plurality of output terminals each associated with one of said
discharge zones;
means for entering an article code into said memory means as an
article is inducted onto said conveyor and for sequentially
shifting an article code to said output terminals of said memory
means in synchronism with the movement of said conveyor to a
zone;
means for providing a zone code identifying each discharge
zone;
first comparator means coupled to said memory means and to said
zone code providing means for each zone for comparing said zone
code and at least a portion of said article code to develop an
enable signal when said codes coincide;
means for generating a time varying code repeated for each zone
period and uniquely identifying each divert location in the
zone;
means for supplying a location code for each discharge
location;
second comparator means coupled to said last named generating means
and to said supplying means for providing a control signal in
response to the coincidence between said time varying code and said
location code; and
circuit means coupled to said comparators and to diverters for said
discharge locations for actuating a predetermined discharge chute
when said enable and said control signal are provided by said
comparators.
16. The system as defined in claim 15 wherein said article code is
segmented into a zone identification code applied to said first
comparator from said memory means and a chute identification code
applied to said circuit means from said memory means, said circuit
means including decoding means associated with each discharge
zone.
17. The system as defined in claim 16 wherein each of said decoding
means for a zone is programmed to detect chute identification codes
corresponding to chutes within the associated zone and provide an
output signal in response to the presence of an enable signal from
said first comparator and a detected chute code.
18. The system as defined in claim 17 wherein said memory means
comprises a shift register memory.
19. The system as defined in claim 18 wherein said generating means
comprises:
a tachometer coupled to said conveyor for developing electrical
tachometer output signals whose frequency is related to the speed
of said conveyor; and
a code generating circuit coupled to said tachometer output signals
for providing a multiple bit output code comprising signals which
are integer submultiples of the frequency of said tachometer output
signals.
20. The system as defined in claim 19 wherein said code generating
circuit further develops a clock pulse during each zone period
which is applied to said shift register memory to shift stored
article codes therein.
21. The system as defined in claim 20 and further including an
induction station for inducting articles onto said conveyor, and a
control circuit for actuating said induction station to induct an
article, said control circuit coupled to said code generating
circuit for receiving clock pulses therefrom to induct an article
onto said conveyor in response to a clock pulse.
22. A sorting conveyor and control system comprising:
a sorting conveyor including a plurality of discharge zones each
having at least one discharge location and diverter associated
therewith and at least one associated discharge chute;
means for providing an article code uniquely identifying a
discharge zone and chute for each article inducted onto said
conveyor;
memory means coupled to said providing means for receiving said
article codes as articles are inducted onto said conveyor and for
sequentially shifting said code to sequential output terminals of
said memory means as an inducted article enters each discharge
zone;
means coupled to said conveyor for generating a time varying
repetitive code in timed relationship to the conveyor movement and
a clock pulse applied to said memory means for periodically
shifting said article code in said memory in timed relationship to
the conveyor movement;
means for providing a unique zone code identifying each discharge
zone;
means coupled to said zone code providing means of each discharge
zone and to said memory for comparing an article code at an output
terminal of said memory means associated with a predetermined zone
and said zone code for said predetermined zone for producing an
enable signal in response to the coincidence therebetween;
decoding means associated with each discharge zone and coupled to
said memory means and said comparing means and responsive to at
least a portion of an article code in the presence of said enable
signal to develop a first signal when a discharge chute in an
associated zone is identified;
means for supplying a location code uniquely identifying each
discharge location for discharge chutes within a zone;
means coupled to said generating means and said supplying means for
comparing said time varying code and said location code for
developing a second signal in response to the coincidence
therebetween; and
control means coupled to said decoding means, to said last named
comparing means, and to said diverters for actuating a
predetermined diverter in response to the coincident arrival of
said first and second signals thereby diverting an article from
said sorting conveyor onto the desired discharge chute associated
with said predetermined diverter.
23. The system as defined in claim 22 wherein said means for
providing an article code includes an electrical keyboard
actuatable to transfer discharge chute information accompanying an
article to be inducted into said memory means.
24. The system as defined in claim 22 wherein said memory means
comprises a shift register memory.
25. The system as defined in claim 22 wherein said generating means
comprises:
a tachometer coupled to said conveyor for developing electrical
tachometer output signals whose frequency is related to the speed
of said conveyor;
a code generating circuit coupled to said tachometer and responsive
to said tachometer output signals for providing a multiple bit
output code comprising signals which are integer submultiples of
the frequency of said tachometer output signals.
26. The system as defined in claim 22 wherein said means for
providing a unique zone code comprises an adjustable digital code
switch.
27. The system as defined in claim 22 wherein said means for
supplying a location code comprises an adjustable digital code
switch.
Description
BACKGROUND OF THE INVENTION
The present invention relates to sorting systems and particularly
to a control system for a sorting conveyor.
There are several known systems employed to control the diverting
of articles inducted onto a sorting conveyor. Such known systems
include the detection of a code impressed upon the article by a
sensor at each discharge location such that when the article aligns
with the discharge location identified by the same code, the
article is diverted. Although providing flexibility of positioning
the discharge chutes along a sorting conveyor, this system relies
upon the detection of a code positioned on the article which
requires alignment of the article with respect to the code sensing
mechanism. Frequently, this alignment is very difficult if not
impossible to achieve in a commercial installation. Also, the
expense of the sensing equipment necessary at each chute outweighs
the flexibility obtained by employing such a control.
Another approach generally employed is to assign an article
inducted onto the sorting conveyor a predetermined identification
code which is fed into a shift register memory and shifted
therealong in synchronism with the conveyor movement. Each
discharge location has a code assigned thereto and is coupled to an
output of the shift register such that when coincidence between the
code assigned the article and the code assigned a discharge chute
is detected, the diverter for the discharge chute is actuated to
divert the article from the conveyor system. Such a system is
useful in installations where discharge chutes are fixed at evenly
spaced locations such that the code inserted into the shift
register can be shifted along at regular intervals by clock pulses.
In systems, however, where discharge chutes are randomly spaced or
frequently moved from place to place, the control cannot be easily
adapted to accommodate such variations.
More recently, a system has been proposed whereupon each discharge
location is assigned an identification code and includes electronic
circuitry thereat for counting timing pulses from the time an
article is inducted at a fixed position on the sorting conveyor
until the article is predicted to be in alignment with the
discharge location. When the article is inducted onto the conveyor,
a unique code assigned to the article identifies the chute at which
the article is to be discharged and activates the counter at the
discharge chute location to achieve synchronization
therebetween.
In this system, discharge chutes can be positioned at intervals
physically spaced in a corresponding relationship to the time
intervals and conveyor movement between the timing pulses employed.
This permits some degree of flexibility for the initial
installation of the discharge chutes at random locations but
requires rewiring of the counters when for example, a discharge
chute is to be moved to a different location along the conveyor
line. Additionally, such a system requires relatively complex and
expensive electrical circuitry at each discharge location. As the
size of the installation increases thereby increasing the number of
discharge chutes employed, the circuitry cost may become
prohibitive.
SUMMARY OF THE PRESENT INVENTION
The present invention solves the problems of the known prior
control systems by providing a control system adapted for random
spacing of discharge chutes along a conveyor line together with the
capability of moving the discharge chutes and easily reprogramming
the control for new chute locations. This provides a sorting
conveyor system adaptable to a variety of physical locations within
a warehouse or the like. In addition, a unique coding system is
employed which vastly simplifies the circuitry required at each
discharge location as well as that required for the master control
circuit.
Apparatus embodying the present invention includes a sorting
conveyor having a plurality of discrete discharge zones each
including one or more discharge locations thereat with one or two
discharge chutes assigned to each discharge location. An article
inducted onto the conveyor is assigned a unique data code
comprising a plurality of bits some of which identify a discharge
zone in which the article is to be diverted while the remaining
bits identify the discharge chute within the zone at which the
article is to be diverted. The article code is applied to the
memory circuit which is controlled in synchronism with the conveyor
movement to shift the article code in synchronism with the conveyor
movement. A code comparator and a chute decoder are provided for
each zone and are coupled to the memory circuit. A code generator
provides a repetitive time varying code having pulses related in
time to the conveyor movement and which is applied to comparator
means for each discharge chute. A chute location code associated
with each chute is also applied to the comparator. The diverter
mechanism for a discharge chute is actuated upon the coincident
detection of the assigned article code with the corresponding zone
and chute code and the location code assigned each chute with the
coorresponding time varying generated code as an article aligns
with the desired chute.
It is an object of the present invention to provide an improved
control system for a sorting conveyor which permits the random
spacing of discharge chutes.
It is another object of the prevent invention to provide an
improved method for diverting articles from a sorting conveyor onto
predetermined discharge chutes.
A further object of the present invention is to provide an improved
control system for a sorting conveyor which easily permits a
discharge chute position to be changed.
Another object of the present invention is to provide a control
system for a sorting conveyor which employs a unique coding
arrangement.
Still a further object of the present invention is to provide a
control circuit which is relatively inexpensive and permits the
random spacing and relocation of discharge chutes with a minimum of
adjustment to the control system.
These and other objects of the present invention will become
apparent upon reading the following specification together with
accompanying drawings in which:
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a fragmentary plan schematic view of a sorting conveyor
system embodying the present invention;
FIG. 2 is a schematic diagram of a portion of the conveyor system
shown in FIG. 1 illustrating the division of the conveyor into
discharge zones and the division of the discharge zones into
discharge locations;
FIG. 3 is a circuit diagram in block form of a control system
embodying the present invention;
FIG. 4 is a table illustrating assigned article codes and
corresponding zone and chute codes for the discharge chutes shown
in FIGS. 1 and 2; and
FIG. 5 is a waveform diagram showing the time varying code
generated by the code generator circuit of FIG. 3 and which is
synchronized with the conveyor movement.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIGS. 1 and 2, there is shown in schematic form a
sorting conveyor 10 comprising a plurality of longitudinally
extending chains or belts 12 receiving articles 16 at an induction
station 14 at one end thereof. The conveyor is of conventional
design with the chains 12 moving in a direction indicated by the
arrows A and driven by a conveyor drive motor 18 coupled to the
chain by suitable coupling means 19. The chains are spaced from
each other with interleaved mechanical diverting mechanisms 20
positioned at each discharge location.
Each diverter 20 comprises a vertically movable frame 22 housing a
plurality of powered rollers 24. The frames and rollers are
actuated by a diverter control 26 for each discharge location which
raises the frame with an article on the rollers and rotates the
rollers in one direction or the other to divert the article into a
discharge chute 30 positioned on the left or right side of the
conveyor. The construction of the diverters is conventional and is
not discussed in detail here.
Although the sorting conveyor system illustrated in FIG. 1 is of
the chain type with roller diverting mechanisms, the present
invention can likewise be used with other sorting conveyors
including a closed loop sorting conveyor system employing discrete
article carrying trays such as that described in U.S. Pat. No.
3,034,665 to R. L. Speaker.
The induction station 14 includes a transfer mechanism 28 which is
a vertically movable frame 32 with a plurality of article receiving
powered rollers 33 therein. Frame 32 is reciprocated between a
normally upward position where it can receive articles 16 from a
powered infeed conveyor 34 when released by an indexing stop 25 at
the end of conveyor 34. Mechanism 28 positions the articles so
received against a stop 36, and when momentarily lowered, inducts
the article onto chains 12 of conveyor 10. A control circuit 50
(described in detail below) receives timing signals from an
electro-optical tachometer 60 of conventional design to
periodically provide an induct signal to an indexing control 38
which momentarily lowers frame 30 to induct an article onto the
conveyor at a known reference time.
Adjacent the input end of induction station 14 there is provided an
operating platform 39 with a data keyboard 40. With an article at
rest against the indexing stop 25, an operator positioned on
platform 39 can read an article destination code 17 applied to each
article 16 to be sorted and program the control system with the
article code which uniquely identifies the discharge chute to which
the article is to be diverted. Once the operator types the article
code on keyboard 40, the indexing stop 25 releases the article
which is transported onto the power roller transfer mechanism 28.
Transfer mechanism 28 is actuated by a signal from circuit 38 to
release an article onto conveyor 10 when the next induct signal is
applied to circuit 38 from circuit 50.
As seen in FIGS. 1 and 2, the sorting conveyor 10 is divided into a
plurality of discharge zones 35 numbered consecutively 1, 2, 3,
etc. Only three zones are shown for purposes of illustration in the
figures. The discharge zones 35 are in turn each divided into a
plurality of discharge locations 45, each being capable of having
left and right discharge chutes 30 associated therewith. For the
purposes of illustration only, FIG. 2 shows a discharge zone having
eight individual discharge locations, each capable of including two
discharge chutes.
As will become readily apparent, the system is adapted to include
as many discharge zones as necessary and each zone can be
conveniently subdivided into as many discrete discharge locations
as needed. Generally, only a few discharge locations will be
employed, the remaining locations being available for repositioning
the discharge chutes or adding additional chutes.
As seen in FIG. 2, zone 1 includes discharge chutes numbered 5 and
6. Chute No. 5 is on the left side of conveyor 10 and is located at
discharge location No. 2. Chute No. 6 is on the right side of
conveyor 10 and located at discharge location No. 4. Zone 2
includes a pair of discharge chutes 25 and 26 on the left and right
side of conveyor 10 and positioned at discharge location No. 3.
Zone 3 includes one discharge chute 33 on the right side and
located at discharge location No. 1. The representation of FIG. 2
is merely illustrative showing the possible random distribution of
discharge chutes along the conveyor instead of the regularly spaced
symmetrical chute distribution frequently required by many known
systems.
By subdividing the sorting conveyor 10 into a plurality of discrete
zones, an article code identifying the zone and chute can be
provided and which requires relatively inexpensive circuitry
synchronized with the conveyor movement to track an article as it
travels along the conveyor through the various zones. By
subdividing the zones into a plurality of discharge locations, a
repetitive time varying code generated in synchronism with the
conveyor movement can be employed together with a location code
uniquely identifying the positioning of a discharge chute within a
zone to provide a diverting control signal when an article is in
alignment with a desired discharge chute. The design of the control
circuit utilizing this dual code system is discussed with reference
to FIGS. 3, 4 and 5.
Data keyboard 40 is coupled to the control circuit 50 by means of a
decimal to binary coded decimal convertor 48. The operator, upon
examining an article at the induction station, types in the chute
number at which the article is to be diverted (or some other
suitable indicia). Convertor 48 converts the information received
into an eight bit binary code uniquely identifying the chute and
the zone in which it is located. This article code is shown for the
chutes of FIG. 1 in FIG. 4.
It is noted here that although the preferred embodiment is coded
for four discharge chutes for each zone by employing the last two
digits of the binary code associated with the article as the bin
identification digits: the number of discharge chutes within a zone
can be expanded as desired by redistributing the bits of the
article code as desired or if necessary, adding additional bits and
expanding the code detecting circuitry for the different code
arrangement.
The output of the convertor 48 is applied to a storage circuit 52
having a clock input line 53 and an output which is coupled to a
memory circuit 55 comprising a plurality of serially coupled shift
registers 57. Memory 55 is, therefore, a shift register type of
memory incorporating a plurality of shift register modules which
may be integrated circuits and each of which has an output which is
coupled to a digital comparator associated with one of the zones.
Comparator 58 is associated with zone 1 and receives a digital code
from the shift register 57 by means of a six bit line 57' which
applies the six most significant digits of the article code stored
in the shift register memory to the comparator.
A code switch 62 associated with zone 1 is of conventional
construction and applies a six bit code to comparator 58. When an
article to be discharged to one of the chutes in the zone enters
the zone, the six most significant digits of the article code in
register 57 and the six bit binary code from switch 62 coincide.
Comparator 58 detects the coincidence and generates an enable pulse
applied to a decoder circuit 65.
The two least significant bits of the article code are applied to
the decoder from shift register 57 by means of a two line conductor
59. Decoder 65 is a two-line to four-line decoder-demultiplexer
which is a commercially available integrated circuit and which is
programmed to detect the applied two bit data signal and activate
one of the output lines 66, 67, 68 or 69 when enabled by circuit 58
and when the two least significant digits of the article code
stored in shift register 57 correspond to one of the discharge
chute codes programmed into decoder 65.
Each of the remaining zones 2, 3 and etc., also include as seen in
phantom lines in FIG. 3, a corresponding shift register, digital
comparator, decoder and code switch which uniquely identifies the
zone. As seen in FIG. 3, the detail circuitry for only bins 4, 5, 6
and 7 in zone 1 are specifically shown. The circuitry for the
remaining discharge chutes and zones are generally the same and are
added as seen by the phantom blocks of FIG. 3.
To provide circuit 50 with timing information related to the
conveyor movement, a conventional electro-optical tachometer 60 is
coupled to the conveyor chain 12 by means of a mechanical coupling
such as gear 15. Tach 60 applies relatively high frequency pulses
to the pulse and code generator 70 via conductor 61. In the
preferred embodiment, each revolution of gear 15 represented 40
inches of conveyor movement and tachometer 60 produced 1,000 pulses
during this time interval which for a conveyor speed of 200 feet
per minute is approximately equal to one second. The pulse and code
generator 70 comprises a plurality of series connected commercially
available frequency divider integrated circuits which divide the
tach pulses to provide phase pulses. The phase pulses (63 in FIG.
5) are frequency divided further to provide the various integer
sub-multiple frequency divided outputs to an eight line output
conductor 75. Conductor 75 is coupled to each of a plurality of
digital comparators 80 associated with each one of the discharge
chutes in the system. The eight line time varying code signals
uniquely identifying each phase pulse interval are shown in FIG. 5
on time axes labeled 1-8.
During each zone period which corresponds to the movement of a
point on the conveyor through one discrete discharge zone, a clock
pulse T is developed by generator 70 and employed to reset the
divider circuits of the generator. The clock pulse is also applied
to conductor 72 and serves as an induct pulse for the index control
38 as well as a shift pulse for the storage circuit 52. This signal
causes the article code from the keyboard and temporarily stored in
the storage circuit 52 to be shifted into the first shift register
57 of memory 55 and shifts the article codes in the register memory
to the next of the series of register modules. In this manner, the
article code follows the movement of the article from zone to zone
in synchronization with the conveyor movement.
During the time interval when the article is traversing a discrete
discharge zone, the time varying code developed by circuit 70 is
applied to the bank of digital comparators 80. Each comparator 80
is a commercially available eight bit comparator which also
receives a continuous eight bit digital code from one of the
digital code switches 85 which are associated with each of the
discharge chutes 30. During a zone period (i.e., the time an
article requires to transverse a discharge zone), the location code
assigned the discharge location and selected by a switch 85; and
the time varying code from generator 70 will coincide. When this
occurs, the comparator 80 will apply an output signal on line 83
which is applied to an AND gate 87 associated with the discharge
chute.
Upon the coincident arrival of a signal on line 83 and a signal
from decoder 65 which is applied to the other input terminal of the
AND gate 87, the gate applies a signal to the diverter drive
circuit 90 for the chute. Circuit 90 in turn applies a signal to
the diverter 20 causing its actuation and the transfer of the
article from the conveyor onto the assigned discharge chute 30.
Having briefly described circuit 50 and its overall operation, a
detailed description of the diverting of an article onto discharge
chute 6 of zone 1 is presented to provide a more thorough
understanding of the control system and the coding arrangement of
the present invention.
OPERATION
Referring now to FIGS. 3, 4 and 5, the article code generated by
the convertor 48 in response to a signal from keyboard 40, is shown
for each of the four bin locations in zones 1, 2 and 3. The first
six bits, i.e., the most significant bits of the code, are employed
as a zone identification code which is applied to comparator 58 as
described above. The remaining least significant two bits is
employed as a chute identifying code and applied to decoder circuit
65 for each zone from memory 55. It is seen in the table of FIG. 4
that the zone 1 code is 000001; zone 2 is 000110 and zone 3 is
001000. The four chutes of each zone are conveniently coded with
the two digits as 00, 01, 10 and 11. Chute 6, which is seen in FIG.
2, is at location 4 in zone 1 and an article to be diverted thereto
will have an eight bit article code 00000110.
The positioning of chute 6 at location 4 also corresponds to a
unique eight bit code generated by the code generator 70 and which
occurs within a zone period in relationship to the position of
chute 6 within the zone. This code is seen in FIG. 5 and can be
identified by following the vertical line extending from the
discharge location axis corresponding to location 4 in zone 1 (FIG.
2) through (from top to bottom) the eight output lines of the
generator 70. The time varying code at the time in the zone period
corresponding to location 4 and also the location code set in the
code switch 85 for chute 6 is 11111110. The eight lines from
circuit 70 represent the frequency division of the phase pulses 63
by 1, 2, 4, 8, 16, 32, 64 and 128. The first clock pulse which
occurs as an article inducted onto the conveyor enters zone 1, is
indicated as T.sub.1 on the diagram. As the article travels along
the conveyor, the time varying code will vary as seen by following
the time axis for the signals on lines 1- 8 of FIG. 5. The location
code for chute 5, for example, is 10011100 which uniquely
identifies bin 5 and which occurs in timed coincidence with the
arrival of an article at chute 5. It is noted here that the zones
are positioned such that they begin at an even zone width or
multiple integer thereof from the induction station 14. Clock pulse
T.sub.1 occurs as an article enters zone 1, clock pulse T.sub.2
occurs as the article enters zone 2 and so forth. This delay caused
by the spacing of the induction station from zone 1 can be
accommodated by for example, incorporating a predetermined number
of shift registers in storage circuit 52 such that the article code
will be shifted from storage circuit 52 into the first shift
register 57 of memory 55 as the inducted article enters zone 1.
The time varying code generated by circuit 70 and illustrated by
the diagram of FIG. 5 is repeated for each zone period and will be
identical at a given instant of time for each of the periods. Thus,
a discharge location at a predetermined position at each zone will
have the same location code and corresponding time varying code.
The article will only be discharged, however, when the article code
has been detected by comparator 58 indicating that the article is
to be discharged in the zone set in code switch 62; and at a
discharge chute identified and detected by decoder 65 as being
present within the zone. In this manner, therefore, each discharge
chute is identified by a dual code which, due to the cyclical
nature of the time varying code generated by circuit 70, obviates
the need for individual counters at each discharge location and,
therefore, greatly simplifies the circuitry. Since a discharge
location can have two chutes, the chute code programmed in decoder
65 provides the control signal which actuates a diverter 20 to
divert an article to the desired chute. In cases where two chutes
are aligned opposite the conveyor, a single diverter is employed to
serve two chutes. In such case, the diverter drives 90 are
appropriately coupled to the diverter to control its direction of
operation.
If it is desired to move the location of the discharge chute within
a zone, all that is required is to reset the code switch 85
associated with the discharge chute in accordance with the time
varying code at that instant of time in the zone period
corresponding to the new location of the chute. A waveform similar
to that of FIG. 5 can serve as a chart from which the new location
code can be ascertained by drawing a vertical line from the new
discharge location (i.e., the bottom line in FIG. 5), through the
eight lines. The discharge location will always align with one of
the phase pulses 63 shown in line 1 of FIG. 5 which are frequency
divided tach pulses. In the preferred embodiment, the phase pulse
interval represents movement of approximately 0.3 inches of the
conveyor for the tachometer frequency used. Thus for each 0.3 inch
increment of conveyor movement, a unique time varying code is
available for positioning a chute with a corresponding location
code. If greater resolution is necessary, the drive for tachometer
60 can be varied to provide a higher pulse repetition rate for the
desired conveyor speed or the phase pulse frequency used can be
higher.
If an additional chute is added to a zone (as for example, a chute
4 or 7 in zone 1 of FIG. 1), an available decoder output line for
the zone is used to determine its chute code. The location code is
determined as discussed above. In such case, a code switch and
comparator (80, 85) are also added together with an AND gate and
diverter drive. These units can be in the form of plug-in modules
to simplify the addition of chutes. Also with this system, the
chutes can easily be redesignated by merely changing the code
switches 62.
By employing the tachometer and phase pulses together with circuit
70 to generate a repetitive time varying code, it is seen that the
conveyor speed can increase or decrease without affecting the
diverting accuracy of the system. If for example, the conveyor
speed decreases, the time scale of FIG. 5 merely is expanded as is
the location axis such that the relationship between the occurrence
of the time varying code and the chute location code will remain in
coincidence with the arrival of an article with the chute.
Likewise, the shifting of the article code in the shift register
memory 55 will occur at a slower rate corresponding to the reduced
conveyor speed.
It will become apparent to those skilled in the art that various
modifications to the present invention can be made. For example, as
briefly mentioned above, a discharge zone can be subdivided into a
greatly increased number of discharge locations, each accommodating
a pair of discharge chutes on opposite sides of the conveyor. It is
necessary only to provide an article code which will uniquely
identify the zone in which the discharge chute is positioned and
the chute within the zone. The circuits employed in the system can
easily be expanded as needed for particular installations to
accommodate the desired discharge chute density. Additionally, if
greater resolution is desired for the discharge chute positioning,
the pulse and code generator 70 can be expanded upon to provide a
ten, twelve or etc., bit time varying code for uniquely identifying
any number of bins within a discharge zone. These and other
modifications will, however, fall within the scope of the present
invention as defined by the appended claims.
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