Modular power roller conveyor

Abstract

A modular power roller conveyor is described having a conveyor section for transporting a product unit. The conveyor section comprises a number of active zones, each active zone containing means for sensing the entry of a product unit into the active zone. A programmable controller generates activation signals to a drive roller in response to the means for sensing. A plurality of carrier rollers are slaved to the drive roller within the active zone such that activation of the drive roller actuates all of the carrier rollers to drive the product unit through the active zone and into the next active zone. The programmable controller also generates a deactuation signal to deactivate the active zone as a product unit exits the zone.

1 . A divert section for a modular conveyor system that includes a series of separate conveyor sections connected end-to-end for transporting a product unit from one conveyor section to another, wherein the divert section comprises: 
 a frame;    a series of active conveyor zones each including a conveyor mechanism mounted on the frame, each conveyor mechanism including a drive roller and a plurality of carrier rollers, the drive rollers and carrier rollers being mounted between side rails of the frame, wherein the active zones define a main path for movement of a product unit and a divert path that branches from the main path;    a sensor for each zone of each conveyor section, which sensors are positioned to sense entry of a product unit into the respective active zone and generate a detection signal in response thereto;    a divert mechanism, which allows products to travel along the main path when deactuated and directs product units along the divert path when actuated; and    a programmable controller, including a memory for storing program code, a microprocessor for execution of the program code, sensor signal inputs coupled to the microprocessor for receiving sensor signals from each sensor of the divert section, control circuits coupled to the microprocessor which permit the microprocessor to individually control the conveyor mechanism of each active zone of the divert section, wherein the programmable controller further actuates the divert mechanism to divert selected product units from the main path to the divert path.    
     
     
         2 . The divert section of    claim 1   , further comprising means for interconnecting the carrier rollers for rotation in unison with the drive roller.  
     
     
         3 . The divert section of    claim 1   , wherein the divert mechanism includes a pneumatic cylinder, the programmable controller actuating the pneumatic cylinder to engage the divert mechanism.  
     
     
         4 . The divert section of    claim 3   , wherein the divert mechanism further includes a divert arm, the divert arm being moved into the main path upon actuation.  
     
     
         5 . The divert section of    claim 1   , further comprising means for interconnecting open ends of the main and divert paths with adjacent conveyor sections.  
     
     
         6 . The divert section of    claim 1   , wherein the programmable controller further comprises a communications interface whereby the programmable controller of the divert section can be connected to and communicate with a programmable controller of an adjacent conveyor section.  
     
     
         7 . The divert section of    claim 1   , wherein the sensors comprise photosensors.