Product handling apparatus

Information

  • Patent Grant
  • 6520342
  • Patent Number
    6,520,342
  • Date Filed
    Wednesday, February 16, 2000
    24 years ago
  • Date Issued
    Tuesday, February 18, 2003
    21 years ago
Abstract
A product handling apparatus, components of a product handling apparatus, a method of handling products and a software program for controlling a product handling apparatus. The apparatus includes an induct area, in which products are inducted or fed, either automatically or manually, into the product handling apparatus, an identification area, in which the product configuration, the product type and the product title are identified, a labeling area, in which product labels are printed, applied to each product and verified, and a product sorting area, in which the products are sorted into the individual customer order product collection locations for packaging and shipment to the customer. In the product sorting area, products are diverted by air knife diverter mechanisms, and stackable products are stacked in stacker assemblies. An “endless” main conveyor assembly conveys products from the induct area, through the product handling apparatus, to the product sorting area. A main controller electronically communicates with and controls, through the software program, the components of the product handling apparatus.
Description




BACKGROUND OF THE INVENTION




The present invention relates to a product handling apparatus and, more particularly, to a product handling apparatus for labeling and sorting products.




Products, such as, for example, compact discs (CDs), cassette tapes, video cassettes and digital video discs (DVDs), are stored in vast quantities in large warehouses. The products are typically stored in warehouse locations by product type and product title.




A customer generally orders a certain number of product types and product titles. To fill a customer order, the product distributor must gather or pick the specific number of ordered product types and product titles from the various warehouse locations. If the products are not sorted during picking, the distributor will sort the products into the different customer orders and package the products for shipment to each customer. In addition, some distributors print and apply customer specific labels to the products.




In some cases, the order filling process is completed manually. The distributor manually gathers and sorts the products into different customer orders, prints and manually applies labels to the products, as necessary, and then packages the products in a customer order for shipment to that customer.




In other cases, a product handling apparatus is used to complete some steps in the order filling process. For example, after the products in a customer order are manually gathered and sorted into the customer order, a labeling apparatus is used to print and apply a label to each product and to restack the products in the same customer order.




In other product handling apparatus, the products of several customer orders may be sorted and labeled at one time. In such apparatus, the products are conveyed in a flat orientation on a conveyor belt to maintain the stability of the products on the conveyor belt during transport, labeling and sorting. To sort the products, a mechanical diverter mechanism enters the product stream and engages designated products to divert the products into an associated customer order product collection location. The mechanical diverter mechanism must then be moved out of the product stream to allow other non-designated products to pass the associated product collection location so that those products can be diverted into subsequent customer order product collection locations.




In these product handling apparatus, when products are diverted into a customer order product collection location, the products are typically jumbled and disorganized. An operator collects the products from the location and organizes and arranges the products for packaging and shipment to the customer.




SUMMARY OF THE INVENTION




One problem with the above-described manual order filling process is that this manual process is very time-consuming and labor-intensive.




One problem with the above-described product labeling apparatus is that, while the labeling apparatus improves the efficiency of one step of the order filling process, the remainder of the process must still be completed manually. Specifically, the products in a given customer order must be manually gathered and sorted into the desired customer order before being placed in the product handling apparatus for labeling.




Another problem with some product handling apparatus is that the apparatus can only handle products of one product configuration (products having, for example, the same width, height, length, weight and/or center of gravity) at any one time. To handle products of different product configurations, the apparatus must be stopped and adjusted, if such adjustment is possible, to accommodate the different product configuration, slowing the order filling process.




Yet another problem with some product handling apparatus is that the label is not firmly affixed to the product and may be removed during conveying or by the diverter mechanism when the product is diverted from the conveyor assembly. The product must then be re-labeled, either manually or by being passed through the apparatus a second time.




A further problem with some product handling apparatus is that, if the products are not conveyed in a flat orientation, products can be knocked off of the conveyor belt when a force, such as the force required to apply a label, is applied to the product, and the process will be disrupted. To reduce the likelihood of such an occurrence, the products are thus conveyed in a flat and more stable orientation on the conveyor belt.




Another problem with some product handling apparatus is that, because the products are conveyed in the flat, stable orientation, a significant diverting force must be applied to each product to divert the product from its stable position on the conveyor belt. Such a significant diverting force can normally only be achieved by using a mechanical diverter mechanism which physically engages each product to move the product from the conveyor belt.




One problem with the above-described product handling apparatus including a mechanical diverter mechanism is that, to accommodate the continuous movement of the mechanical diverter mechanism into and out of the product stream, the products can only be conveyed at a relatively slow rate to ensure proper sorting of the products and proper operation of the apparatus. If the products are conveyed at too fast a rate, the mechanical diverter mechanism may disrupt the product stream by engaging products which are not to be diverted to the associated customer order product collection location. As a result, the apparatus can become jammed, stopping the order filling process and requiring operator attention, and products can be damaged.




Another problem with some product handling apparatus is that the diverter mechanism is not controlled to vary the diverting force applied to divert different products. As a result, a product having a different product configuration may not be effectively diverted by the diverter mechanism, disrupting the sorting process.




Yet another problem with some product handling apparatus is that, in the customer order product collection locations, the products are typically jumbled and disorganized. An operator collects the products from the location and must organize and properly arrange the products for packaging and shipment to the customer.




A further problem with some product handling apparatus is that, because of the force applied by the mechanical diverting mechanisms, among other factors, it is difficult to orient the products to be stacked in an organized manner. Further, it is difficult to control movement of the stacked products to provide a consistent stacking surface for subsequent products. Mechanical movement of a product stack to accommodate the following products is awkward to control, and such control becomes increasingly awkward as additional products are loaded onto the product stack. Inconsistent and jerky movement of the product stack results, causing disruption of such a stacking process.




Another problem with some product handling apparatus is that the conveyor assembly includes several independently driven conveyor belts. To effectively transfer products from one conveyor belt to the next, the individual conveyor belts must be synchronized, or the conveying process may be disrupted. Such synchronization requires additional components for sensing and coordinating the movement of the separate and independent conveyor belts.




Yet another problem with some product handling apparatus is that the components of the product handling apparatus are arranged in a relatively straight line along the conveyor assembly. Limited work area space thus limits the number of components, such as customer order product collection locations, which can be included in the product handling apparatus. This limits the number of customer orders which may be processed by the apparatus at any one time. Also, operators of the product handling apparatus must walk the full length of the apparatus, or additional operators are required, to service the widely-spaced components of the apparatus.




The present invention provides a product handling apparatus, components of the product handling apparatus, a method of handling products, and a software program for controlling a product handling apparatus that alleviate the problems with the above-described product handling apparatus and processes. The product handling apparatus of the present invention provides an apparatus and a method for quickly, efficiently and accurately identifying, labeling and sorting products into separate customer orders.




Generally, the product handling apparatus includes an induct area, in which products are inducted or fed, either automatically or manually, into the product handling apparatus, an identification area, in which the product configuration, the product type and the product title are identified, a labeling area, in which product labels are printed, applied to each product and verified, and a product sorting area, in which the products are sorted into the individual customer order product collection locations for packaging and shipment to the customer. A core or main conveyor assembly conveys products from the induct area, through the product handling apparatus, to the product sorting area. A main controller electronically communicates with and controls the components of the product handling apparatus.




In general, products are handled as follows: a wave or group of separate customer orders is bulk collected by operators from locations throughout the warehouse and delivered en masse to the product handling apparatus. The products are then inducted or fed into the product handling apparatus. The products may be automatically fed into the product handling apparatus in a feeder assembly or may be manually fed onto the main conveyor assembly by an operator. The inducted or fed products are then conveyed by a core or main conveyor assembly through the remainder of the product handling apparatus. The products are identified. Corresponding labels are printed, if printing is necessary, and applied to each product. The products are then sorted, and the sorted customer orders are packaged and removed from the product handling apparatus.




One advantage of the present invention is that an apparatus and a method for quickly, efficiently and accurately identifying, labeling and sorting products into separate customer orders are provided, reducing the time and the labor required to complete the order filling process.




Another advantage of the present invention is that the apparatus improves the efficiency of several additional steps in the order filling process.




Yet another advantage of the present invention is that, with minor and automatic adjustments, the product handling apparatus can handle products having different product configurations at one time during one wave of separate customer orders.




A further advantage of the present invention is that the labels are firmly affixed to the product and will not be removed during conveying or by the diverter mechanism.




Another advantage of the present invention is that, while products are conveyed in a less stable, almost upright conveying position, balancing forces are applied to the products to prevent the products from being knocked off of the conveyor belt when a force, such as the force required to apply a label, is applied to the product.




Yet another advantage of the present invention is that, because the products are conveyed in a non-horizontal, almost upright conveying position, a decreased diverting force is required to divert the product from its position on the conveyor belt. Such a decreased diverting force can be achieved by using an air flow provided by an air knife.




A further advantage of the present invention is that, because an air knife diverting mechanism is used, the products can be conveyed at a relatively fast rate. The air knife does not include any mechanical components which enter the product stream and which may disrupt the product stream. As a result, the apparatus is less likely to become jammed and stop the order filling process and, thus, requires less operator attention. Also, products are less likely to be damaged.




Another advantage of the present invention is that the air knife diverter mechanism is controlled to vary the diverting force of the air flow applied to divert different products. As a result, products having different product configurations are effectively diverted by the diverter mechanism.




Yet another advantage of the present invention is that, with stackable products, the products are not jumbled and disorganized in the customer order product collection locations. An operator simply collects the stacked products from the location and packages the stacked products for shipment to the customer.




A further advantage of the present invention is that, because of the controlled force applied by an air knife diverting mechanism, among other factors, the products are more easily oriented for stacking. Further, with the pneumatically-controlled movement of the stack plate, movement of the stacked products is controlled to provide a consistent stacking surface for subsequent products. Pneumatically-controlled movement of a product stack is smooth, and such control remains smooth as additional products are loaded onto the product stack.




Another advantage of the present invention is that the conveyor assembly includes several conveyor belts driven by a common drive motor to provide an “endless” conveyor assembly. The individual conveyor belts are automatically synchronized by this drive arrangement so that products are effectively transferred from one conveyor belt to the next.




Yet another advantage of the present invention is that the components of the product handling apparatus are arranged in parallel sections connected by a turning arrangement. In a limited work area space, the number of components, such as customer order product collection locations, which can be included in the product handling apparatus is effectively increased to almost double, increasing the number of customer orders which may be processed by the apparatus at any one time. Also, operators of the product handling apparatus are not required to walk the full length of the apparatus, and additional operators are not required, to service widely-spaced components of the apparatus.




Other features and advantages of the invention will become apparent to those skilled in the art upon review of the following detailed description, claims and drawings.











DESCRIPTION OF THE DRAWINGS





FIG. 1

is a schematic diagram of a product handling apparatus embodying the invention.





FIG. 2

is a plan view of a portion of the product handling apparatus schematically illustrated in FIG.


1


.





FIG. 3

is a plan view of another portion of the product handling apparatus schematically illustrated in FIG.


1


.





FIG. 4

is a view looking downstream of a feeder assembly illustrated in

FIGS. 1-2

.





FIG. 5

is a top view of a portion of the feeder assembly illustrated in FIG.


4


.





FIG. 6

is a view of a portion of the feeder assembly and a portion of a main conveyor assembly taken generally along line


6





6


in FIG.


2


.





FIG. 7

is a top view of a portion of the main conveyor assembly.





FIG. 8

is a view of the portion of the main conveyor assembly taken generally along line


8





8


in FIG.


7


.





FIG. 9

is a view of the portion of the main conveyor assembly taken generally along line


9





9


in FIG.


7


.





FIG. 10

is a view of another portion of the main conveyor assembly taken generally along line


10





10


in FIG.


3


.





FIG. 11

is a top view of another portion of the main conveyor assembly.





FIG. 12

is an enlarged view of a portion of the main conveyor assembly illustrated in FIG.


11


.





FIG. 13

is a view of a product identification area taken generally along line


13





13


in FIG.


2


.





FIG. 14

is a view of the product identification area taken generally along line


14





14


in FIG.


13


.





FIG. 15

is a view of the product identification area taken generally along line


15





15


in FIG.


13


.





FIG. 16

is a view looking downstream of a labeler assembly of a product labeling area illustrated in

FIGS. 1-2

.





FIG. 17

is a top view of a portion of the product labeling area illustrated in

FIGS. 1-2

.





FIG. 18

is a view of a portion of the product labeling area taken generally along line


18





18


in FIG.


17


.





FIG. 19

is a view looking upstream of an early divert product collection assembly illustrated in

FIGS. 1-2

.





FIG. 20

is a view of a diverter assembly taken generally along line


20





20


in FIG.


19


.





FIG. 21

is a view of a portion of a product sorting area taken generally along line


21





21


in FIG.


1


.





FIG. 22

is a view of a portion of the product sorting area taken generally along line


22





22


in FIG.


1


.





FIG. 23

is an enlarged and more detailed view of a portion of a stacker assembly illustrated in FIG.


22


.





FIG. 24

is a view looking upstream of the stacker assembly illustrated in FIG.


23


.





FIG. 25

is a view of a guide assembly taken generally along line


25





25


in FIG.


24


.











Before one embodiment of the invention is explained in detail, it is to be understood that the invention is not limited in its application to the details of the construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or carried out in various ways. Also, it is understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.




DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT




A product handling apparatus


30


embodying the invention is schematically illustrated in FIG.


1


. The product handling apparatus


30


is used to identify, label and sort products P. The products P have opposite faces (one shown) and a bottom edge, a top edge, a leading edge and a trailing edge. Each product P typically includes an identifying code, such as an UPC/EAN bar code, which includes information representing the product type and the product title. In the illustrated construction, the products P are music and video products, such as compact discs (CDs), cassette tapes, video cassettes and digital video discs (DVDs). In other constructions (not shown), the products may be other packaged customer products.




A first product P


1


, having a first product configuration, and a second product P


2


, having a second product configuration, are illustrated in FIG.


1


. To handle the products P


1


and P


2


, the product handling apparatus


30


will require a different machine configuration for each product, as explained below in more detail.




“Product configuration” relates to the physical parameters of a product and includes the length (along the apparatus axis), width (transverse to the apparatus axis), height, weight, center of gravity and surface texture of the product. Products having substantially the same product configuration form a machine configuration. Generally, these products can be diverted and sorted by the product handling apparatus


30


using a common set of divert parameters for the components of the product handling apparatus


30


, i.e., the products will be conveyed and diverted in the same manner. Products having different product configurations typically will not be conveyed and will not be diverted in the same manner but will behave in a different manner. Accordingly, different machine configurations are typically required to handle products having different product configurations.




For purposes of discussion, a standard product is a product which can be run through the product handling apparatus


30


because the physical characteristics and the product configuration of the product are accommodated by the product handling apparatus


30


. Non-standard products are products which cannot be handled by the product handling apparatus


30


due to the physical limitations of the product handling apparatus


30


and due to the physical characteristics of such products, i.e., oversize, unusual shape and/or poor stacking qualities.




Products are divided into several product categories. A stackable product is a product that can be effectively handled by all components of the product handling apparatus


30


. A stackable product is automatically inducted, identified, labeled, diverted and stacked. A non-stackable product is a product which can be inducted, identified, labeled and sorted. However, a non-stackable product cannot be effectively stacked. During sorting, non-stackable products are typically diverted into a product collection location provided by a sort bin for collection of a customer order.




A manually-inducted product is a product that cannot be automatically inducted into the product handling apparatus. An operator manually places the manually-inducted product on the core or main conveyor assembly. A manually-inducted product is then identified, labeled and diverted a product collection location. A conveyable product is a product which can be run on the product handling apparatus


30


. Conveyable products include stackable, non-stackable and manually-inducted products.




Finally, a non-conveyable product is a product which cannot be processed by the product handling apparatus


30


. Non-conveyable products must be handled manually or by another product handling apparatus capable of accommodating such products. In the illustrated order filling process, the non-conveyable products in a specific customer order are manually gathered, sorted and labeled and are then packaged with the conveyable products of the customer order which are handled by the product handling apparatus


30


.




For purposes of discussion, the terms “upstream” and “downstream” are used to identify the relative positions of components of the product handling apparatus


30


relative to the first conveying direction (indicated by arrow A) and the second conveying direction (indicated by arrow B). Also, the term “front” describes a view from an apparatus axis


32


towards either of the conveying directions (arrow A or arrow B). The term “rear” is used to describe a view from outside of the product handling apparatus


30


, across either of the conveying directions (arrow A or arrow B), and toward the apparatus axis


32


.




Products are bulk picked or gathered from warehouse storage locations as a group of separate customer orders or a wave, and the conveyable products of the wave are processed by the product handling apparatus


30


. In general, as shown in

FIG. 1

, the product handling apparatus


30


includes a product induct area


34


, in which products are inducted or fed, either automatically or manually, into the product handling apparatus


30


, a product identification area


38


, in which the product configuration, the product type and the product title are identified, a product labeling area


42


, in which product labels are printed, applied to each product and verified, and a product sorting area


46


, in which the products are sorted into the individual customer order product collection locations for packaging and shipment to the customer. The product sorting area includes a plurality of separate product collection locations


50


in which products P are collected. A core or main conveyor assembly


54


conveys products from the product induct area


34


, through the other components of the product handling apparatus


30


, to the product sorting area


46


. A main controller


58


electronically communicates with and controls the components of the product handling apparatus


30


.




As shown in FIGS.


2


and


4


-


5


, the product induct area


34


includes a feeder assembly


62


for feeding products into the product handling apparatus


30


. The feeder assembly


62


includes feed conveyor assembly


64


and a strip-off conveyor assembly


70


. In the product induct area


34


, individual products of varying product configurations are introduced into the product handling apparatus


30


. Product rates are determined in the product induct area


34


and, for example, may be set at 100, 200 or 300 products per minute (ppm).




The feed conveyor assembly


64


includes a feed conveyor belt


72


which is a powered belt conveyor and which generally slopes downwardly at approximately 15° towards a strip-off conveyor assembly


70


. The operator stages the products P in a feed stack on the feed conveyor belt


72


. The feed stack has a forward end, adjacent the strip-off conveyor assembly


70


, and a rearward end, on which additional products may be staged. The products are positioned in the feed stack in face-to-face relation and are supported on their respective bottom edges by the feed conveyor belt


72


.




Preferably, the products P are oriented in the feed stack to ensure proper labeling of the products in the product labeling area


42


. Also, the products P are preferably staged by product configuration for proper sorting and stacking in the product sorting area


46


, as explained below in more detail. In addition, the products P are preferably inducted in sets having the same product configuration so that a single machine configuration can be used at one time. However, the main controller


58


is capable of controlling the components of the product handling apparatus


30


to allow products of various product configurations to be inducted and handled by the product handling apparatus


30


.




The strip-off conveyor assembly


70


includes a strip-off conveyor belt


74


which is a dual, cleated conveyor belt and which is oriented non-horizontally and, preferably, almost vertically. The strip-off conveyor belt


74


includes a belt surface and a plurality of cleat members


78


spaced apart along the apparatus axis


32


and extending from the belt surface. The strip-off conveyor assembly


70


also includes a lower support member


82


having a smooth, low-friction support surface.




To strip a product from the feed conveyor assembly


64


, the product P at the forward end of the feed stack moves into the strip-off area. The lower support member


82


engages the bottom edge of the product P to support the product P, and the belt surface of the strip-off conveyor belt


74


engages one face of the product P. A cleat member


78


engages the trailing edge of a product P to strip the product P from the feed stack. The cleat member


78


engages the product P at a height and a distance from the bottom edge sufficient to prevent the product P from tipping in an upstream direction. The strip-off conveyor assembly


70


supports the product P in a conveying position in which the one face of the product P is in a non-horizontal, almost upright orientation and, preferably, is angled at least 70° from a horizontal plane H (shown in FIG.


4


).




The feeder assembly


62


also includes (see

FIG. 5

) a back pressure assembly


86


which ensures that only one product at a time is stripped from the forward end of the feed stack. The back pressure assembly


86


is adjustable to allow products of different widths (such as product P


1


and P


2


) to be fed into the product handling apparatus


30


. The back pressure assembly


86


includes a back pressure door


90


which is movably supported by a biasing mechanism, such as a cylinder assembly


94


. The back pressure door


90


engages the leading edge of the following products in the feed stack to ensure that only one product at a time is stripped from the feed stack.




The cylinder assembly


94


allows the back pressure door


90


to apply a back pressure on the products in the feed stack. The cylinder assembly


94


also allows the back pressure door


90


to be positioned relative to the strip-off conveyor assembly


70


to define a space which is less than the width of more than one product. The back pressure door


90


may be positioned in a first position, defining a space less than the width of more than one first product P


1


(as shown in FIG.


5


), and a second position, defining a space less than the width of more than one second product P


2


.




The feeder assembly


62


also includes (see

FIG. 4

) an induct stop or hold-off assembly


98


to hold the products P in the feed stack in spaced relation from the strip-off conveyor assembly


70


to prevent products P from being inducted. The hold-off assembly


98


includes a hold-off plate


102


which is supported for movement between a hold-off position, in which products are prevented from being inducted, and an induct position (shown in FIG.


4


), in which products may be inducted. Preferably, the hold-off plate


102


is pneumatically operated and is movably supported by a cylinder assembly


106


. An activation switch (not shown) operates the hold-off assembly


98


.




The feeder assembly


62


also includes (see

FIG. 4

) a low-level detecting mechanism, such as a photo eye


110


and receptor (not shown). When sufficient products are staged in the feed stack (as shown in FIG.


4


), the eye


110


is blocked. When the number of products in the feed stack reaches a low level, the eye


110


is unblocked, and a low-level indicator (not shown) indicates that a low-level of products has been reached. In the illustrated construction, the hold-off plate


102


then automatically extends to the hold-off position to engage the products in the feed stack and to stop induction of products. Once the operator has staged sufficient products P, the operator activates the switch, and the hold-off plate


102


moves to the induct position to allow induction of products P.




If, as shown in

FIG. 5

, the operator is at the end of a wave session and wants to induct the last remaining products in the wave, an induct assist block


118


is used. The induct assist block


118


engages the trailing products at the rearward end of the feed stack to assist in the smooth induction of a short stack of products. The induct assist block


118


triggers (see

FIG. 4

) a low-level proximity switch


122


(which serves the same purpose as the eye


110


and receptor) and assists the products onto the strip-off conveyor assembly


70


. However, the induct assist block


118


does not enter the strip-off area. When the last product in the feed stack is inducted and the feed conveyor belt


72


is empty, the hold-off plate


102


is again extended to the hold-off position.




The hold-off plate


102


also moves to the hold-off position if a blockage occurs in the product handling apparatus


30


. This ensures that additional products will not be fed into the obstructed portion of the product handling apparatus


30


.




The feeder assembly


62


also includes (see

FIG. 5

) a feed stack stop


130


behind which products can be staged. The operator can stage products from a subsequent wave behind the feed stack stop


130


while the remaining products in a first wave are inducted.




In operation, the operator stages products P


1


(and/or P


2


) on the feed conveyor belt


72


in the feed stack. When a sufficient number of products P


1


are staged, the hold-off plate


102


is moved to the induct position so that products P


1


can be inducted. The product P


1


at the forward end of the feed stack moves into the strip-off area. The one face of the product P


1


engages the belt surface of the strip-off conveyor belt


74


, and the bottom edge of the product P


1


engages the lower support member


82


so that the product P


1


is supported. A cleat member


78


engages the trailing edge of the product P


1


to strip the product P


1


from the feed stack and convey the product to the main conveyor assembly


54


. The back pressure door


90


applies a back pressure to the leading edge of the remaining products in the feed stack to ensure that only one product P


1


is stripped-off at a time.




When products of a different product configuration, such as the second products P


2


, are to be inducted into the product handling apparatus


30


, the back pressure door


90


is adjusted to the second position (not shown). In the second position, the back pressure door


90


allows the second products P


2


to be stripped-off but ensures that only one second product P


2


at a time is stripped from the feed stack.




Products on the strip-off conveyor belt


74


are transferred to the main conveyor assembly


54


. As shown in

FIGS. 2-3

and


6


-


12


, the main conveyor assembly


54


includes a plurality of conveyor belts which run from the product induct area


34


through the remainder of the product handling apparatus


30


. The main conveyor assembly


54


provides an “endless” conveyor assembly of separate conveyor belts which are synchronized.




As shown in

FIG. 6

, a first conveyor belt


138


is supported adjacent the downstream end of the strip-off conveyor belt


74


and includes a belt surface and a plurality of first cleat members


142


spaced apart along the apparatus axis


32


and extending from the belt surface. A first drive sprocket


146


drivingly engages the first conveyor belt


138


.




The main conveyor assembly


54


also includes a product guide and support assembly


150


. The product guide and support assembly


150


includes a first support member


154


associated with the first conveyor belt


138


. The first support member


154


extends substantially parallel to the first conveyor belt


138


and has a smooth, low friction first support surface.




As shown in

FIG. 6

, the belt surface of the first conveyor belt


138


is substantially coplanar with the support surface of the lower support member


82


of the strip-off conveyor assembly


70


and is engageable with the bottom edge of the product to support the product. Similarly, the support surface of the first support member


154


is substantially coplanar with the belt surface of the strip-off conveyor belt


74


and is engageable with the one face of the product P to support the product P in the non-horizontal, almost upright conveying position.




The strip-off conveyor belt


74


and the first conveyor belt


138


are synchronized so that a product P is smoothly transferred from the product induct area


34


to the main conveyor assembly


54


. As the cleat member


78


conveys the product downstream onto the first conveyor belt


138


, a first cleat member


142


engages the trailing edge, proximate the bottom edge, to continue conveying the product downstream. Such synchronization ensures that the product does not slow down when disengaged by the cleat member


78


and tip in the upstream direction when engaged by the first cleat member


142


and, thereby, reduces the likelihood that the product handling apparatus


30


will become blocked.




As shown in

FIG. 6

, a manual induct area


156


is provided adjacent the strip-off conveyor assembly


70


and is used for manually-inducted products. The manual induct area


154


is provided by an open section of the first conveyor belt


138


after the automatic induct area, provided by the feeder assembly


62


, and before the product identification area


38


. In the manual induct area


156


, the operator carefully places a product onto the first conveyor belt


138


between cleat members


142


. During induct, the operator can manually induct any manually-inducted products (not shown) in the manual induct area


134


so that all conveyable products are inducted into the product handling apparatus


30


.




The main conveyor assembly


54


also includes (see

FIG. 7

) a second conveyor belt


158


positioned downstream to receive products from the first conveyor belt


138


. The second conveyor belt


158


has a belt surface and a plurality of second cleat members


162


spaced apart along the apparatus axis


32


and extending from the belt surface. A second drive sprocket


166


drivingly engages the second conveyor belt


158


.




The product guide and support assembly


150


also includes a second support member


170


associated with the second conveyor belt


158


. The second support member


170


extends substantially parallel to the second conveyor belt


158


and has a smooth, low friction support surface. As shown in

FIG. 7

, the first conveyor belt


138


and the second conveyor belt


158


are laterally offset. The product guide and support assembly


150


also includes a transfer guide member


174


having a smooth, low friction guide surface which is engageable with the one face of the product P to guide the product P from the first conveyor belt


138


to the second conveyor belt


158


.




The main conveyor assembly


54


supports and conveys products through the product handling apparatus


30


in the non-horizontal, almost upright conveying position. Preferably, the products are supported so that the one face engaged by the product guide and support assembly


150


is angled at least 70° from a horizontal plane.




The main conveyor assembly


54


also includes a drive motor


178


having a rotatable drive shaft


182


drivingly engaging the first drive sprocket


146


, through a first drive chain


184


, and drivingly engaging the second drive sprocket


166


, through a second drive chain


186


. During assembly of the main conveyor assembly


54


, the first conveyor belt


138


and the second conveyor belt


158


are synchronized so that a product is transferred smoothly from the first conveyor belt


138


to the second conveyor belt


158


. As the product is transferred, a second cleat member


162


engages the trailing edge of the product P to continue to convey the product P downstream. The second support surface member


170


engages the one face of the product P to support the product P in the non-horizontal conveying position.




Because the first conveyor belt


138


and the second conveyor belt


158


are initially synchronized, and because the first conveyor belt


138


and the second conveyor belt


158


are driven by a common drive motor


178


, the first conveyor belt


138


and the second conveyor belt


158


are automatically synchronized and remain synchronized during operation of the main conveyor assembly


54


. Subsequent conveyor belts of the main conveyor assembly


54


are driven and synchronized in a similar manner.




As shown in

FIG. 1

, a first portion of the main conveyor assembly


54


conveys products in a first conveying direction (indicated by arrow A), and a second conveyor portion conveys products in a second conveying direction (indicated by arrow B) opposite to the first conveying direction. The second conveyor portion includes (see

FIG. 10

) a third conveyor belt


190


having a belt surface and a plurality of third cleat members


194


spaced apart along the apparatus axis


32


and extending from the belt surface.




To direct products from the first conveying direction to the second conveying direction, the main conveyor assembly


54


includes (see

FIG. 11

) a turning guide assembly


198


supported to receive products from the first conveying portion in the first conveying direction and to transfer the products to the second conveyor portion in the second conveying direction. The turning guide assembly


198


provides a 180° turn in the main conveyor assembly


54


. The turning guide assembly


198


includes a curved guide member


202


having a smooth, low friction support surface engaging the one face of the product to support the product in the non-horizontal, almost upright conveying position.




Due to the momentum of the products being transferred from the first conveying portion to the turning guide assembly


198


, some products may have a tendency to “jump” from the main conveyor assembly


54


as these products approach the turning guide assembly


198


. To prevent the products from leaving the main conveyor assembly


54


, at least one and, in the construction illustrated in

FIGS. 11-12

, two air knife assemblies


206


are supported proximate the junction between the first conveying portion and turning guide assembly


198


. The air knife assemblies


206


provide an air flow to maintain the products on the main conveyor assembly


54


and to guide the products from the first conveying portion and onto the turning guide assembly


198


.




The turning guide assembly


198


and the 180° turn allow additional components, such as sort destinations or product collection locations to be included in the product handling apparatus


30


in the limited work area space. Also, operators are not required to walk the full length of the product handling apparatus to service the components of the product handling apparatus


30


.




As shown in

FIG. 2

, after receiving products from the product induct area


34


, the main conveyor assembly


54


conveys the products through the product identification area


38


. The product identification area


38


includes (see

FIGS. 13-15

) an array of bar code readers


210


to read the UPC/EAN bar code on each product P. The array of bar code readers


210


is constructed so that the opposite faces, the top edge, the leading edge and the trailing edge of each product P can be examined.




The array of bar code readers


210


reads the bar code on the product and outputs an identification signal, corresponding to the information in the bar code, to the main controller


58


. The identification signal represents the information identifying the product configuration, the product type and the product title. The main controller


58


compares the information in the identification signal to the stored information representing the customer orders and, based on the identification signal, outputs signals to the components of the product handling apparatus


30


corresponding to the information in the identification signal. If the array of bar code readers


210


is not able to identify a product, the array of bar code readers


210


will output a no-read identification signal to the main controller so that the main controller


58


can cause the no-read product to be diverted into a no-read product collection location


50


, as explained below in more detail.




After product identification, the main conveyor assembly


54


then conveys the products to the product labeling area


42


and continuously conveys the products through the product labeling area


42


. As shown in

FIG. 2

, the product labeling area


42


includes a plurality of and, in the illustrated construction, ten labeler assemblies


218


for applying a label to a product. Six of the labeler assemblies


218


are printer/labeler assemblies


222


including (see

FIG. 16

) a printer


226


, for printing specific information on a label L, and four of the labeler assemblies


218


are checkpoint labeler assemblies


230


which apply checkpoint-type labels. The printer/labeler assemblies


222


and the checkpoint labeler assemblies


230


include (see

FIG. 16

) a label applicator, such as an air knife


234


, which provides an application air flow having an application force and duration to apply the label L to the one face of the product P.




To balance the application force applied by the label applicators, each labeler assembly


218


also includes a balancing force applicator, such as a balancing air knife


246


, which provides a balancing air flow having a balancing force and duration to the other face of the product to balance the application force and to maintain the product on the main conveyor assembly


54


. Preferably, the application force and the balancing force are applied for a substantially equal duration. To do so, the application air knife


234


and the balancing air knife


246


are preferably supplied simultaneously from the same air supply


247


through a control valve (not shown).




Each labeler assembly


218


includes a label controller


248


communicating with the main controller


58


to control printing of a label, if required, and application of the label to the product. Label information is stored in the product wave information in the main controller


58


. The main controller


58


conducts a look-up for each product based on the identification signal for that product, and specific label information for that product is accessed. The main controller


58


outputs a label control signal corresponding to the specific label information to the label controller


248


for the appropriate labeler assembly


218


. The label controller


248


then controls the associated labeler assembly


218


to correctly label the corresponding product.




The product labeling area also includes (see

FIGS. 17-18

) an iron-on/brush-on assembly


250


to firmly affix the label L to the product P. The iron-on/brush-on assembly


250


includes a pressure applicator, such as a resilient brush


254


, which extends into the product stream. The iron-on/brush-on assembly


250


also includes a second balancing force applicator, such as a second balancing air knife


258


, to apply a second balancing air flow having a second balancing force and duration to the other face of the product to press the product and the label against the brush


254


as the product is conveyed downstream and to maintain the product on the main conveyor assembly


54


. The pressure applicator


254


thus provides a fixing pressure to firmly affix the label on the product.




As shown in

FIG. 17

, a label verification scanner or bar code reader


260


is positioned downstream of the labeler assemblies


218


and the iron-on/brush-on assembly


250


. The bar code reader


260


verifies that the proper label was properly affixed to the product. If there is an error, the bar code reader


214


outputs a label error signal to the main controller


58


which, in turn, will cause the mislabeled product to be diverted into a non-customer product collection location


50


.




As shown in

FIGS. 1 and 3

, the main conveyor assembly


54


then conveys the products to the product sorting area


46


so that the products can be diverted into and collected in product collection locations


50


. These product collection locations


50


may correspond to a non-customer location, such as a no-read or no-need divert location, or to a customer order location into which products are sorted. However, a majority of the product collection locations


50


are customer order product collection locations.




As shown in

FIGS. 19-24

, each product collection location


50


includes an associated diverter assembly


262


for selectively diverting products from the main conveyor assembly


54


into the product collection location


50


. As shown in more detail in

FIGS. 19-20

, the diverter assembly


262


includes a diverter mechanism


266


including an air knife


270


which selectively produces a divert air flow against the one face of the product P to divert the product P from the main conveyor assembly


54


and into the product collection location


50


. The air knife


270


includes a plurality of nozzles


274


communicating with an air supply


278


(schematically illustrated). The air knife


270


is a pneumatic device and uses a blast of air, the divert air flow, to guide or divert a product from the main conveyor assembly


54


.




The diverter assembly


262


also includes a diverter controller


282


communicating with the main controller


58


. The diverter controller


282


controls a valve


286


to control the air knife


270


. A photo eye


290


signals the diverter controller


282


when the product to be diverted approaches the diverter area.




The diverter controller


282


controls the air knife


270


to selectively produce an air flow against the one face of the product to divert the product. The diverter controller


282


controls the air knife


270


so that the air flow is variable and controllable to provide a different air flow for different product configurations. In the illustrated construction, the diverter controller


282


controls the valve


286


to select the amount of air that will be supplied through the nozzles


274


to provide the selected air flow. In other constructions (not shown), the diverter controller


282


may vary the air flow by, for example, selecting the nozzles


274


through which air is supplied or varying the size of the nozzles


274


.




When a product P is to be diverted into the associated product collection location


50


, the main controller


58


outputs a divert signal to the diverter controller


282


. As the designated product P approaches the diverter assembly


262


, the photo eye


290


senses the product P and outputs a position signal to the diverter controller


282


to indicate that the product P is approaching the diverter area. At the proper time, the diverter controller


282


controls the valve


286


to provide the divert air flow through the air knife


270


to divert the designated product P into the associated product collection location


50


.




The diverter controller


282


also controls the diverter assembly


262


to not provide the divert air flow so that a non-designated product is not diverted into the associated product collection location


50


. The non-designated product can thus pass the associated product collection location


50


so that the product can be diverted into a subsequent product collection location


50


to which that product is designated.




The air flow is selected based on the information provided in the divert signal output by the main controller


58


. To divert a first product P


1


, the air knife


270


is controlled to produce a first air flow, and to divert a second product P


2


, the air knife


270


is controlled to produce a second air flow. Because the air flow from the air knife


270


is controlled and variable, the air knife


270


can effectively divert products having different product configurations.




The length, timing and force of the air blast or divert air flow required to divert a product into a product collection location


50


is determined by the product configuration. The main controller


58


and the diverter controller


282


cooperate to control the diverter assembly


262


to divert a given product having a given product configuration.




Because the products are conveyed in a non-horizontal and, preferably, almost upright conveying position by the main conveyor assembly


54


, the air knife


270


is able to provide a sufficient diverting force with the divert air flow to divert the products from the main conveyor assembly


54


. The speed of the product handling apparatus


30


is greatly increased due to the use of the diverter assemblies


262


including air knifes


270


, instead of mechanical diverter mechanisms, as described above.




As discussed above, the product collection locations


50


include non-customer product collection locations and customer order product collection locations. As shown in

FIG. 2

, the main conveyor assembly


54


first conveys products through some non-customer product collection location


294


. Several of the non-customer product collection locations


294


are positioned downstream of the product labeling area


42


. These non-customer product collection locations


294


include an early divert location


296


, a no-read divert location


298


and a no-need divert location


300


.




Each of the non-customer product collection locations


294


is typically provided by (see

FIG. 19

) a sort bin


304


into which products are diverted. In the sort bin


304


, the products are not collected in an arranged manner. The sort bin


304


includes a hinged door


308


which is opened by an operator to access the products in the sort bin


304


. The hinged door


308


includes a latch (not shown), and a locking pin (not shown) locks the hinged door


308


in the closed position during sorting operations.




When the sort bin


304


is full, the main controller


58


will stop sending products to the sort bin


304


and controls an indicator (not shown) to notify the operator that the sort bin


304


must be emptied. When the indicator is activated to signal a full sort bin


304


, scanning of an appropriate box by the operator causes the sort bin


304


to automatically become available for loading. To unload the sort bin


304


, the operator will activate a switch (not shown) on the sort bin


304


to release the locking pin. The hinged door


308


is then opened, and the products are removed from the sort bin


304


. Once the sort bin


304


is emptied, the hinged door


308


is closed and latched by the operator. This causes the main controller


58


to re-engage the locking pin and to make the sort bin


304


available to again receive products.




The switch also enables the operator to take the sort bin


304


off-line and to signal to the main controller


58


to stop sending products to the sort bin


304


. While the sort bin


304


is off-line, no products will be diverted to the sort bin


304


. The operator brings the sort bin


304


back on-line by again depressing the switch.




Once a product is identified in the product identification area


42


, the main controller


58


determines if a customer order product collection location


50


is available and ready to receive the product. If there is no product collection location


50


ready to receive the product, the main controller


58


will output an early divert signal to the diverter controller


282


of the diverter assembly


262


associated with the early divert location


296


. The air knife


270


will produce a divert air flow to divert the product into the early divert location


296


. Products diverted into the early divert location


296


are removed and returned to the product induct area


34


by the operator for handling at a later time by the product handling apparatus


30


.




If the array of bar code readers


210


in the product identification area


38


outputs a no-read signal to the main controller


58


(because the product bar code cannot be read) or if the label verification bar code reader


260


outputs a label error signal to the main controller


58


(because the product has been mislabeled), the main controller


58


will output a no-read signal to the diverter controller


282


of the diverter assembly


262


associated with the no-read divert location


298


. The air knife


270


will produce a divert air flow to divert the “no-read” product into the no-read divert location


298


. “No-read” products will be removed from the no-read divert location


298


, possibly re-labeled and returned to the product induct area


34


by an operator. Alternatively, the “no-read” products can be manually sorted into the proper customer order.




If, after identifying the product, the main controller


58


determines that the product is not needed for the wave of customer orders, the main controller


58


outputs a no-need signal to the diverter controller


282


of the diverter assembly


262


associated with the no-need divert location. The air knife


270


produces a divert air flow to divert the unneeded product into the no-need divert location


300


. Unneeded products will be collected from the no-need divert location


300


and returned to the warehouse locations.




If a product is properly identified in the product identification area


38


, confirmed by the main controller


58


as being assigned to a customer order and a customer order product collection location


50


and properly labeled, the main controller will output a divert signal to the diverter controller


282


of a diverter assembly


262


of (see

FIGS. 21-22

) a customer order product collection location


312


assigned to collect the product. The product will then be diverted by the diverter assembly


262


into the assigned customer order product collection location


312


.




Customer order product collection locations


312


are provided by (see

FIGS. 21-22

) sets of stacker assemblies


316


and product sort bins


320


. Each set preferably includes two stacker assemblies


316


and a sort bin


320


and may be used to collect a single customer order. Alternatively, each component of a set, each stacker assembly


316


and the sort bin


320


, may be used to receive a separate customer order. Each customer order product collection location


312


includes an associated diverter assembly


262


.




The sort bin


320


is similar to the sort bin


304


of the non-customer product collection locations


294


, as described above. In the sort bin


320


, the products are not collected in an arranged manner. The sort bin


320


includes a hinged door


324


which is opened by an operator to access the products in the sort bin


320


. The hinged door


324


includes a latch (not shown), and a locking pin (not shown) locks the hinged door


324


in the closed position during sorting operations.




When the sort bin


320


is full, the main controller


58


will stop sending products to the sort bin


320


and controls an indicator (not shown) to notify the operator that the sort bin


320


must be emptied. When the indicator is activated to signal a full sort bin


320


, scanning of an appropriate box B by the operator causes the sort bin


320


to automatically become available for loading. To unload the sort bin


320


, the operator will activate a switch (not shown) on the sort bin


320


to release the locking pin. The hinged door


324


is then opened, and the products are removed from the sort bin


320


. Once the sort bin


320


is emptied, the hinged door


324


is closed and latched by the operator. This causes the main controller


58


to re-engage the locking pin and to make the sort bin


320


available to again receive products.




The switch also enables the operator to take the sort bin


320


off-line and to signal to the main controller


58


to stop sending products to the sort bin


320


. While the sort bin


320


is off-line, no products will be diverted to the sort bin


320


. The operator brings the sort bin


320


back on-line by again depressing the switch.




As shown in more detail

FIGS. 23-24

, in each stacker assembly


316


, products are stacked in an organized and arranged manner in a product stack. Each stacker assembly


316


provides a curved product chute


318


and uses the product's momentum, created by the movement on the main conveyor assembly


54


and by the diverter force of the diverter assembly


262


, and gravity to guide the product flat onto a product stack.




The stacker assembly


316


includes a product collection housing


320


having spaced apart side walls and a rear wall positioned adjacent the main conveyor assembly


54


. An aperture


324


is defined in the product collection housing


320


. The stacker assembly


316


also includes a movable throat member


328


which defines a portion of the aperture


324


and which aids in guiding products into the product chute


318


.




The stacker assembly


316


also includes (see

FIGS. 23 and 25

) a plurality of guide members, such as a first guide member


332


and a second guide member


316


, which are movable to define the upper portion of the aperture


324


and the product chute


318


. As shown in

FIGS. 22-23

, a plurality of front plates, such as first, second and third front plates


340


,


344


and


348


, define the front wall of a portion of the product collection housing


320


. The front plates


340


,


344


and


348


are movable to change the width (transverse to the conveying axis


32


) of the portion of the product collection housing


320


to assist in orderly stacking of the products.




The stacker assembly


316


also includes a movable stack plate


352


which provides a bottom wall in the product collection housing


320


. Products are diverted through the aperture


324


and down the product chute


318


and are stacked in a flat orientation on the stack plate


352


. Initially, as shown in phantom in

FIGS. 23-24

, the stack plate


352


is positioned to define an initial length of the product chute


318


and to provide a surface onto which products are stacked. As products are stacked on the stack plate


352


, the uppermost product P defines the length of the product chute and provides the surface onto which subsequent products are stacked. The stack plate


352


is movable relative to the product collection housing


320


so that the subsequent length of the product chute


318


, defined by the uppermost product, is substantially the same as the initial length, defined by the initial position of the stack plate


352


(shown in phantom in FIGS.


23


-


24


), to provide a consistent product chute


318


and stacking surface. In other words, as the product stack is built, the stack plate


352


lowers to maintain a consistent vertical distance between the product chute


318


and the top of the product stack, helping to maintain consistent stacking orientation.




To move the stack plate


352


, the stacker assembly


316


includes (see

FIG. 24

) a cylinder assembly


356


connected to the stack plate


352


. The cylinder assembly


356


includes a cylinder


360


and a piston


364


movably housed in the cylinder


360


. The cylinder


360


is connected to the stack plate


352


to move the stack plate


352


. The cylinder assembly


356


has first and second ports through which fluid is selectively supplied to move the piston


364


relative to the cylinder


360


. The cylinder assembly


356


also includes an air supply


368


(schematically illustrated) for supplying fluid to the cylinder assembly


356


. A stack plate valve


372


controls fluid flow to the cylinder assembly


356


to control movement of the stack plate


352


. Preferably, the cylinder assembly


356


is pressurized on both sides, and pressure is released from one side of the cylinder assembly


356


to allow the stack plate


352


to be lowered. The pneumatic control of the stack plate


352


provides smooth movement of the stack plate


352


as the stack plate


352


is lowered and products are stacked.




The stacker assembly


316


also includes a stacker controller


376


. The stacker controller


376


controls operation of the stack plate valve


372


to move the stack plate


352


as products are stacked in the stacker assembly


316


.




The stacker controller


376


also controls positioning of the throat member


328


, the guide members


332


and


336


and the front plates


340


,


344


and


348


to define an appropriate size of the product chute


318


for a given product configuration. The stacker controller


376


receives a stack signal from the main controller


58


indicating the product configuration of products being conveyed to the stacker assembly


316


. Accordingly, the stacker controller


376


adjusts the throat member


328


, the guide members


332


and


336


and the front plates


340


,


344


and


348


to accommodate the desired product configuration. If a product having a different product configuration is conveyed to the stacker assembly


316


, the stacker controller


376


adjusts the throat member


328


, the guide members


332


and


336


and the front plates


340


,


344


and


348


to accommodate the different product configuration.




In the illustrated construction, when stacking products in a stacker assembly


316


, products are preferably stacked in the following order from bottom of the order to top of the order: clam shell videocassettes, DVDs, sleeve videocassettes, CDs, double CDs and cassette tapes. The controlled staging and induction of products in the product induct area


34


by different product configuration should eliminate the assignment of a product to a stacker assembly which cannot accept the product because of a previously stacked product. However, if this event occurs, the product will be sent to another customer order product collection location corresponding to the customer order, if available, to the early divert location


296


or to the product collection location


50


at the end of the product handling apparatus


30


.




During processing of stackable products, each product assigned to a customer order will be diverted to the available stacker assembly


316


associated with that customer order. When possible, products will continue to be sent to that stacker assembly


316


until a box is completed. A stacker assembly


316


having a full stack will require emptying by the operator and will become unavailable to receive additional products. The next product for that customer order will be sent to another customer order product collection location


312


corresponding to that customer order.




Photo eye and receptor sets


378


output a stack status signal to the main controller


58


to provide information on the status of stacking operations in the stacker assembly


316


. When a full stack is present, the stack status signal alerts the main controller


58


. If accidentally blocked, the photo eye and receptor sets


378


may also provide a stop signal to the main controller


58


to stop sorting operations in the stacker assembly


316


because, for example, an operator has a body part in the product chute


318


.




An indicator (not shown) for each stacker assembly


316


alerts an operator when the stacker assembly


316


requires attention. When a product stack in the stacker assembly


316


is completed, the main controller


58


will stop sending products to the stacker assembly


316


and will output a full stack signal to the indicator so that the operator will empty the full stack from the stacker assembly


316


. When the full stack indicator is activated, scanning of the appropriate box B by the operator will cause the stacker assembly


316


to automatically move to an unloading position. The stacker controller


376


will cause the stack plate


352


to drop further, allowing the operator to access the full stack. The operator will then remove the full stack as is most convenient. As products are removed from the top of the full stack, the stacker controller


376


will cause the stack plate


352


to rise to provide a consistent top of the product stack elevation to ease unloading for the operator.




As shown in

FIGS. 21-22

, a box holder


380


is positioned with each customer order product collection location


312


or stacker set. A box B is supported on the box holder


380


and full product stacks are loaded into the box B by an operator. Completed boxes B are placed on a gravity feed roller conveyor


384


associated with each stacker set. The completed boxes B are pushed by the operator onto a completed box conveyor assembly


388


. The completed box conveyor assembly


388


is a powered roller conveyor which runs underneath the product collection locations


50


and which transports the completed box B from the product handling apparatus


30


.




As discussed above, non-conveyable products are collected and handled in another manner, such as manually, in which the non-conveyable products are identified, labeled and sorted into each individual customer order. After the conveyable products are handled by the product handling apparatus


30


, the sorted conveyable products and the sorted non-conveyable products may be collected and packaged together in an individual customer order.




Once the operator has emptied the stacker assembly


316


, the operator will depress a stacker switch (not shown) to provide an empty stacker signal to the main controller


58


. The main controller


58


will then reset the stacker assembly


316


and make the stacker assembly


316


available to again receive products. The stacker switch also allows the operator to take the stacker assembly


316


off-line. When a stacker assembly


316


is off-line, no products will be diverted to the stacker assembly


316


. To bring the stacker assembly


316


back on-line, the operator again depresses the switch, and products will again be diverted to the stacker assembly


316


.




If a product passes all of the customer order product collection locations


312


without being diverted, the product will be conveyed to an end-of-the-line product collection location


390


as shown in FIG.


1


. The end-of-the-line product collection location


390


includes a sort bin


304


, as described above. Products in the end-of-the-line product collection location


390


are collected by an operator and may be re-processed through the product handling apparatus


30


.




The main controller


58


includes a software program for controlling the product handling apparatus


30


. The main controller


58


includes (see

FIG. 1

) an information storage location


392


for receiving and storing wave information corresponding to customer orders. The main controller


58


also includes a control location


394


for receiving signals from and for outputting control signals to components of the product handling apparatus


30


.




As described above, the wave information is stored in the main controller


58


, and the wave session is initiated. As products are identified, the main controller


58


receives the associated identification signal from the bar code readers


210


corresponding to the bar code information on a product. The main controller


58


then conducts a look-up and compares the information in the identification signal with the wave information corresponding to the customer order information. Based on the identification signal and the customer order information, the main controller


58


outputs signals to the components of the product handling apparatus


30


to control the components to process the products.




For each product requiring a label, the main controller


58


outputs the label signal to the label controller


248


associated with a labeler assembly


218


. If the product requires a printed label, as indicated in the customer information, the label signal indicates this, and the label controller


248


controls the associated printer


226


.




The main controller


58


also outputs a balancing force signal to the balancing force controller for the balancing force applicator associated with the labeler assembly


218


. As the product is conveyed from the labeler assemblies


218


, the main controller


58


outputs a second balancing force signal to the second balancing force controller to control the second balancing force applicator to provide the second balancing force air flow.




The main controller


58


receives a label verification signal from the bar code reader


260


. The label verification signal indicates whether the proper label was properly applied to a product. The main controller


58


then outputs a divert signal. If the label verification signal indicated that the proper label was properly applied to a product, the product will be diverted into a customer order product collection location


312


assigned to the customer order. If the label verification signal indicated that the product was mislabeled, the main controller


58


will output a divert signal to divert the product to the no-read product collection location


298


.




When a stacker assembly


316


is full, the main controller


58


will receive a stacker full signal. The main controller


58


will output a stacker full indication signal to control the indicator. When the stacker assembly


316


is empty, the main controller


58


will receive the stacker empty signal and will reset the stacker assembly


316


, allowing products to again be diverted to the stacker assembly


316


.




The main controller


58


thus electronically communicates with and controls the components of the product handling apparatus


30


.




Various features of the invention are set forth in the following claims.



Claims
  • 1. A feeder assembly for use in a product handling apparatus for handling multiple products, each product having opposite faces and a bottom edge, a top edge, a leading edge and a trailing edge, said feeder assembly comprising:a feed conveyor assembly including a feed conveyor belt for supporting products in face-to-face relation in a feed stack having a first end and a second end, said feed conveyor belt being engageable with the bottom edge of each product in the feed stack to support the products, said feed conveyor belt feeding products in a feed direction toward the first end of the feed stack; and a strip-off conveyor assembly including a strip-off conveyor belt having a strip-off direction substantially perpendicular to the feed direction, said strip-off conveyor belt having a belt surface and a plurality of cleat members spaced apart in the strip-off direction and extending from said belt surface, said belt surface being generally coplanar with one face of the product at the first end of the feed stack, said belt surface being positioned to engage a portion of the one face of the product at the first end of the feed stack and one of said plurality of cleat members being engageable with the trailing edge of the product to strip the product at the first end of the feed stack from the feed stack.
  • 2. The feeder assembly as set forth in claim 1 wherein said strip-off conveyor assembly further includes a support member extending substantially parallel to said strip-off conveyor belt and having a smooth, low-friction support surface engageable with the bottom edge of the product to support the product.
  • 3. The feeder assembly as set forth in claim 1 wherein said strip-off conveyor assembly supports the product in a conveying position in which the one face of the product is in a non-horizontal and non-vertical orientation.
  • 4. The feeder assembly as set forth in claim 3 wherein said strip-off conveyor assembly supports the product in a conveying position in which the one face of the product is angled at least 70° from a horizontal plane.
  • 5. The feeder assembly as set forth in claim 1 wherein each product has a width extending in the feed direction, and wherein said feeder assembly further comprises a back pressure assembly for controlling strip-off of products from the feed conveyor assembly, said back pressure assembly including a back pressure door engageable with the leading edge of products in the feed stack and selectively positionable relative to said strip-off conveyor belt to define a space smaller than the width of more than one product.
  • 6. The feeder assembly as set forth in claim 1 and further comprising a hold-off plate movable into engagement with products in the feed stack to selectively maintain the products in the feed stack in spaced relation from said strip-off conveyor assembly.
  • 7. The feeder assembly as set forth in claim 1 wherein each product has a height along the trailing edge, and wherein said one of said plurality of cleat members engages the trailing edge of the product at a distance from the bottom edge of the product to prevent the product from tipping.
  • 8. The feeder assembly as set forth in claim 3 wherein said strip-off conveyor assembly supports the product in the conveying position in which the one face of the product is angled at least about 20° from a vertical plane.
  • 9. A feeder assembly for use in a product handling apparatus for handling multiple products, each product having opposite faces and a bottom edge, a top edge, a leading edge and a trailing edge, said feeder assembly comprising:a feed conveyor assembly including a feed conveyor belt for supporting products in face-to-face relation in a feed stack having a first end and a second end, said feed conveyor belt being engageable with the bottom edge of each product in the feed stack to support the products, said feed conveyor belt feeding products in a feed direction toward the first end of the feed stack; and a strip-off conveyor assembly including a strip-off conveyor belt having a strip-off direction substantially perpendicular to the feed direction, said strip-off conveyor belt having a belt surface and a plurality of cleat members spaced apart in the strip-off direction and extending from said belt surface, said belt surface being generally coplanar with one face of the product at the first end of the feed stack, said belt surface being positioned to engage a portion of the one face of the product at the first end of the feed stack and one of said plurality of cleat members being engageable with the trailing edge of the product to strip the product at the first end of the feed stack from the feed stack; wherein each product has a width extending in the feed direction, and wherein said feeder assembly further comprises a back pressure assembly for controlling strip-off of products from the feed conveyor assembly, said back pressure assembly including a back pressure door engageable with the leading edge of products in the feed stack and selectively positionable relative to said strip-off conveyor belt to define a space smaller than the width of more than one product; wherein each of a plurality of first products has a first width and each of a plurality of second products has a second width, the first width and the second width being different, and wherein said back pressure door is selectively positionable in a first back pressure position, to define a space smaller than the width of more than one first product to control strip-off of first products from said feed conveyor assembly, and in a second back pressure position, to define a space smaller than the width of more than one second product to control strip-off of second products from said feed conveyor assembly.
  • 10. A diverter assembly for diverting products from a conveyor assembly, each product having opposite faces and a bottom edge, the conveyor assembly including a lower member engageable with the bottom edge of each product to support the product, the conveyor assembly supporting the products in a conveying position in which one face of each product is in a non-horizontal orientation, the conveyor assembly conveying the products in a conveying direction, each product having a direction of movement, said diverter assembly comprising:a diverter mechanism supported adjacent the conveyor assembly and operable to redirect the direction of movement of products from the conveying direction, said diverter mechanism including an air knife selectively producing an air flow against one face of a product to divert the product from the conveying direction; wherein a first product has a first product configuration and a second product has a second product configuration, the first product configuration and the second product configuration being different, and wherein said diverter assembly further comprises a controller for controlling said air knife to selectively produce a first air flow to divert the first product and a second air flow to divert the second product, said first air flow and said second air flow being different.
  • 11. The diverter assembly as set forth in claim 10 wherein the controller controls said air knife to produce said air flow to divert a first product and to not produce said air flow to not divert a third product.
  • 12. A diverter assembly for diverting products from a conveyor assembly, each product having opposite faces and a bottom edge, the conveyor assembly including a lower member engageable with the bottom edge of each product to support the product, the conveyor assembly supporting the products in a conveying position in which one face of each product is in a non-horizontal orientation, the conveyor assembly conveying the products in a conveying direction, each product having a direction of movement, said diverter assembly comprising:a diverter mechanism supported adjacent the conveyor assembly and operable to redirect the direction of movement of products from the conveying direction, said diverter mechanism including an air knife selectively producing an air flow against one face of a product to divert the product from the conveying direction; wherein a first product has a first product configuration and a second product has a second product configuration, the first product configuration and the second product configuration being different, wherein said diverter mechanism further includes means for varying said air flow so that said air knife selectively produces a first air flow to divert the first product and a second air flow to divert the second product, said first air flow and said second air flow being different.
  • 13. A stacker assembly for stacking products, each product having opposite faces and a bottom edge, the products being conveyed to said stacker assembly by a conveyor assembly, the conveyor assembly including a lower member engageable with the bottom edge of each product to support the product, the conveyor assembly supporting the products in a conveying position in which one face of each product is in a non-horizontal orientation, said stacker assembly comprising:a product collection housing in which products are collected; and a diverter assembly for selectively diverting a product from the conveyor assembly, said diverter assembly including a diverter mechanism supported adjacent the conveyor assembly, said diverter mechanism including an air knife selectively producing an air flow against one face of a product to divert the product from the conveyor assembly and into said product collection housing; wherein a first product has a first product configuration and a second product has a second product configuration, the first product configuration and the second product configuration being different, and wherein said diverter assembly further comprises a controller for controlling said air knife to selectively produce a first air flow to divert the first product and a second air flow to divert the second product, said first air flow and said second air flow being different.
  • 14. The stacker assembly as set forth in claim 13 wherein the controller controls said air knife to produce said air flow to divert a first product and to not produce said air flow to not divert a third product.
  • 15. A stacker assembly for stacking products, each product having opposite faces and a bottom edge, the products being conveyed to said stacker assembly by a conveyor assembly, the conveyor assembly including a lower member engageable with the bottom edge of each product to support the product, the conveyor assembly supporting the products in a conveying position in which one face of each product is in a non-horizontal orientation, said stacker assembly comprising:a product collection housing in which products are collected; and a diverter assembly for selectively diverting a product from the conveyor assembly, said diverter assembly including a diverter mechanism supported adjacent the conveyor assembly, said diverter mechanism including an air knife selectively producing an air flow against one face of a product to divert the product from the conveyor assembly and into said product collection housing; wherein a first product has a first product configuration and a second product has a second product configuration, the first product configuration and the second product configuration being different, wherein said diverter mechanism further includes means for varying said air flow so that said air knife selectively produces a first air flow to divert the first product and a second air flow to divert the second product, said first air flow and said second air flow being different.
  • 16. A stacker assembly for stacking products, each product having opposite faces and a bottom edge, the products being conveyed to said stacker assembly by a conveyor assembly, the conveyor assembly including a lower member engageable with the bottom edge of each product to support the product, the conveyor assembly supporting the products in a conveying position in which one face of each product is in a non-horizontal orientation, said stacker assembly comprising:a product collection housing in which products are collected; a diverter assembly for selectively diverting a product from the conveyor assembly, said diverter assembly including a diverter mechanism supported adjacent the conveyor assembly, said diverter mechanism including an air knife selectively producing an air flow against one face of a product to divert the product from the conveyor assembly and into said product collection housing; wherein said product collection housing defines an aperture through which products are moved from the conveyor assembly into said product collection housing; wherein said stacker assembly further comprises a throat member defining a portion of said aperture; wherein a first product has a first product configuration and a second product has a second product configuration, the first product configuration and the second product configuration being different, and wherein said throat member is selectively movable relative to the product collection housing to define a first size of said aperture so that a first product is divertable through said aperture and a second size of said aperture so that a second product is divertable through said aperture.
  • 17. A stacker assembly for stacking products, each product having opposite faces and a bottom edge, the products being conveyed to said stacker assembly by a conveyor assembly, the conveyor assembly including a lower member engageable with the bottom edge of each product to support the product, the conveyor assembly supporting the products in a conveying position in which one face of each product is in a non-horizontal orientation, said stacker assembly comprising:a product collection housing in which products are collected; a diverter assembly for selectively diverting a product from the conveyor assembly, said diverter assembly including a diverter mechanism supported adjacent the conveyor assembly, said diverter mechanism including an air knife selectively producing an air flow against one face of a product to divert the product from the conveyor assembly and into said product collection housing; a product guide positioned relative to the conveyor assembly to define a portion of a product chute; and a stack plate providing a bottom wall in said product collection housing and onto which products are stacked, wherein a product diverted from the conveyor assembly travels through said product chute and is stacked on said stack plate in a flat orientation relative to said stack plate; wherein said product chute has a size, and wherein said product guide is movable to change the size of said product chute.
  • 18. A stacker assembly for stacking products, each product having opposite faces and a bottom edge, the products being conveyed to said stacker assembly by a conveyor assembly, the conveyor assembly including a lower member engageable with the bottom edge of each product to support the product, the conveyor assembly supporting the products in a conveying position in which one face of each product is in a non-horizontal orientation, said stacker assembly comprising:a product collection housing in which products are collected; and a diverter assembly for selectively diverting a product from the conveyor assembly, said diverter assembly including a diverter mechanism supported adjacent the conveyor assembly, said diverter mechanism including an air knife selectively producing an air flow against one face of a product to divert the product from the conveyor assembly and into said product collection housing; wherein a first product has a first product configuration and a second product has a second product configuration, the first product configuration and the second product configuration being different, and wherein said stacker assembly further comprises: a first product guide movably positioned relative to the conveyor assembly to define a product chute having a first size; a second product guide movably positioned relative to the conveyor assembly to define a product chute having a second size; and a stack plate providing a bottom wall in said product collection housing and onto which products are stacked; wherein, when a first product is to be diverted into said product collection housing, said first product guide is positioned to define said first size so that a first product travels through said product chute and is stacked on said stack plate in a flat orientation relative to said stack plate, and wherein, when a second product is to be diverted into said product collection housing, said second product guide is positioned to define said second size so that a second product travels through said product chute and is stacked on said stack plate in a flat orientation relative to said stack plate.
  • 19. A stacker assembly for stacking products, each product having opposite faces and a bottom edge, the products being conveyed to said stacker assembly by a conveyor assembly, the conveyor assembly including a lower member engageable with the bottom edge of each product to support the product, the conveyor assembly supporting the products in a conveying position in which one face of each product is in a non-horizontal orientation, said stacker assembly comprising:a product collection housing in which products are collected; and a diverter assembly for selectively diverting a product from the conveyor assembly, said diverter assembly including a diverter mechanism supported adjacent the conveyor assembly, said diverter mechanism including an air knife selectively producing an air flow against one face of a product to divert the product from the conveyor assembly and into said product collection housing; wherein each product further has a top edge, a leading edge and a trailing edge, and wherein said stacker assembly further comprises a front plate positioned relative to said product collection housing to define a portion of a product chute, wherein a product diverted from the conveyor assembly travels through said product chute and is stacked on said stack plate in a flat orientation relative to said stack plate, and wherein said front plate is engageable with one edge of the product as the product is stacked on said stack plate; wherein said product chute has a size, and wherein said front plate is movable to change the size of said product chute.
  • 20. A stacker assembly for stacking products, each product having opposite faces and a bottom edge, the products being conveyed to said stacker assembly by a conveyor assembly, the conveyor assembly including a lower member engageable with the bottom edge of each product to support the product, the conveyor assembly supporting the products in a conveying position in which one face of each product is in a non-horizontal orientation, said stacker assembly comprising:a product collection housing in which products are collected; and a diverter assembly for selectively diverting a product from the conveyor assembly, said diverter assembly including a diverter mechanism supported adjacent the conveyor assembly, said diverter mechanism including an air knife selectively producing an air flow against one face of a product to divert the product from the conveyor assembly and into said product collection housing; wherein each product further has a top edge, a leading edge and a trailing edge, and wherein said stacker assembly further comprises a front plate positioned relative to said product collection housing to define a portion of a product chute, wherein a product diverted from the conveyor assembly travels through said product chute and is stacked on said stack plate in a flat orientation relative to said stack plate, and wherein said front plate is engageable with one edge of the product as the product is stacked on said stack plate; wherein a first product has a first product configuration and a second product has a second product configuration, the first product configuration and the second product configuration being different, and wherein said stacker assembly further comprises: a first front plate movably positioned relative to the conveyor assembly to define a product chute having a first size; a second front plate movably positioned relative to the conveyor assembly to define a product chute having a second size; and a stack plate providing a bottom wall in said product collection housing and onto which products are stacked; wherein, when a first product is to be diverted into said product collection housing, said first front plate is positioned to define said first size so that a first product travels through said product chute and is stacked on said stack plate in a flat orientation relative to said stack plate, said first front plate being engageable with one edge of the first product as the first product is stacked on said stack plate, and wherein, when a second product is to be diverted into said product collection housing, said second front plate is positioned to define said second size so that a second product travels through said product chute and is stacked on said stack plate in a flat orientation relative to said stack plate, said second front plate is engageable with one edge of the second product as the second product is stacked on said stack plate.
  • 21. A stacker assembly for stacking products, each product having opposite faces and a bottom edge, the products being conveyed to said stacker assembly by a conveyor assembly, the conveyor assembly including a lower member engageable with the bottom edge of each product to support the product, the conveyor assembly supporting the products in a conveying position in which one face of each product is in a non-horizontal orientation, said stacker assembly comprising:a product collection housing in which products are collected; and a diverter assembly for selectively diverting a product from the conveyor assembly, said diverter assembly including a diverter mechanism supported adjacent the conveyor assembly, said diverter mechanism including an air knife selectively producing an air flow against one face of a product to divert the product from the conveyor assembly and into said product collection housing; wherein said product collection housing defines a housing axis, and wherein said stacker assembly further comprises a stack plate providing a bottom wall in said product housing and onto which products are stacked, said stack plate being movable relative to said product collection housing along said housing axis.
  • 22. The stacker assembly as set forth in claim 21 wherein said product collection housing defines a portion of a product chute, wherein, before a product is stacked on said stack plate, said stack plate defines an initial length of said product chute, wherein, as products are stacked on said stack plate, an uppermost product defines a subsequent length of said product chute, and wherein, as products are stacked on said stack plate, said stack plate is movable so that said subsequent length remains substantially the same as said initial length.
  • 23. The stacker assembly as set forth in claim 21 and further comprising a cylinder assembly for moving said stack plate, said cylinder assembly including a cylinder and a piston movably housed in said cylinder, one of said piston and said cylinder being connected to said stack plate so that said stack plate is movable relative to said product collection housing.
  • 24. The stacker assembly as set forth in claim 23 wherein said cylinder assembly includes a first port and a second port, wherein fluid is selectively supplied to one of said first port and said second port to move said piston relative to said cylinder, and wherein said stacker assembly further comprises a stack plate valve operable to selectively control fluid flow to said one of said first port and said second port to control movement of said stack plate.
  • 25. A product sorting apparatus for sorting products, each product having opposite faces and a bottom edge, the products being conveyed to said product sorting apparatus by a conveyor assembly, the conveyor assembly including a lower member engageable with the bottom edge of each product to support the product, the conveyor assembly supporting the products in a conveying position in which one face of each product is in a non-horizontal orientation, said product sorting apparatus comprising:a first product collection assembly including a first product collection housing in which products are collected, and a first diverter assembly for selectively diverting a product into said first product collection housing, said first diverter assembly including a diverter mechanism supported adjacent the conveyor assembly, said diverter mechanism including an air knife selectively producing an air flow against one face of a product to divert the product from the conveyor assembly and into said first product collection housing; and a second product collection assembly including a second product collection housing in which products are collected, and a second diverter assembly for selectively diverting a product into said second product collection housing, said second diverter assembly including a second diverter mechanism supported adjacent the conveyor assembly and being operable to divert a product from the conveyor assembly and into said second product collection housing; wherein said first product collection assembly is a stacker assembly including a product collection housing defining a housing axis, and a stack plate providing a bottom wall in said product collection housing, said stack plate being movable relative to said product collection housing along said housing axis.
  • 26. The product handling apparatus as set forth in claim 25 wherein said second product collection assembly is a product sort bin including a product collection housing including spaced apart side walls, a bottom wall and a movable front wall cooperating to define a product collection compartment.
  • 27. The product handling apparatus as set forth in claim 25 wherein said second product collection assembly is a second stacker assembly includinga second product collection housing defining a second housing axis, and a second stack plate providing a bottom wall in said second product collection housing, said second stack plate being movable relative to said second product collection housing along said second housing axis.
  • 28. The product handling apparatus as set forth in claim 27 and further comprising a third product collection assembly includinga third product collection housing in which products are collected, said third product collection housing including spaced apart side walls, a bottom wall and a movable front wall cooperating to define a product collection compartment, and a third diverter assembly for selectively diverting a product into said third product collection housing, said third diverter assembly including a third diverter mechanism supported adjacent the conveyor assembly and being operable to divert a product from the conveyor assembly and into said third product collection housing.
  • 29. The product handling apparatus as set forth in claim 25 and further comprising a controller for controlling said first diverter mechanism and said second diverter mechanism to selectively and alternatively divert products into said first product collection housing and said second product collection housing, respectively.
  • 30. A conveyor assembly for conveying products in a product handling apparatus, each product having opposite faces and a bottom edge, a top edge, a leading edge and a trailing edge, said conveyor assembly defining a conveyor axis, said conveyor assembly comprising:a first conveyor belt for supporting and conveying a product through a first portion of the product handling apparatus, said first conveyor belt having a first belt surface and a plurality of first cleat members spaced apart along said conveyor axis and extending from said first belt surface, said first belt surface being engageable with the bottom edge of the product to support the product and one of said plurality of first cleat members being engageable with the trailing edge of the product; a first drive sprocket drivingly engaging said first conveyor belt; a second conveyor belt for supporting and conveying the product through a second portion of the product handling apparatus, said second conveyor belt having a second belt surface and a plurality of second cleat members spaced apart along said conveyor axis and extending from said second belt surface, said second belt surface being engageable with the bottom edge of the product to support the product and one of said plurality of second cleat members being engageable with the trailing edge of the product; a second drive sprocket drivingly engaging said second conveyor belt; and a drive motor having a rotatable drive shaft drivingly engaging said first drive sprocket and said second drive sprocket; wherein, as said drive shaft drives said first drive sprocket and said second drive sprocket, said first conveyor belt and said second conveyor belt are moved so that said plurality of first cleat members and said plurality of second cleat members are respectively moved, and wherein movement of said plurality of first cleat members and said plurality of second cleat members is initially synchronized so that said second conveyor belt receives the product from said first conveyor belt.
  • 31. The conveyor assembly as set forth in claim 30 and further comprising:a first support member extending substantially parallel to said first conveyor belt and having a smooth, low friction first support surface engageable with one face of the product to support the product in a conveying position in which the one face is in a non-horizontal orientation; and a second support member extending substantially parallel to said second conveyor belt and having a smooth, low friction second support surface engaging the one face of the product to support the product in the conveying position in which the one face is in the non-horizontal orientation.
  • 32. The conveyor assembly as set forth in claim 30 wherein said conveyor assembly supports the product in the conveying position in which the one face of the product is angled at least 70° from a horizontal plane and is in a non-vertical orientation.
  • 33. The conveyor assembly as set forth in claim 30 wherein said first conveyor belt is offset from said second conveyor belt relative to said conveyor axis, and wherein said conveyor assembly further comprises an angled guide member having a smooth, low friction guide surface engageable with one face of the product to support the product in a conveying position in which the one face is in a non-horizontal orientation and to guide the product from said first conveyor belt to said second conveyor belt.
  • 34. The conveyor assembly as set forth in claim 32 wherein said conveyor assembly supports the product in the conveying position in which the one face of the product is angled at least about 20° from a vertical plane.
  • 35. A conveyor assembly for conveying products in a product handling apparatus, each product having opposite faces and a bottom edge, a top edge, a leading edge and a trailing edge, said conveyor assembly defining a conveyor axis, said conveyor assembly comprising:a first conveyor belt for supporting and conveying a product through a first portion of the product handling apparatus, said first conveyor belt having a first belt surface and a plurality of first cleat members spaced apart along said conveyor axis and extending from said first belt surface, said first belt surface being engageable with the bottom edge of the product to support the product and one of said plurality of first cleat members being engageable with the trailing edge of the product; a first drive sprocket drivingly engaging said first conveyor belt; a second conveyor belt for supporting and conveying the product through a second portion of the product handling apparatus, said second conveyor belt having a second belt surface and a plurality of second cleat members spaced apart along said conveyor axis and extending from said second belt surface, said second belt surface being engageable with the bottom edge of the product to support the product and one of said plurality of second cleat members being engageable with the trailing edge of the product; a second drive sprocket drivingly engaging said second conveyor belt; a drive motor having a rotatable drive shaft drivingly engaging said first drive sprocket and said second drive sprocket; a first support member extending substantially parallel to said first conveyor belt and having a smooth, low friction first support surface engageable with one face of the product to support the product in a conveying position in which the one face is in a non-horizontal orientation; a second support member extending substantially parallel to said second conveyor belt and having a smooth, low friction second support surface engaging the one face of the product to support the product in the conveying position in which the one face is in the non-horizontal orientation; wherein, as said drive shaft drives said first drive sprocket and said second drive sprocket, said first conveyor belt and said second conveyor belt are moved so that said plurality of first cleat members and said plurality of second cleat members are respectively moved, and wherein movement of said plurality of first cleat members and said plurality of second cleat members is initially synchronized so that said second conveyor belt receives the product from said first conveyor belt; wherein said first conveyor belt and said second conveyor belt convey products in a first conveying direction, and wherein said conveyor assembly further comprises: a third conveyor belt for supporting and conveying the product through a third portion of the product handling apparatus in a second conveying direction, said second conveying direction being opposite to said first conveying direction, said third conveyor belt having a third belt surface and a plurality of third cleat members spaced apart along said conveyor axis and extending from said third belt surface, said third belt surface being engageable with the bottom edge of the product to support the product and one of said plurality of third cleat members being engageable with the trailing edge of the product; and a turning guide assembly supported to receive products from said second conveyor belt and said second support member in said first conveying direction and in the conveying position in which the one face is in the non-horizontal orientation and to transfer the products to said third conveyor belt in said second conveying direction and in the conveying position in which the one face is in the non-horizontal orientation, said turning guide including an upper turning guide support member having a smooth, low friction upper support surface engaging the one face of the product to support the product in the conveying position in which the one face is in the non-horizontal orientation, and a lower turning guide member engaging the bottom edge of the product to support the product.
  • 36. A conveyor assembly for conveying products in a product handling apparatus, each product having opposite faces and a bottom edge, a top edge, a leading edge and a trailing edge, said conveyor assembly defining a conveyor axis, said conveyor assembly comprising:a first conveyor belt for supporting and conveying a product through a first portion of the product handling apparatus, said first conveyor belt having a first belt surface and a plurality of first cleat members spaced apart along said conveyor axis and extending from said first belt surface, said first belt surface being engageable with the bottom edge of the product to support the product and one of said plurality of first cleat members being engageable with the trailing edge of the product; a first drive sprocket drivingly engaging said first conveyor belt; a second conveyor belt for supporting and conveying the product through a second portion of the product handling apparatus, said second conveyor belt having a second belt surface and a plurality of second cleat members spaced apart along said conveyor axis and extending from said second belt surface, said second belt surface being engageable with the bottom edge of the product to support the product and one of said plurality of second cleat members being engageable with the trailing edge of the product; a second drive sprocket drivingly engaging said second conveyor belt; a drive motor having a rotatable drive shaft drivingly engaging said first drive sprocket and said second drive sprocket; wherein, as said drive shaft drives said first drive sprocket and said second drive sprocket, said first conveyor belt and said second conveyor belt are moved so that said plurality of first cleat members and said plurality of second cleat members are respectively moved, and wherein movement of said plurality of first cleat members and said plurality of second cleat members is initially synchronized so that said second conveyor belt receives the product from said first conveyor belt; an upper support member extending substantially parallel to said first conveyor belt and having a smooth, low friction upper support surface engageable with one face of the product to support the product in a conveying position in which the one face is in a non-horizontal orientation; and a strip-off conveyor assembly including a strip-off conveyor belt oriented substantially parallel to said first conveyor belt, said strip-off conveyor belt having a strip-off belt surface and a plurality of strip-off cleat members spaced apart along said conveyor axis and extending from said belt surface, said belt surface being engageable with a portion of one face of a product and one of said plurality of cleat members being engageable with the trailing edge of the product to strip the product from a feeder assembly, said belt surface of said strip-off conveyor being substantially coplanar with said support member, a strip-off drive sprocket drivingly engaging said strip-off conveyor belt, a strip-off drive motor including a strip-off drive shaft drivingly engaging said strip-off drive sprocket, and a lower support member extending substantially parallel to said strip-off conveyor belt and having a smooth, low-friction lower support surface engageable with the bottom edge of the product to support the product, said lower support surface being substantially coplanar with said first belt surface, wherein, as said drive shaft drives said first drive sprocket, said first conveyor belt is moved so that said plurality of first cleat members is moved, wherein, as said strip-off drive shaft drives said strip-off drive sprocket, said strip-off conveyor belt is moved so that said plurality of strip-off cleat members is moved, and wherein movement of said plurality of first cleat members and said plurality of strip-off cleat members is synchronized so that said first conveyor belt receives the product from said strip-off conveyor assembly.
  • 37. A conveyor assembly for conveying products in a product handling apparatus, each product having opposite faces and a bottom edge, a top edge, a leading edge and a trailing edge, said conveyor assembly defining a conveyor axis, said conveyor assembly comprising:a conveyor belt for supporting and conveying a product through the product handling apparatus, said conveyor belt having a belt surface and a plurality of cleat members spaced apart along said conveyor axis and extending from said belt surface, said belt surface being engageable with the bottom edge of the product to support the product and one of said plurality of cleat members being engageable with the trailing edge of the product; and a support member extending substantially parallel to said conveyor belt and having a smooth, low friction support surface engageable with one face of the product to support the product in a conveying position in which the one face is in a non-horizontal and non-vertical orientation.
  • 38. A product handling apparatus for handling products, each product having opposite faces and a bottom edge, a top edge, a leading edge and a trailing edge, said product handling apparatus comprising:a feeder assembly for feeding products into said product handling apparatus, said feeder assembly including a feed conveyor assembly including a feed conveyor belt for supporting products in face-to-face relation in a feed stack having a first end and a second end, said feed conveyor belt being engageable with the bottom edge of each product in the feed stack to support the products, said feed conveyor belt feeding products in a feed direction toward the first end of the feed stack, and a strip-off conveyor assembly including a strip-off conveyor belt having a strip-off direction substantially perpendicular to the feed direction, said strip-off conveyor belt having a strip-off belt surface and a plurality of strip-off cleat members spaced apart in the strip-off direction and extending from said strip-off belt surface, said strip-off belt surface being generally coplanar with one face of the product at the first end of the feed stack, said strip-off belt surface being positioned to engage a portion of the one face of the product at the first end of the feed stack and one of said plurality of strip-off cleat members being engageable with the trailing edge of the product to strip the product at the first end of the feed stack from the feed stack, said strip-off conveyor belt supporting the product in a conveying position in which the one face is in a non-horizontal orientation, a strip-off drive sprocket drivingly engaging said strip-off conveyor belt, a strip-off drive motor including a strip-off drive shaft drivingly engaging said strip-off drive sprocket, and a lower support member extending substantially parallel to said strip-off conveyor belt and having a smooth, low-friction lower support surface engageable with the bottom edge of the product to support the product; a conveyor assembly for conveying products through said product handling apparatus, said conveyor assembly having a conveyor axis, said conveyor assembly including a first conveyor belt for supporting and conveying a product through a first portion of the product handling apparatus, said first conveyor belt having a first belt surface and a plurality of first cleat members spaced apart along the conveyor axis and extending from said first belt surface, said first belt surface being engageable with the bottom edge of the product to support the product and one of said plurality of first cleat members being engageable with the trailing edge of the product, first belt surface being substantially coplanar with said lower support surface, a first drive sprocket drivingly engaging said first conveyor belt, a first support member extending substantially parallel to said first conveyor belt and having a smooth, low friction first support surface engageable with the one face of the product to support the product in the conveying position in which the one face is in the non-horizontal orientation, said first support surface being substantially coplanar with said strip-off belt surface, a second conveyor belt for supporting and conveying the product through a second portion of the product handling apparatus, said second conveyor belt having a second belt surface and a plurality of second cleat members spaced apart along the conveyor axis and extending from said second belt surface, said second belt surface being engageable with the bottom edge of the product to support the product and one of said plurality of second cleat members being engageable with the trailing edge of the product, a second drive sprocket drivingly engaging said second conveyor belt, a second support member extending substantially parallel to said second conveyor belt and having a smooth, low friction second support surface engaging the one face of the product to support the product in the conveying position in which the one face is in the non-horizontal orientation, and a drive motor having a rotatable drive shaft drivingly engaging said first drive sprocket and said second drive sprocket, wherein, as said drive shaft drives said first drive sprocket and said second drive sprocket, said first conveyor belt and said second conveyor belt are moved so that said plurality of first cleat members and said plurality of second cleat members are respectively moved, wherein movement of said plurality of first cleat members and said plurality of second cleat members is initially synchronized so that said second conveyor belt receives the product from said first conveyor belt, wherein, as said strip-off drive shaft drives said strip-off drive sprocket, said strip-off conveyor belt is moved so that said plurality of strip-off cleat members is moved, and wherein movement of said plurality of first cleat members and said plurality of strip-off cleat members is synchronized so that said first conveyor belt receives the product from said strip-off conveyor assembly; a labeler assembly for applying a label to a product on said conveyor assembly, said labeler assembly including a label applicator supported adjacent said conveyor assembly and for applying the label with an application force to the one face of the product, a first balancing force applicator supported adjacent said conveyor assembly and for applying a first balancing force to the product to balance the application force and to maintain the product on said conveyor assembly, a pressure applicator supported adjacent said conveyor assembly and downstream of said label applicator, said pressure applicator applying a fixing pressure to the label on the product, and a second balancing force applicator supported adjacent said conveyor assembly and for applying a second balancing force to the product to balance the fixing pressure and to maintain the product on said conveyor assembly; and a product sorting apparatus for sorting products on said conveyor assembly, said product sorting apparatus including a first product collection assembly including a first product collection housing supported adjacent said conveyor assembly and in which products are collected, and first diverter assembly for selectively diverting a product into said first product collection housing, said first diverter assembly including a diverter mechanism supported adjacent said conveyor assembly, said diverter mechanism including an air knife selectively producing an air flow against the one face of a product to divert the product from said conveyor assembly and into said first product collection housing; and a second product collection assembly including a second product collection housing supported adjacent said conveyor assembly and in which products are collected, and a second diverter assembly for selectively diverting a product into said second product collection housing, said second diverter assembly including a second diverter mechanism supported adjacent said conveyor assembly and being operable to divert a product from said conveyor assembly and into said second product collection housing.
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Entry
Hydraulic and Pneumatic Check and Relief Check Valves, Kepner Products Company, 995 N. Ellsworth Ave, Villa Park, IL 60181.