Method and apparatus for tracking a load on a conveyor system

1. A method of tracking a load having a trailing edge and a leading edge, the load being conveyed on a conveyor system having a first sensor, said method comprising the steps of:

sensing only the trailing edge of the load with the first sensor;

updating a load record for the load in response to sensing only the trailing edge of the load with the first sensor; and

tracking the load throughout the conveyor system.

2. The method of claim 1 wherein said conveyor system includes a first conveyor segment and a second conveyor segment arranged relative to the first conveyor segment to transfer the load from the first conveyor segment to the second conveyor segment and wherein said conveyor system further includes a first data array associated with the first conveyor segment and a second data array associated with the second conveyor segment and wherein said step of updating the load record further includes the step of transferring the load record from the first data array to the second data array upon sensing the trailing edge of the load with the first sensor.

3. The method of claim 2 wherein said conveyor system further includes a source sensor and wherein said method further includes the step of generating a load record upon sensing the load with the source sensor before said step of updating the load record.

4. The method of claim 3 wherein said step of generating a load record upon sensing a load with the source sensor further includes the steps of:

sensing the trailing edge of the load with the source sensor; and

inputting the load record into the first data array.

5. The method of claim 2 wherein said conveyor system further includes a second sensor associated with the second conveyor segment, said method further including the steps of:

sensing the trailing edge of the load with the second sensor; and

removing the load record from the second data array upon sensing the trailing edge of the load with the second sensor.

6. The method of claim 5 wherein said conveyor system includes a third conveyor segment having an associated third data array, said method further comprising the step of adding the load record to the third data array after removing the load record from the second data array.

7. A method of tracking a load on a conveyor system and of controlling the conveyor system wherein the load includes a trailing edge and a leading edge and wherein the conveyor system includes a first conveyor segment and a source load sensor associated with the first conveyor segment, the load sensor being in communication with a controller, said method comprising the steps of:

sensing the trailing edge of the load with the source load sensor;

updating a load record in the controller only in response to sensing the trailing edge of the load;

generating a pulse signal having a number of pulses directly proportional to the travel of the load on the first conveyor segment; and

tracking the load on the first conveyor segment using the generated pulse signal and load record updated in response to sensing the trailing edge of the load.

8. The method of claim 7 further including the steps of:

sensing the leading edge of the load; and

controlling the operation of the individual conveyor segments using the leading edge of the load.

9. The method of claim 7 wherein said conveyor system includes a second conveyor segment and a first sensor associated with the first conveyor segment and wherein said step of updating a load record in the controller further includes the step of updating a distance field comprising the distance between the trailing edge of the load and the first sensor upon sensing the trailing edge of the load with the source sensor.

10. The method of claim 9 further including the step of reducing the distance field in response to each generated pulse.

11. The method of claim 8 wherein the conveyor system further includes a first sensor associated with the first conveyor segment, and a second conveyor segment, said method further comprising the steps of:

sensing the trailing edge of the load by the first sensor; and

updating a first data array associated with a first conveyor segment upon sensing the trailing edge.

12. The method of claim 9 further including the steps of:

sensing the leading edge of the load by the first sensor;

controlling the movement of the load on the first and second conveyor segments upon sensing the leading edge.

13. The method of claim 11 wherein said step of updating a first data array associated with the first conveyor segment further includes the step of transferring a load record in the first data array to a second data array associated with the second conveyor segment.

14. A conveyor system for tracking a load having a leading edge and a trailing edge, said system comprising:

a first conveyor segment;

a second conveyor segment arranged relative to said first conveyor segment to transfer the load from said first conveyor segment to said second conveyor segment;

a first sensor operatively associated with said first conveyor segment, said first sensor being configured to sense the trailing edge of the load;

a controller communicating with said first sensor, said controller configured to update and transfer load records from a first data array associated with said first conveyor segment to a second data array associated with said second conveyor segment only in response to said first sensor sensing the trailing edge of the load.

15. The conveyor system of claim 14 further including:

a source sensor in communication with the controller, said source sensor and said first sensor being located at opposing ends of said first conveyor segment, said controller generating a load record in said first data array upon said source sensor sensing the trailing edge of the load.

16. A method of tracking a load having a trailing edge and a leading edge, the load being conveyed on a conveyor system having a first sensor, said method comprising the steps of:

creating and storing information regarding the load in a load record of a controller;

sensing only the trailing edge of the load with the first sensor;

updating the load record for the load in response to sensing only the trailing edge of the load with the first sensor; and

tracking only the trailing edge of the load throughout the conveyor system by periodically updating the load record for the load in response to sensing only the trailing edge of the load.

17. The method of claim 16 wherein said conveyor system includes a first conveyor segment and a second conveyor segment arranged relative to the first conveyor segment to transfer the load from the first conveyor segment to the second conveyor segment and wherein said conveyor system further includes a first data array associated with the first conveyor segment and a second data array associated with the second conveyor segment and wherein said step of updating the load record further includes the step of transferring the load record from the first data array to the second data array upon sensing the trailing edge of the load with the first sensor.