Integrated control card for conveying systems

1. A motorized roller integrated control card for use with a material handling system having a conveying surface and a plurality of motorized rollers, said conveying surface defining a plurality of individually controlled zones, at least one of the said motorized rollers propelling said conveying surface at each of said zones, each of said motorized rollers rotating in response to a command signal supplied to that motorized roller and including at least one rotation sensor that produces a rotation signal in response to rotation of that motorized roller, said integrated control card comprising:

a plurality of motor controller circuits each adapted to control one of said motorized rollers;

an upper level control circuit in communication with said plurality of motor controller circuits, said upper level control circuit adapted to communicate with said motor controller circuits for controlling said motorized rollers; and

a circuit board, wherein said upper level control circuit and said plurality of motor controller circuits are commonly mounted on said circuit board;

wherein each of said motor controller circuits is adapted to respond to the rotation signal of said one of said motorized rollers and to produce a command signal as a function of the rotation signal, wherein each of said motor controller circuits supplies the command signal to said one of said motorized rollers to rotate that motorized roller, wherein each of said motor controller circuits defines a voltage range and responds to a voltage level of the rotation signal that falls within the voltage range and wherein each of said motor controller circuits is adapted to produce electrical power at a plurality of different voltage levels and to supply electrical power to said one of the motorized rollers at one of the voltage levels, the one of the voltage levels being a function of said one of the motorized rollers connected with that one of said motor controller circuits.

2. The integrated control card of claim 1 wherein each of said motor controller circuits includes a closed loop circuit and a voltage comparator, said voltage comparator converting a rotation signal within the voltage range to another voltage level that is compatible with said closed loop circuit.

3. The integrated control card of claim 2 wherein said voltage range is between approximately 7 volts and approximately 8 volts.

4. The integrated control card of claim 1 wherein each of said motor controller circuits is adapted to respond to a rotation signal produced by a Hall-effect rotation sensor.

5. The integrated control card of claim 1 wherein said upper level control circuit is adapted to control the zones according to a plurality of different modes.

6. The integrated control card of claim 5 wherein said plurality of different modes includes (i) an accumulation mode, (ii) a merge mode, (iii) a divert mode (iv) a transfer mode and (v) a transport mode.

7. The integrated control card of claim 5 including a mode select switch that is adapted to select one of said plurality of modes.

8. The integrated control card of claim 1 including at least one input that is adapted to receive a sensor signal from a product sensor device.

9. The integrated control card of claim 1 wherein each said motor controller circuit is adapted to control the speed, the position, and the direction of the one of said motorized rollers as a function of said rotation signal.

10. A motorized roller integrated control card for use with a material handling system having a conveying surface and a plurality of motorized rollers, said conveying surface defining a plurality of individually controlled zones, at least one of the said motorized rollers propelling said conveying surface at each of said zones, each of said motorized rollers rotating in response to a command signal supplied to that motorized roller and including at least one rotation sensor that produces a rotation signal in response to rotation of that motorized roller, said integrated control card comprising:

a plurality of motor controller circuits, each adapted to control one of said motorized rollers;

an upper level control circuit in communication with said plurality of motor controller circuits, said upper level control circuit adapted to communicate with said motor controller circuits for controlling said motorized rollers; and

a circuit board, wherein said upper level control circuit and said plurality of motor controller circuits are commonly mounted on said circuit board;

wherein each of said motor controller circuits is adapted to respond to the rotation signal of said one of said motorized rollers and to produce a command signal as a function of the rotation signal, wherein each of said motor controller circuits supplies the command signal to said one of said motorized rollers to rotate that motorized roller; and

a motor connector conversion circuit that is adapted to connect one of said motor controller circuits with said one of said motorized rollers, said motor connector conversion circuit comprising a plurality of electrical connectors having different configurations and a plurality of different electrical interconnections between the one of said motor controller circuits and said electrical connectors, wherein the electrical interconnection between the one of said motor controller circuits and said one of said motorized rollers being a function of which of said electrical connectors is connected with said one of said motorized rollers.

11. The integrated control card of claim 10 wherein each of said motor controller circuits defines a voltage range and responds to a voltage level of the rotation signal that falls within the voltage range and wherein each of said motor controller circuits is adapted to produce electrical power at a plurality of different voltage levels and to supply electrical power to said one of the motorized rollers at one of the voltage levels, the one of the voltage levels being a function of said one of the motorized rollers connected with that one of said motor controller circuits.

12. The integrated control card of claim 11 wherein each of said motor controller circuits includes a closed loop circuit and a voltage comparator, said voltage comparator converting a rotation signal within the voltage range to another voltage level that is compatible with said closed loop circuit.

13. The integrated control card of claim 12 wherein said range is between approximately 7 volts and approximately 8 volts.

14. The integrated control card of claim 10 wherein each of said motor controller circuits is adapted to respond to a rotation signal produced by a Hall-effect rotation sensor.

15. The integrated control card of claim 10 wherein said upper level control circuit is adapted to control the zones according to a plurality of different modes.

16. The integrated control card of claim 15 wherein said plurality of different modes includes (i) an accumulation mode, (ii) a merge mode, (iii) a divert mode (iv) a transfer mode and (v) a transport mode.

17. The integrated control card of claim 15 including a mode select switch that is adapted to select one of said plurality of modes.

18. The integrated control card of claim 10 including at least one input that is adapted to receive a sensor signal from a product sensor device.

19. The integrated control card of claim 10 wherein each said motor controller circuit is adapted to control the speed, the position, and the direction of the one of said motorized rollers as a function of said rotation signal.

20. A material handling system, comprising a conveying surface and a plurality of motorized rollers, said conveying surface defining a plurality of individually controlled zones, at least one of the said motorized rollers propelling said conveying surface at each of said zones, each of said motorized rollers rotating in response to a command signal supplied to that motorized roller and including at least one rotation sensor that produces a rotation signal in response to rotation of that motorized roller; and

an integrated control card connected with said motorized rollers, said integrated control card comprising a plurality of motor controller circuits, each adapted to control one of said motorized rollers, an upper level control circuit in communication with said plurality of motor controller circuits for controlling said motorized rollers and a circuit board, wherein said upper level control circuit and said plurality of motor controller circuits are commonly mounted on said circuit board;

wherein each of said motor controller circuits is adapted to respond to the rotation signal of said one of said motorized rollers and to produce a command signal as a function of the rotation signal, wherein each of said motor controller circuits supplies the command signal to said one of said motorized rollers to rotate that motorized roller, wherein each of said motor controller circuits defines a voltage range and responds to a voltage level of the rotation signal that falls within the voltage range, and wherein each of said motor controller circuits is adapted to produce electrical power at a plurality of different voltage levels and to supply electrical power to said one of the motorized rollers at one of the voltage levels, the one of the voltage levels being a function of said one of the motorized rollers connected with that one of said motor controller circuits.

21. A material handling system, comprising a conveying surface and a plurality of motorized rollers, said conveying surface defining a plurality of individually controlled zones, at least one of the said motorized rollers propelling said conveying surface at each of said zones, each of said motorized rollers rotating in response to a command signal supplied to that motorized roller and including at least one rotation sensor that produces a rotation signal in response to rotation of that motorized roller; and

an integrated control card connected with said motorized rollers, said integrated control card comprising a plurality of motor controller circuits, each adapted to control one of said motorized rollers, an upper level control circuit in communication with said plurality of motor controller circuits for controlling said motorized rollers and a circuit board, wherein said upper level control circuit and said plurality of motor controller circuits are commonly mounted on said circuit board;

wherein each of said motor controller circuits is adapted to respond to the rotation signal of said one of said motorized rollers and to produce a command signal as a function of the rotation signal, wherein each of said motor controller circuits supplies the command signal to said one of said motorized rollers to rotate that motorized roller;

a motor connector conversion circuit operable for connecting each said motor controller circuit with said one of said motorized rollers, said motor connector conversion circuit comprising a plurality of electrical connectors having different configurations and a plurality of different electrical interconnections between one of said motor controller circuits and said electrical connectors, wherein the electrical interconnection between the one of said motor controller circuits and said one of said motorized rollers being a function of which of said electrical connectors is connected with said one of said motorized rollers.