Virtual lug loader

1. A lug loader for loading workpieces in a flow direction into the spaced apart lugs on a lugged conveyor wherein the workpieces are transversely oriented relative to the flow direction, the lug loader comprising:

an array of pairs of endless conveyors wherein each pair of endless conveyors in said array include first and second endless conveyors which are spaced laterally apart across said flow direction and each are substantially aligned in said flow direction,

and wherein said array forms a continuous upper surface in said flow direction for supporting a workpiece translating downstream in said flow direction, said each pair of endless conveyors in said array overlapping adjacent pairs of endless conveyors in said array in said flow direction,

wherein at least one of said each pair of endless conveyors in said array include independently actuable first and second drives independently driving corresponding said first and second endless conveyors respectively,

wherein, when the workpiece is skewed from its transverse orientation, said first or second drive corresponding to said at least one of said each pair of endless conveyors advances the upstream-most end of the workpiece relative to its downstream-most end to correct the workpiece to an un-skewed position oriented transversely to the flow direction.

2. The device of claim 1 wherein said array includes an upstream gapping section and a downstream lug loading section, wherein said at least one of said each pair of endless conveyors is within said lug loading section.

3. The device of claim 2 wherein said pairs of endless conveyors in said gapping section translate the workpiece in said flow direction at increasing downstream velocities between an upstream end of said gapping section and a downstream end of said gapping section.

4. The device of claim 3 wherein said increasing downstream velocities are successively increasing downstream velocities corresponding to successive said pairs of endless conveyors between said upstream and downstream ends of said gapping section.

5. The device of claim 3 wherein substantially half of all of said each of said first and second endless conveyors of said pairs of endless conveyors in said lug loading section have corresponding selectively actuable drives so that said each pair of endless conveyors in said lug loading section is asymmetrically actuable to drive one endless conveyor ahead of another endless conveyor in said each pair of endless conveyors in said lug loading section to correct skew of a workpiece on any one of those endless conveyors.

6. The device of claim 5 wherein said adjacent pairs of endless conveyors in said array overlap at adjacent ends thereof by one endless conveyor of said adjacent pairs being inset laterally across said flow direction relative to a corresponding second endless conveyor of said adjacent pairs.

7. A method for loading workpieces in a flow direction into the spaced apart lugs on a lugged conveyor wherein the workpieces are transversely oriented relative to the flow direction, and wherein the lug loader includes an array of pairs of endless conveyors wherein each pair of endless conveyors in said array include first and second endless conveyors which are spaced laterally apart across said flow direction and each are substantially aligned in said flow direction, and wherein said array forms a continuous upper surface in said flow direction for supporting the workpieces translating downstream in said flow direction, said each pair of endless conveyors in said array overlapping adjacent pairs of endless conveyors in said array in said flow direction, and wherein at least one of said each pair of endless conveyors in said array include independently actuable first and second drives independently driving corresponding said first and second endless conveyors respectively, the method comprising the steps of:

a) creating gaps between the workpieces by accelerating the workpieces as they are translated downstream on the array, and

b) when one or more of the workpieces are skewed from their transverse orientation, said first or second drives corresponding to said at least one of said each pair of endless conveyors advances the upstream-most end of a skewed workpiece relative to its downstream-most end to correct the skewed workpiece to an un-skewed position oriented transversely to the flow direction.

8. The method of claim 7 wherein said array includes an upstream gapping section and a downstream lug loading section, wherein said at least one of said each pair of endless conveyors is within said lug loading section.

9. The method of claim 7 wherein said pairs of endless conveyors in said gapping section translate the workpiece in said flow direction at increasing downstream velocities between an upstream end of said gapping section and a downstream end of said gapping section.

10. The method of claim 8 wherein said increasing downstream velocities are successively increasing downstream velocities corresponding to successive said pairs of endless conveyors between said upstream and downstream ends of said gapping section.

11. The method of claim 8 wherein substantially half of all of said each of said first and second endless conveyors of said pairs of endless conveyors in said lug loading section have corresponding selectively actuable drives so that said each pair of endless conveyors in said lug loading section is asymmetrically actuable to drive one endless conveyor ahead of another endless conveyor in said each pair of endless conveyors in said lug loading section to correct skew of a workpiece on any one of those endless conveyors.

12. The method of claim 11 wherein said adjacent pairs of endless conveyors in said array overlap at adjacent ends thereof by one endless conveyor of said adjacent pairs being inset laterally across said flow direction relative to a corresponding second endless conveyor of said adjacent pairs.