Load assist system

1. A load assist module for transferring an article onto a downstream conveyor, the load assist module comprising:

a roller conveyor comprising one or more rollers that together define a conveyor plane, wherein the one or more rollers are actuatable to convey the article along the conveyor plane in a direction of a downstream conveyor;

a pusher assembly that is positioned adjacent to the conveyor plane, wherein the pusher assembly comprises a track-guided vertical popup with a base and a pop-up, wherein the pop-up is actuatable such that the pop-up extends through the conveyor plane to contact the article, wherein the pusher assembly is configured to drive the track-guided vertical popup toward the direction of the downstream conveyor such that the track-guided vertical popup pushes the article; and

one or more pneumatic pop-out stops positioned adjacent to the downstream conveyor, such that the one or more pneumatic pop-out stops extend to stop the article against the one or more pneumatic pop-out stops until the downstream conveyor is ready to receive the article.

2. The load assist module of claim 1 , wherein the pusher assembly further comprises a drive assembly operatively coupled to the track-guided vertical popup, wherein the drive assembly:

drives the track-guided vertical popup in a first direction, towards the downstream conveyor, to transfer the article onto the downstream conveyor; and

drives the track-guided vertical popup in a second direction, away from the downstream conveyor, once the article is transferred onto the downstream conveyor.

3. The load assist module of claim 2 , wherein the drive assembly comprises a timing belt driven by a pair of roller mounted timing pulleys, wherein the timing belt is coupled to the track-guided vertical popup for driving the track-guided vertical popup in the first direction and the second direction.

4. The load assist module of claim 3 , wherein the drive assembly further comprises a flag coupled to the timing belt such that the flag moves in a direction opposite to a direction of movement of the track-guided vertical popup.

5. The load assist module of claim 1 , wherein the track-guided vertical popup comprises a popup head operatively coupled to a base, such that the popup head is vertically movable to extend above the conveyor plane for pushing the article onto the downstream conveyor and retract below the conveyor plane for receiving a next article onto the load assist module.

6. The load assist module of claim 1 , further comprising a controller operatively coupled to the roller conveyor and the pusher assembly, wherein the controller is configured to:

receive a notification of a presence of the article on the roller conveyor;

in response to the notification, drive the roller conveyor to convey the article along the conveyor plane towards the downstream conveyor;

actuate the pusher assembly to extend the track-guided vertical popup above the conveyor plane such that the track-guided vertical popup contacts the rear end of the article; and

actuate the pusher assembly to drive the track-guided vertical popup against the rear end of the article to push the article onto the downstream conveyor.

7. The load assist module of claim 1 , further comprising one or more guide rails positioned parallel to the conveyor plane for aligning and guiding the article while the article is being conveyed by the roller conveyor.

8. A material handling system, comprising:

a conveyor for conveying an article in a conveyance direction; and

a load assist module positioned adjacent the conveyor for receiving the article from the conveyor, the load assist module comprising:

a roller conveyor comprising one or more rollers that together define a conveyor plane, wherein the one or more rollers are actuatable to convey the article along the conveyor plane in a direction of a downstream conveyor in response to receiving a notification of a presence of the article on the roller conveyor; and

a pusher assembly that is positioned adjacent to the conveyor plane, wherein the pusher assembly comprises a track-guided vertical popup with a base and a pop-up, wherein the pop-up is actuatable such that it extends through the conveyor plane to contact the article, wherein the pusher assembly is configured to drive the track-guided vertical popup toward the direction of the downstream conveyor such that the track-guided vertical popup pushes the article.

9. The material handling system of claim 8 , wherein the downstream conveyor includes a vertical conveyor for moving the article vertically across one or more levels.

10. The material handling system of claim 8 , wherein the pusher assembly further comprises a drive assembly operatively coupled to the track-guided vertical popup, wherein the drive assembly:

drives the track-guided vertical popup in a first direction, towards the downstream conveyor, to transfer the article onto the downstream conveyor; and

drives the track-guided vertical popup in a second direction, away from the downstream conveyor, once the article is transferred onto the downstream conveyor.

11. The material handling system of claim 10 , wherein the drive assembly comprises a timing belt driven by a pair of roller mounted timing pulleys, wherein the timing belt is coupled to the track-guided vertical popup for driving the track-guided vertical popup in the first direction and the second direction.

12. The material handling system of claim 11 , wherein the drive assembly further comprises a flag coupled to the timing belt such that the flag moves in a direction opposite to a direction of movement of the track-guided vertical popup.

13. The material handling system of claim 8 , wherein the popup is vertically movable to extend above the conveyor plane for pushing the article onto the downstream conveyor and retract below the conveyor plane for receiving a next article onto the load assist module.

14. The material handling system of claim 8 , further comprising a controller operatively coupled to the load assist module, wherein the controller is configured to:

receive the notification of the presence of the article on the roller conveyor;

actuate the pusher assembly to extend the track-guided vertical popup above the conveyor plane such that the track-guided vertical popup contacts the rear end of the article; and

actuate the pusher assembly to drive the track-guided vertical popup against the rear end of the article to push the article onto the downstream conveyor.

15. A method of operating a load assist module for transferring an article onto a downstream conveyor, the method comprising:

receiving a notification of a presence of the article on a roller conveyor of the load assist module;

in response to the notification, driving the roller conveyor to convey the article along a conveyor plane towards the downstream conveyor;

actuating a pusher assembly, positioned adjacent the conveyor plane, having a track-guided vertical popup to extend the track-guided vertical popup above the conveyor plane such that the track-guided vertical popup contacts a rear end of the article; and

actuating the pusher assembly to drive the track-guided vertical popup against the rear end of the article to push the article onto the downstream conveyor.

16. The method of claim 15 , further comprising:

receiving a notification of transfer of the article onto the downstream conveyor;

in response to the notification, actuating the pusher assembly to retract the track-guided vertical popup adjacent the conveyor plane; and

actuating the pusher assembly to drive the track-guided vertical popup away from the downstream conveyor and into the load assist module to an initial position.

17. The method of claim 15 , further comprising:

receiving a notification of conveyance of the article on the roller conveyor towards the downstream conveyor;

actuating one or more pneumatic pop-out stops positioned adjacent to the downstream conveyor, such that the one or more pneumatic pop-out stops extend to stop the article against the one or more pneumatic pop-out stops;

detecting that the downstream conveyor is ready to receive the article; and

actuating the one or more pneumatic pop-out stops to retract to allow the article to be transferred onto the downstream conveyor.