SENSING SYSTEM FOR A CONVEYOR AND A METHOD THEREOF

1 . A sensing system for a conveyor having at least a first chain for propelling the conveyor, the first chain comprising a first plurality of chain links, the sensing system comprising:

a first sensor positioned to detect each of the first plurality of chain links moving past the first sensor as the first chain moves to propel the conveyor; and

at least one processor configured to:

determine a count of the first plurality of chain links detected by the first sensor;

determine a first elapsed time for the count of the first plurality of chain links to reach a predetermined target count;

determine whether the first elapsed time for the count of the first plurality of chain links to reach the predetermined target count exceeds a first threshold time; and

generate a first alarm signal if the first elapsed time for the count of the first plurality of chain links to reach the predetermined target count exceeds the first threshold time.

2 . The sensing system of claim 1 , wherein the conveyor has a second chain for propelling the conveyor, the second chain comprising a second plurality of chain links;

wherein the sensing system further comprises a second sensor positioned to detect each of the second plurality of chain links moving past the second sensor as the second chain moves to propel the conveyor;

wherein the at least one processor is further configured to:

determine a count of the second plurality of chain links detected by the second sensor;

determine a second elapsed time for the count of the second plurality of chain links to reach the predetermined target count;

determine whether the second elapsed time for the count of the second plurality of chain links to reach the predetermined target count exceeds a second threshold time; and

generate a second alarm signal if the second elapsed time for the count of the second plurality of chain links to reach the predetermined target count exceeds the second threshold time.

3 . The sensing system of claim 2 , wherein the at least one processor is further configured to:

determine a difference between the first elapsed time and the second elapsed time;

determine if the difference between the first elapsed time and the second elapsed time exceeds a third threshold time; and

generate a third alarm signal if the difference between the first elapsed time and the second elapsed time exceeds the third threshold time.

4 . The sensing system of claim 3 , further comprising:

a first counter unit communicatively coupled to the first sensor to detect a signal generated by the first sensor in response to each of the first plurality of chain links moving past the first sensor;

a first register communicatively coupled to the first counter unit to increment when each signal from the first sensor is detected;

a second counter unit communicatively coupled to the second sensor to detect a signal generated by the second sensor in response to each of the second plurality of chain links moving past the second sensor; and

a second register communicatively coupled to second counter unit to increment when each signal from the second sensor is detected;

wherein the first register is communicatively coupled to the at least one processor;

wherein the second register is communicatively coupled to the at least one processor;

wherein the first register has a first overflow value;

wherein the second register has a second overflow value equal to the first overflow value of the first register; and

wherein the predetermined target count equals the first overflow value of the first register.

5 . The sensing system of claim 4 , wherein the at least one processor determines the first elapsed time for the count of the first plurality of chain links to reach the predetermined target count when the at least one processor receives an overflow signal from the first register; and

wherein the at least one processor determines the second elapsed time for the count of the second plurality of chain links to reach the predetermined target count when the at least one processor receives an overflow signal from the second register.

6 . The sensing system of claim 3 , further comprising an alarm unit communicatively coupled to the at least one processor.

7 . The sensing system of claim 6 , wherein the alarm unit is configured to trigger an alarm based at least on the generated first alarm signal, the generated second alarm signal, and/or the generated third alarm signal;

wherein the triggered alarm based on the first alarm signal indicates an elongation of the first chain;

wherein the triggered alarm based on the second alarm signal indicates an elongation of the second chain; and

wherein the triggered alarm based on the third alarm signal indicates a delta exists between an elongation of the first chain and an elongation of the second chain.

8 . The sensing system of claim 2 , wherein the first threshold time corresponds to an elapsed time for the count of the first plurality of chain links to reach the predetermined target count during a calibration test of the sensing system; and

wherein the second threshold time corresponds to an elapsed time for the count of the second plurality of chain links to reach the predetermined target count during the calibration test of the sensing system.

9 . The sensing system of claim 2 , wherein the first sensor and the second sensor correspond to an optical sensor.

10 . The sensing system of claim 2 , wherein the first plurality of chain links and the second plurality of chain links correspond to at least one of shoe sorter pins, shoe sorter rollers, connecting pins, attachment links, or guide links.

11 . A method comprising:

detecting, via a first sensor, each of a first plurality of chain links moving past the first sensor as a first chain moves to propel a conveyor;

determining, via at least one processor, a count of the first plurality of chain links detected by the first sensor;

determining, via the at least one processor, a first elapsed time for the count of the first plurality of chain links to reach a predetermined target count;

determining, via the at least one processor, whether the first elapsed time for the count of the first plurality of chain links to reach the predetermined target count exceeds a first threshold time; and

generating, via the at least one processor, a first alarm signal if the first elapsed time for the count of the first plurality of chain links to reach the predetermined target count exceeds the first threshold time.

12 . The method of claim 11 , further comprising:

detecting, via a second sensor, each of a second plurality of chain links moving past the second sensor as a second chain moves to propel the conveyor;

determining, via at least one processor, a count of the second plurality of chain links detected by the second sensor;

determining, via the at least one processor, a second elapsed time for the count of the second plurality of chain links to reach the predetermined target count;

determining, via the at least one processor, whether the second elapsed time for the count of the second plurality of chain links to reach the predetermined target count exceeds a second threshold time; and

generating, via the at least one processor, a second alarm signal if the second elapsed time for the count of the second plurality of chain links to reach the predetermined target count exceeds the second threshold time.

13 . The method of claim 12 , further comprising:

determining, via the at least one processor, a difference between the first elapsed time and the second elapsed time;

determining, via the at least one processor, if the difference between the first elapsed time and the second elapsed time exceeds a third threshold time; and

generating, via the at least one processor, a third alarm signal if the difference between the first elapsed time and the second elapsed time exceeds the third threshold time.

14 . The method of claim 13 , further comprising:

detecting, via a first counter unit communicatively coupled to the first sensor, a signal generated by the first sensor in response to each of the first plurality of chain links moving past the first sensor;

incrementing, via a first register communicatively coupled to the first counter unit, when each signal from the first sensor is detected;

detecting, via a second counter unit communicatively coupled to the second sensor, a signal generated by the second sensor in response to each of the second plurality of chain links moving past the second sensor; and

incrementing, via a second register communicatively coupled to second counter unit, when each signal from the second sensor is detected;

wherein the first register is communicatively coupled to the at least one processor;

wherein the second register is communicatively coupled to the at least one processor;

wherein the first register has a first overflow value;

wherein the second register has a second overflow value equal to the first overflow value of the first register; and

wherein the predetermined target count equals the first overflow value of the first register.

15 . The method of claim 14 , further comprising:

determining, via the at least one processor, the first elapsed time for the count of the first plurality of chain links to reach the predetermined target count when the at least one processor receives an overflow signal from the first register; and

determining, via the at least one processor, the second elapsed time for the count of the second plurality of chain links to reach the predetermined target count when the at least one processor receives an overflow signal from the second register.

16 . The method of claim 13 , further comprising communicatively coupling an alarm unit to the at least one processor.

17 . The method of claim 16 , further comprising:

triggering, via the alarm unit, an alarm based at least on the generated first alarm signal, the generated second alarm signal, and/or the generated third alarm signal;

wherein the triggered alarm based on the first alarm signal indicates an elongation of the first chain;

wherein the triggered alarm based on the second alarm signal indicates an elongation of the second chain; and

wherein the triggered alarm based on the third alarm signal indicates a delta exists between an elongation of the first chain and an elongation of the second chain.

18 . The method of claim 12 , wherein the first threshold time corresponds to an elapsed time for the count of the first plurality of chain links to reach the predetermined target count during a calibration test of a sensing system; and

wherein the second threshold time corresponds to an elapsed time for the count of the second plurality of chain links to reach the predetermined target count during the calibration test of the sensing system.

19 . The method of claim 12 , wherein the first sensor and the second sensor correspond to an optical sensor.

20 . The method of claim 12 , wherein the first plurality of chain links and the second plurality of chain links correspond to at least one of shoe sorter pins, shoe sorter rollers, connecting pins, attachment links, or guide links.