The present invention is generally in the field of storage and transfer equipment.
In agriculture, and particularly in the agricultural seed industry, high volume planting seed is generated by large seed manufacturers. The seed is loaded into seed boxes which typically include a base and a removable upper ring portion which sits on and engages the base thereby practically doubling the height and volumetric capacity of the box. Typical seed boxes store approximately 50 acres of seed and weigh a total of about 300 pounds, the upper ring weighing about 175 pounds.
Typical seed box upper rings are designed so they can be removed from the base, turned over 180 degrees so the internal cavity faces the base, and lowed down over the top of the base to nest thereby reducing the height of the boxes for compact storage and transportation.
When the seed box is to be filled, prior processes required two or more individuals to manually assemble the nested seed box. This required manually lifting and rotating the inverted ring and installing it on back on the base. On high volume seed manufacture, hundreds and hundreds of seed boxes are cycled every day and several thousand are typically in process at the manufacturing facility, in transport to buyers and farms, and/or in transport to be returned to the seed manufacturing for cleaning, refilling and/or temporary storage.
The present invention improves on prior equipment and processes which required burdensome operations which are slow, imprecise and required numerous human operators. Prior devices were often specific to a specific storage container and could not easily accommodate other containers. Prior devices were also not suitable for the high volume demands of modern manufacturing facilities.
The present storage container manipulator has many uses, but is particularly useful in the automated manipulation, assembly and disassembly into nested storage position of agricultural seed boxes.
In one example, the present invention includes a modular, self-contained frame structure having lifting and manipulator mechanisms. The lifting mechanism selectively raises and lowers the manipulator to accommodate and receive different sized storage containers. The manipulator mechanism operates to grip the upper seed box ring, rotate the ring 180 degrees to either assemble or disassemble the seed box.
A conveyor is connected to the frame to quickly move seed boxes into and out of the frame structure for processing.
In another example, a container lid removal device is used for removing the lids from seed boxes, reorienting the upper box ring, lowering the ring over the base in a nested state and placing the lid back on the box for further processing.
In another example, a lid removal and transport system is used. In the example, lids are individually removed and transferred through a second and third lid station positioned in a bridge section and second tower frame. The lids are then reinstalled on the reoriented containers that have been moved out of the first tower frame and passed through an inspection or other process.
In an exemplary process, a container oriented in a first state, for example an assembled seed box, is positioned in the manipulation device. Lift and manipulation devices are positioned to engage and alter the state of the container from the first state to, for example, a second state where the container is reoriented to a nested position for compact storage and transportation. The process is reversed to assemble the seed boxes for use.
In one example, the manipulator includes a device and process to remove the lid from a container box, hold the lid above the container while the ring is manipulated to either an assembled or nested storage position and then lower the lid and connect it to the bottom of the ring structure for secure storage and transport of the seed box. The process is repeated to install the lid on an assembled seed box ready to be filled. In an alternate lid removal process, the lids are transferred through a second and third lid station to a second tower frame and reinstalled after the containers have gone through additional processes, for example an inspection process.
The description herein makes reference to the accompanying drawings wherein like reference numerals refer to like parts throughout the several views, and wherein:
In
Referring to
In the example, first tower frame 16 includes four vertical pillars 50 connected by several cross-members 54 which define a generally rectangular space for movement and manipulation of the seed box 36 as further described below. Other structural members, orientations and configurations of the pillars 50 and cross-members 54 suitable for the application may be used.
In the example illustrated, a conveyor 26 is used on one side of the tower frame 16 leading into the processing space for movement of seed boxes 36 into and out of the frame for manipulation and/or other processing. As best seen in
In a preferred example, conveyor 26 includes at least several rollers 68 that are engaged with a powered drive mechanism 70 which selectively and forcibly rotates at least several rollers to forcibly move the seed box 36 positioned on the conveyor in a direction toward or away from the frame 16 as best seen in
Referring to
Exemplary lift mechanism 20 includes a lift frame 80 which includes vertical support structures 84 and cross-members 90 forming a generally rectangular frame structure having a processing space between the supports and members. In the example, at least two of the vertical support members are engaged with the vertical pillars 50 allowing the lift frame 80 to move vertically relative to pillars 50 and frame 16. Guide tracks, rollers and other mechanical devices and structures (not shown) connecting the frame 80 to the tower frame 16 allowing for such controlled, accurate, precise and relative vertical movement known by those skilled in the art may be used.
Lift mechanism 20 further includes a lift drive 96 having a drive motor 100 connected to frame 16 as generally shown. A drive shaft 104 is connected to the motor 100 and extends across frame 16 to span the lift frame 80 as best seen in
Referring to FIGS. 5 and 7-10, a preferred example of container manipulator mechanism 22 is illustrated. In the example, manipulator mechanism includes a first gripper 112 and an opposing second gripper 116 connected to the lift frame 80 for use in selectively engaging the sides of seed box 36 upper ring portion 46. Each gripper 112 and 116 includes a frame structure 120 and a plurality of pads 122 connected to the frame and extending into the processing space defined by frame 16 and lift frame 80. In the example shown, first gripper 112 is a drive gripper connected to a drive mechanism described below, and second gripper 116 is a slave gripper which is not powered. It is understood that second gripper 116 could alternatively serve as the drive gripper or both grippers could be synchronously driven to suit the particular application and performance specifications.
In the example illustrated, both grippers' frames 120 are rotatably connected to the lift frame 80 allowing for relative and independent rotational movement of the respective gripper 112 and 116 to the lift frame 80 and frame 16. In the examples, each gripper frame 120 includes a mounting plate 126 with compression coil springs 130 allowing a predetermined amount of transverse movement of the gripper frames 120 relative to the lift frame 80 to provide tolerance for a secure grip of the grippers to the seed box 36 as further explained below.
Referring to
As best seen in
Referring to
As illustrated, each exemplary locator 180 includes a locating arm 186 including a contact pad 190 on a distal end of the arm which is pivotally connected at a pivot point 196 to a respective rail 60 as generally shown. A pneumatic cylinder and piston 200 mounted to the rail 60 selectively rotates arm 186 about pivot 196 to engage contact pad 186 with an adjacently position side or corner portion of box base 40. Cylinders 166 are in communication with a controller and are preferably synchronized to move and engage the box base 40 according to a predetermined program to suit the particular application. In a preferred example, four box locators are used and are positioned at different corners of box base 40 to positively locate the seed box 36 in the X and Y directions relative to frame 16. Locators 180 precisely and accurately position box 36 relative to frame 16, lift frame 80 and grippers 112 and 116.
Referring to
In an example not shown, manipulator 10 may further include a device (not shown) and method for dislodging a removable lid 206 covering seed box 36. In one example, two or more actuators, preferably four, one for each corner of the lid, are connected to the first tower frame 16 and are selectively cycled to extend into the processing area and engage the lid with sufficient force and/or movement to dislodge the secured lid from the upper ring 46. In a preferred device and method of operation, the actuators are controlled by controller 30 and are sequentially activated one at a time, although other methods known by those skilled in the art may be used. In one example, the actuators are pneumatic cylinders with pistons having an end effector or device suitable to grasp or dislodge the lid or, for example, a lever or fastener that is used to secure the lid to the box.
As best seen in
In the example, the lift device 20 would then again raise the reoriented upper ring 46 to again place the upper ring in contact with the suspended and stationary lid 206. In one example, the lid 206 positively engages a portion of the inverted upper ring 46. On satisfaction of safety checks, the suction cups are deactivated releasing lid 206. The lift 20 is then lowered placing the upper ring 46 over the base 40 in a second, nested container state.
Where a seed box container 36 is being assembled, the first state is the compact/nested state and the second state is the assembled/full-height container with the upper ring 46 atop the base 40. The lid 206 would first be removed from the upper ring and then installed atop the ring 46 through use of the lid removal device 210 in a similar manner as described. Other methods and devices known by those skilled in the art to install and remove lids 206 may be used.
Referring to
In the example, the first tower frame 16 and lid removal device 210 serve as a first lid station 238, an area of the tower bridge serves as a second lid station 240 and the second frame tower 230 defining a third lid station 246 as generally illustrated. In the example shown in
As best seen in
In a preferred example, the two lid removal devices 210, one for first carriage 254 and one for second carriage 258 are positioned along a third path of travel 254 substantially longitudinally along bridge 236 between the first 16 and the second 230 frame towers. The lid removal devices 210 connected to trolley 250 are spaced apart along the third path of travel a distance equal to the distance between the first 238 and second 240 lid stations which is substantially equivalent to the distance between the second 240 and third 246 lid stations.
In the exemplary lid transfer device 226, a drive 280 is used to selectively move the trolley 250 to position a lid removal device 210 at the first 238 and second 240 lid stations or the second 240 and third 246 lid stations. The drive 280 includes a drive shaft 286 connected to a motor 294 attached to the second frame tower 230. At least one belt 290, shown in
In an example of operation of the lid transfer device 226, a first seed box 36 lid 206 is removed from the seed box 36 in the device 10 first tower frame 216 as generally described. Following reorientation of the seed box 36 as desired in device 10, while that seed box 36 is transferred to a position below the bridge 236 for inspection or other processes, the lid 206 is moved by the lid transfer device 226 along a third path of travel 252 to the second lid station 240. In this position, the second carriage 258 and connected lid removal device 210 is positioned at the third lid station 246. When a new seed box is positioned in device 10 for reorientation, the suction cups 216 of the first carriage 254 are released and the lid is lowered by gravity into a holding fixture (not shown) to await further processing. In a preferred example, the lid 206 is released onto a fixture (not shown).
The trolley 250 is then moved by drive 280, through commands or signals from the controller 30, back to the first lid station 238 to receive and engage another lid 206 in the manner described. In this position, second carriage 258 and lift 260 are positioned over the lid positioned in the fixture at the second lid station 240. Lift 240 lowers to engage the fixture lid and raise it free from the fixture. The trolley 250 is then moved to position the two engaged lids to the second 240 and third 246 lid stations wherein the lid at the second lift station 240 is released in the manner described above and the lift lowers lid 230 onto an awaiting seed box 36 positioned under lid station 246 in the manner described above. The lid removal and transfer of lids 206 repeats in a similar manner. Other processes for removing and transferring lids 206 may be used to suit the particular container or lids that are used with the containers as known by those skilled in the art.
As generally shown in
In the exemplary process, in step 320 individual seed boxes in a first state or condition (assembled, full height) are positioned onto conveyor 26 as best seen in
Although a simple conveyor is shown in the illustrations, it is understood that other conveyor and transfer devices, lifts, rotators and other equipment known by those skilled in the art may be used on both sides of the tower frame 16 and processing area to effectively and efficiently deliver and exit seed boxes 36 from the device 10 to suit the particular application and environment.
At this stage, lift frame 80 and grippers 112 and 116 are cycled or positioned to an elevated height, and the grippers positioned outward relative to frame 16 providing clearance for the box 36 to enter the processing area without contact with the lifting frame 80 and grippers 112 and 116.
On satisfying safety checks that the lift frame is in the upward and outward position, step 340 includes activating the conveyor drive 70 which rotate the rollers 68 to move the box into the processing area inside and below the lift frame 80.
In an optional but preferred step 350, locators 180 are activated to engage the base 40 of box 36 to accurately and precisely position the box relative to frame 16 and lift frame 80.
In an optional step not shown, a vision or other verification device may be used to determine what specific type of container or the state that a particular container is in has been loaded onto conveyor 26 or positioned in the process area. On such determination or verification, the controller 30 may access, load and execute a preloaded program specific to that detected and identified type of container.
Once the container 36 is positioned in the processing area in frame 16, step 360 includes actuating the lift device 20 to lower the lift frame 80 and attached grippers 112 and 116 to a predetermined position adjacent the box 36, preferably positioning the grippers adjacent opposing sides of box upper ring 46.
In step 380, gripper pivot arms 156 are rotated about pivot points 160 by movement of the respective cylinders 166 to synchronously place the grippers 112 and 116 and pads 122 into contact with opposing sides of the box ring 46 and apply a predetermined pressure by compression of springs 130.
In step 400, the container is manipulated from a first state to a second state according to the predetermined and desired manipulation of the container. In a preferred example of disassembling a seed box 36 that was in a first or assembled state having a base 40 and upper ring 46 to a second or nested or storage state, the lift frame is raised thereby disengaging the upper ring 46 from the base 40. Once the box upper ring 46 is raised to a sufficient height above and clear of base 40, the drive gripper, here first gripper 112, is forcibly rotated by drive 136 to rotate about 180 degrees to invert box ring 46 to a position where the respective cavities of the base 40 and ring 46 face one another. The second, non-driven gripper 116 maintains engagement with the ring 46 and rotates with the ring as directed by the driven gripper 112.
The lift frame 80 is then lowered to achieve a second state wherein the base 40 is nested inside the inverted upper ring 46 reducing the height of the box 36 for storage and/or transportation.
In an alternate process where the seed box 36 is to be assembled. In other words, the first state of the container is a nested box 36 (as described above), and the inverted ring 46 is to be manipulated to assemble the seed box to a full height second state to be loaded with seed or other media. In the example, the lift and manipulator devices 20 and 22 would grip, lift and rotate the upper ring an opposite 180 degrees and then lower to set the upright ring 46 atop the base as substantially described for disassembling box 36.
On satisfaction of safety checks, for example lift frame 80 and grippers 112 and 116 are positioned in a high height and outward positions with respect to frame 16, in step 420, the assembled or disassembled box 36 is transported from the processing area in frame 16 by conveyor 26 and another box 36 is loaded onto conveyor 26 for manipulation and processing.
In an option method step 410 a lid 206 of the box 36 may be manipulated, removed and/or installed as part of the device 10 and process 300 as previously described above. In the example, four actuators are connected to the lift frame 80 on opposing sides of the lift frame 80. The actuators are each connected to a pneumatic cylinder which operates to selectively engage a portion of the lid to dislodge the lid from the upper ring 46 which is then supported on a top surface of ring 46 by gravity. In one example, the ring and loose lid is raised by the lift mechanism 20 as described above and placed in contact with a plurality of pneumatic suction cup devices (not shown) connected to the frame 16 cross members 54 which engage the lid preventing movement of the lid with respect to the stationary suction cups. The lift device 20 is then lowered and manipulator device 22 then continues through the predetermined cycle, for example, inverting the box ring 46 to a nested or storage position. Once nested, the lid is place atop the nested box 36 before being moved from the frame 16. In the reverse process where the box 36 is manipulated to assemble the ring 46 atop the base 40, the process is essentially reversed and completed with the lid being placed atop the ring 46.
Additional process steps, and the order in which such steps occur, known by those skilled in the art may be used. For example, when the lid transfer system 226 is used, the lid 206 may not be reinstalled on the seed box 36 until after the seed box is transferred from the first tower base and processing area as generally shown in
It is further understood that other containers or devices, other than seed box 36, are usable with the device 10 and process 300. Through changes in the form and orientation of the grippers 112 and 116 as well as the movement of lift frame 80 and conveyor 26, the device 10 and process 300 are easily adapted and used for a variety of operations on large containers and other objects, both inside and outside of the agricultural field as known by those skilled in the art.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiments but, on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims, which scope is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures as is permitted under the law.
This application claims priority benefit to U.S. provisional patent application No. 61/509,722 filed Jul. 20, 2011, the entire contents of which is incorporated by reference.
Number | Name | Date | Kind |
---|---|---|---|
2468326 | Gleason | Apr 1949 | A |
2889912 | Franklin et al. | Jun 1959 | A |
3291329 | Ord | Dec 1966 | A |
3656634 | Pearne et al. | Apr 1972 | A |
3703242 | Marradi | Nov 1972 | A |
4187095 | Frank | Feb 1980 | A |
4221517 | Guzzetta et al. | Sep 1980 | A |
4470744 | Steimel et al. | Sep 1984 | A |
5833428 | Szinte | Nov 1998 | A |
5888043 | Jatcko | Mar 1999 | A |
6120231 | Christ et al. | Sep 2000 | A |
6139243 | Jackson et al. | Oct 2000 | A |
6224315 | Van Arkel et al. | May 2001 | B1 |
6524058 | Watters | Feb 2003 | B1 |
6722841 | Haas | Apr 2004 | B2 |
6962271 | Gregson, Jr. | Nov 2005 | B2 |
20050060932 | Ramp | Mar 2005 | A1 |
20080025831 | Ikehata | Jan 2008 | A1 |
Number | Date | Country | |
---|---|---|---|
20130022437 A1 | Jan 2013 | US |
Number | Date | Country | |
---|---|---|---|
61509722 | Jul 2011 | US |