Patent Grant
7036679
1. Field of the Invention
The present invention relates generally to dispensing systems and methods. In particular, the present invention relates to dispensing systems and methods in which a plurality of items may be dispensed, such that dispensed items may be directed to containers or diverted away from containers depending upon a measured physical characteristic of each of the dispensed items.
2. Description of Related Art
In known dispensing systems and methods, a dispenser may receive and dispense a plurality of items. For example, a known dispenser may receive a plurality of items on an item-receiving surface, direct the items from the item-receiving surface to dispensing paths positioned around the item-receiving surface, and dispense the items from the dispensing paths. Moreover, known dispensing systems may count each dispensed item, so that predetermined quantities of items may be directed to containers, e.g., packages, boxes, bottles, jars, cans, bowls, plates, pans, and the like.
However, known dispensing systems may dispense items that are out-of-specification, i.e., items that have a measured physical characteristic that is greater than or less than a predetermined range of physical characteristics for that item. If within a plurality of items to be dispensed, some items have a physical characteristic that is greater than or less than a predetermined range of physical characteristics for that item, a problem may arise in maintaining a quality of items dispensed to each container. For example, known dispensing systems may receive and dispense out-of-specification items, i.e., items having a volume, density, or weight that is greater than or less than a predetermined range of volumes, densities, or weights for that particular item. If within a plurality of items to be dispensed, some of the items are “out-of-specification”, known dispensers may dispense the out-of-specification items to containers. Thus, containers may have one or more items, the measured physical characteristic of which is greater than or less than a predetermined range of physical characteristics for that item.
A need has arisen for dispensing systems and methods that dispense items in predetermined quantities to containers. More particularly, a need has arisen for dispensing systems that accurately measure a physical characteristic of each dispensed item and direct predetermined quantities of dispensed items, the measured physical characteristic of which is within a predetermined range of physical characteristics, to a container. A further need has arisen for dispensing systems and methods that divert items, the measured physical characteristic of which is greater than or less than a predetermined range of physical characteristics, away from a container.
Dispensing systems of the present invention may dispense predetermined quantities of a variety of food items, e.g., dried food items, frozen food items, thawed food items, or the like. For example, such dispensing systems may dispense dried food items, such as dried pasta, dehydrated vegetables, or the like. Moreover, such dispensing systems may dispense frozen food items, e.g., frozen meat, frozen vegetables, or the like. The dispensing system of the present invention may dispense items of varying physical characteristic, e.g., varying weight, volume, density, temperature, or the like, including non-food items. For example, the dispensing system of the present invention may dispense fasteners, hardware, medical items, electronic parts, mechanical parts, metallic and non-metallic items, or the like.
In an embodiment of the invention, a system for dispensing items comprises a dispenser, a sensing unit, a plurality of container chutes, and a plurality of diversion chutes. The dispenser comprises a plurality of dispensing paths for dispensing the items. The sensing unit measures a physical characteristic of each of the dispensed items. The plurality of container chutes directs each of the dispensed items, the measured physical characteristic of which is within a predetermined range of physical characteristics, to containers. The plurality of diversion chutes diverts each of the dispensed items, the measured physical characteristic of which is greater than or less than the predetermined range of physical characteristics, away from the containers.
In another embodiment of the invention, a dispensing system comprises a rotary, vibratory dispenser for receiving and dispensing items, at least one sensing unit, a plurality of container chutes, and a plurality of diversion chutes. The rotary, vibratory dispenser comprises a rotation drive for rotating said dispenser, a plurality of dispensing paths, and at least one vibration device for vibrating the plurality of dispensing paths, so that the plurality of dispensing paths dispenses the items singularly. The at least one sensing unit measures a physical characteristic of each of the singularly-dispensed items. The plurality of container chutes direct each of the singularly-dispensed items, the measured physical characteristic of which is within a predetermined range of physical characteristics, to containers. The plurality of diversion chutes diverts each of the singularly-dispensed items, the measured physical characteristic of which is greater than or less than the predetermined range of physical characteristics, away from the containers.
In a further embodiment of the invention, a dispensing method comprises the steps of dispensing items from a dispenser. A physical characteristic of each of the dispensed items is measured. Each of the dispensed items, the measured physical characteristic of which is within a predetermined range of physical characteristics, is directed to a container chute. Each of the items, the measured physical characteristic of which is greater than or less than the predetermined range of physical characteristics, to a diversion chute.
In yet another embodiment of the invention, a dispensing method comprises the steps of dispensing items singularly from a rotary, vibratory dispenser. A physical characteristic of each of the singularly-dispensed items is measured. Each of the singularly-dispensed items, the measured physical characteristic of which is within a predetermined range of physical characteristics is directed to a container. Each of the dispensed items, the measured physical characteristic of which is greater than or less than the predetermined range of physical characteristics, is diverted away from the container. The diverted items are conveyed to a rejection bin.
A system for dispensing items comprises a dispenser, a sensing unit, and a plurality of container chutes, and a plurality of buckets. The dispenser comprises a plurality of dispensing paths for dispensing items. The sensing unit measures a physical characteristic of each of the dispensed items. The plurality of container chutes directs each of the dispensed items, the measured physical characteristic of which is within a predetermined range of physical characteristics, to containers. The plurality of buckets receives each of the dispensed items, the measured physical characteristic of which is greater than or less than the predetermined range of physical characteristics.
A method of dispensing items comprises the steps of dispensing items from a dispenser, measuring a physical characteristic of each of the dispensed items, directing each of the dispensed items the measured physical characteristic of which is within a predetermined range of physical characteristics to a container chute, and diverting each of the dispensed items the measured physical characteristic of which is greater than or less than the predetermined range of physical characteristics to a bucket.
In still yet another embodiment of the present invention, a dispensing system comprises a dispenser for receiving and dispensing items. The dispenser comprises a plurality of dispensing paths, at least one rotation drive for rotating the plurality of dispensing paths, and at least one vibration device for vibrating the plurality of dispensing paths, such that the plurality of dispensing paths dispenses the items singularly the dispensing system also comprises at least one sensing unit for measuring a physical characteristic of each of the singularly-dispensed items, and a plurality of container chutes for directing each of the singularly-dispensed items, the measured physical characteristic of which is within a predetermined range of physical characteristics, to containers. Moreover, the dispensing system comprises a plurality of diversion chutes for diverting each of the singularly-dispensed items, the measured physical characteristic of which is greater than or less than the predetermined range of physical characteristics, away from the containers.
Other objects, features, and advantages of embodiments of the present invention will be apparent to persons of ordinary skill in the art from the following description of preferred embodiments with reference to the accompanying drawings.
The invention may be understood more readily by reference to the following drawings.
a–7h show an operation of a dispensing head according to another embodiment of the present invention.
As shown in
Feeder bowl 101 also may comprise a sloped member 908 fixed to dispensing paths 102, such that sloped member 908 may rotate with dispensing paths 102. Sloped member 908 may be separate from second sloped portion 904, such that a gap 910 is formed between second sloped portion 904 and sloped member 908. In an embodiment, sloped member 908 may be inclined in a downward direction relative to a third horizontal plane 970 which is parallel to second horizontal plane 960. In operation, items fall from second sloped portion 904 onto the surface of sloped member 908 and, subsequently may become airborne. A slope S3 of sloped member 908 relative to third horizontal plane 970 may be selected to reduce the amplitude of the airborne items. For example, slope S3 of sloped portion 908 may be between about 1° and about 15°, and in a preferred embodiment, slope S3 of sloped portion 908 is about 15°. Moreover, dispensing paths 102 may be inclined in a downward direction, such that a slope of dispensing paths 102 is about the same as slope S3 of sloped member 908. Although in
Referring again to
Moreover, each dispensing path 102 may comprise one or more channels, each of which channels may dispense items singularly. For example, each dispensing path 102 may comprise a single channel 303, as shown in
A bulk delivery apparatus 104 may be used to deliver items to rotary, vibratory dispenser. Bulk delivery apparatus 104 may be positioned adjacent to rotary, vibratory dispenser, as shown in
As shown in
In another embodiment of the invention, bulk delivery apparatus 104 may include a conveyor or the like for delivering items to feeder bowl 101 of rotary, vibratory dispenser. In a further embodiment of the invention, the rate of delivery of items from bulk delivery apparatus 104 to rotary, vibratory dispenser may be regulated by adjusting an aperture, or the like, of bulk delivery apparatus 104.
Rotary, vibratory dispenser may include a feeder bowl rotation drive 105, a feeder bowl vibration device 106, and one or more dispensing path vibration devices 107. Feeder bowl rotation drive 105 may rotate feeder bowl 101 at different rotational speeds, which may correspond to a desired rate at which packages, e.g., containers, or the like, are to be transported to dispenser 100. For example, if rotary, vibratory dispenser includes 48 dispensing paths 102 and each dispensing path 102 includes two item-dispensing channels, and rotary, vibratory dispenser 100 must fill 480 containers per minute, feeder bowl rotation drive 105 may rotate feeder bowl 101 and dispensing paths 102 at five (5) revolutions per minute (rpm), so that rotary, vibratory dispenser may dispense items to 480 containers per minute. If each dispensing path 102 includes a single item-dispensing channel, rotation drive 105 may rotate feeder bowl 101 and dispensing paths 102 at ten (10) ten rpm, so that rotary, vibratory dispenser may dispense items to 480 containers per minute.
In one embodiment of the invention, feeder bowl rotation drive 105 may rotate dispensing paths 102 in synchronization with feeder bowl 101, e.g., at a substantially similar rotational speed as feeder bowl 101. For example, feeder bowl rotation drive 105 may rotate a frame 108, which supports feeder bowl 101 and dispensing paths 102. According to another embodiment of the present invention, feeder bowl rotation drive 105 may rotate dispensing paths 102 at a rotational speed that is greater than or less than a rotational speed at which feeder bowl rotation drive 105 rotates feeder bowl 101. For example, feeder bowl rotation drive 105 may rotate dispensing paths 102 at different relative rotational speeds, e.g., via a transmission (not shown), or the like, so that a rotational speed of dispensing paths 102 may be varied relative to a rotational speed of feeder bowl 101. In a still further embodiment of the invention, feeder bowl rotation drive 105 may rotate dispensing paths 102 in a direction of rotation that is opposite to a direction of rotation of feeder bowl 101.
Feeder bowl vibration device 106 may vibrate feeder bowl 101 at different vibrational settings, e.g., at different vibrational magnitudes, at different vibrational frequencies, in different vibrational planes, or combinations thereof, so that feeder bowl 101 may supply items uniformly to each dispensing path 102. Feeder bowl vibration device 106 may vibrate feeder bowl 101 at vibrational magnitudes and at vibrational frequencies that are proportionate to a physical characteristic, e.g., a density, a volume, a weight, a temperature, or the like, of items to be supplied by feeder bowl 101 to dispensing paths 102. Such feeder bowl vibration devices 106 may include Syntron® Electromagnetic Vibrators, available from FMC Technologies Material Handling Solutions of Homer City, Pa.
Feeder bowl vibration device 106 may vibrate feeder bowl 101 at different vibrational magnitudes, different vibrational frequencies, or both, in a first plane, in a second plane, or in a first plane and a second plane. First plane may be generally transverse to second plane. In particular, first plane may be a substantially horizontal plane, while second plane may be a substantially vertical plane. Feeder bowl vibration device 106 may vibrate feeder bowl 101 at vibrational settings that correspond to one or more of a rate of delivery of items to feeder bowl 101, a rotational speed of feeder bowl 101, or a desired rate of supplying items from feeder bowl 101 to dispensing paths 102. Feeder bowl vibrational settings may be adjusted, as necessary, so that feeder bowl 101 may receive a plurality of items, e.g., from a bulk delivery apparatus 104 or the like, and supply items uniformly to each dispensing path 102.
A dispensing path vibration device 107 may vibrate each dispensing path 102 and associated item-dispensing channel. Each dispensing path vibration device 107 may vibrate each dispensing path 102 at different vibrational settings, e.g., at different vibrational frequencies, at different vibrational magnitudes, in different vibrational planes, or combinations thereof, so that each dispensing path 102 may dispense items singularly. Moreover, each dispensing path vibration device 107 may vibrate each dispensing path 102 at different vibrational settings in a first plane, in a second plane, or in a first plane and a second plane, so that each dispensing path 102 may dispense items singularly. First plane may be generally transverse to second plane. In particular, first plane may be substantially horizontal, while second plane may be substantially vertical. Such dispensing path vibration devices 107 may include Syntron® Solid Mount Linear Drives, which are available from FMC Technologies Material Handling Solutions of Homer City, Pa.
Each dispensing path vibration device 107 may vibrate one or more respective dispensing paths 102 proportionately to a physical characteristic e.g., a density, a volume, a weight, a temperature, or the like, of each item to be dispensed. Moreover, each dispensing path vibration device 107 may vibrate each dispensing path 102 proportionately to one or more of a rate of supply of items from feeder bowl 101 to each dispensing path 102, a rotational speed of dispensing paths 102, or a desired dispensing rate of items from each dispensing path 102.
A sensing unit may be positioned at each dispensing path 102, e.g., adjacent to a distal end of each dispensing path 102 and its associated item-dispensing channel(s). If a dispensing path 102 comprises more than one item-dispensing channel a sensing unit may be positioned at each channel, e.g., at a distal end of each channel of a dispensing path 102. In one embodiment of the invention, a sensing unit 109 may be positioned at a dispensing head 110. For example, a sensing unit 109 may be positioned adjacent to an opening of each dispensing head 110, as shown in
Sensing units 109 may measure a physical characteristic, e.g., a volume, a weight, a density, or the like, of each item dispensed from a dispensing path 102 or item-dispensing channel. Each sensing unit 109 transmits each measurement to a control unit, which determines whether the measurement is within a predetermined range of physical characteristics for a particular item. For example, each sensing unit 109 may comprise an optic sensor that may measure a volume of each item dispensed from a dispensing path 102 or item-dispensing channel and transmit each measurement to control unit. Control unit may compare each measurement to a predetermined range of volumes for that particular item to determine whether the measured volume of each item is within the predetermined range of volumes, or whether the measured volume for an item is greater than or less than the predetermined range of volumes for the item.
By measuring a physical characteristic of each dispensed item and transmitting each measurement to a control unit, sensing units 109 enable identification of items, the measured physical characteristic of which is greater than or less than a predetermined range of physical characteristics for the item. In this way, sensing units 109 may identify out-of-specification items, i.e., items the measured physical characteristic of which is greater than or less than a predetermined range of physical characteristics.
In addition to determining whether a measured physical characteristic of each item is within a predetermined range of physical characteristics, control unit may count items dispensed from each dispensing path 102 or channel. For example, control unit may count each item, the measured physical characteristic of which is within a predetermined range of physical characteristics. Control unit may identify each item, the measured physical characteristic of which is greater than or less than the predetermined range of physical characteristics, so that each item, the measured physical characteristic of which is greater than or less than a predetermined range, may not be counted.
Based on this measured count, control unit may activate each dispensing head 110 to direct predetermined quantities of items, the measured physical characteristic of each of which items is within a predetermined range of physical characteristics, to a container. Control unit may activate each dispensing head 110 to divert items, the measured physical characteristic of which is greater than or less than a predetermined range of physical characteristics, away from a container. Moreover, control unit may activate each dispensing head 110 to divert quantities of items in which at least one item has a measured physical characteristic that is greater than or less than a predetermined range of physical characteristics away from containers. In this way, control unit enables containers to be filled with predetermined quantities of items, the measured physical characteristic of each of which is within a predetermined range of physical characteristics. Control unit ensures that dispensing heads 110 may divert away from containers each item the measured physical characteristic of which is greater than or less than a predetermined range of physical characteristics.
As shown in
As shown in
Holding chamber 115 may be positioned at a lower portion of each dispensing head 110 to receive items from first chamber 113 or second chamber 114. In one embodiment of the present invention, holding chamber 115 may include a pair of doors 116, 117. Each door 116, 117 of holding chamber 115 may be activated to direct items from dispensing head 110 in a first direction, which may be toward a container or a container chute 119. Each door 116, 117 may be activated to divert items in a second direction, which may be away from a container and toward a diversion chute 120.
To direct items in a first direction, each door 116, 117 may rotate in a clockwise direction, e.g., about a pivot 119 shown in
Referring to
In an another embodiment of the present invention, holding chamber 115 may include two pairs of reconfigurable doors (not shown). One pair of doors may be positioned beneath first chamber, while a second pair of reconfigurable doors may be positioned beneath second chamber. The first pair of reconfigurable doors may receive items from first chamber 113, while the second pair of reconfigurable doors may receive items from second chamber 114. Each pair of doors may be activated to direct items in a first direction, e.g., toward a container, or to divert items in a second direction, e.g., away from a container.
A dispensing and diversion system of the present invention may include a star wheel 118. As shown in
Star wheel 118 may be driven directly by feeder bowl rotation drive 105. For example, feeder bowl rotation drive 105 may drive a frame 108 which supports star wheel 118 and feeder bowl 101. In an alternate embodiment, star wheel 118 may be driven indirectly by feeder bowl rotation drive 105, e.g., via a transmission. In a further embodiment, a separate drive may drive star wheel 118 at different rotational speeds, so that star wheel 118 may position containers in synchronization with rotary, vibratory dispenser.
A plurality of apertures 602 may be formed through star wheel 118. Each aperture 602 may extend from a top surface of star wheel 118 to a bottom surface of star wheel 118, so that items may pass through star wheel 118, via apertures 602. The number, shape, and position of star wheel apertures 602 may vary according to the number of dispensing heads 110 of rotary, vibratory dispenser, a physical characteristic of each dispensed item, a configuration of one or more chutes positioned in alignment with apertures 602, or the like.
A guard rail 603 may be positioned adjacent to star wheel 118. For example, a guard rail 603 may be positioned adjacent to a periphery of star wheel 118, as shown in
As shown in
The number, shape, and position of container chutes 119 may vary depending upon the number and configuration of dispensing heads 110 of rotary, vibratory dispenser, the number and configuration of container-receiving grooves of star wheel 118, or the like. Moreover, container chutes 119 of varying size and dimension may be positioned interchangeably on star wheel 118 to direct items of varying physical characteristics, e.g., volume, weight, density, or the like, to containers positioned around star wheel 118. In another embodiment of the invention (not shown), container chutes 119 may be positioned adjacent to star wheel 118 to receive items from dispensing paths 102 or dispensing heads 110 and to deliver the items to a respective container. For example, container chutes 119 may be supported by a respective dispensing head 110 or a frame 108, or the like, rather than being positioned on star wheel 118.
One or more diversion chutes 120 may be positioned on star wheel 118. Diversion chutes 120 may be positioned around a periphery of star wheel 118, e.g., adjacent to container chutes 119, to receive items diverted by one or more dispensing heads 110. Moreover, each diversion chute 120 may communicate with an aperture 602 of star wheel 118, so that each diversion chute 120 may divert items through a respective star wheel aperture 602 and away from containers positioned at container-receiving grooves 601 of star wheel 118. Star wheel 118 may position each diversion chute 120 in alignment with one or more dispensing heads 110.
The number, shape, and position of diversion chutes 120 may vary depending upon the number and configuration of dispensing heads 110 of rotary, vibratory dispenser, the number and configuration of star wheel apertures 602, or the like. Each diversion chute 120 may communicate with, i.e., divert items through, one or more star wheel apertures 602. Moreover, diversion chutes 120 of varying size and dimension may be positioned interchangeably on star wheel 118 to divert items of varying physical characteristics, e.g., volume, weight, density, or the like, away from containers positioned around star wheel 118. For example, diversion chutes 120 may be formed by concentric walls extending from a surface of star wheel 118 to form an annular space over star wheel apertures 602. In another embodiment of the invention, diversion chutes 120 may be positioned adjacent to star wheel 118 to receive items diverted by respective dispensing heads 110. For example, diversion chutes 120 may be supported by a frame or by a respective dispensing head 110, rather than being supported by star wheel 118.
The dispensing and diversion system of the present invention may include a rejection system. The rejection system may include a rejection conveyor 121, as shown in
According to another embodiment of the invention, each dispensing head 110 may divert items through star wheel apertures 602a to a plurality of buckets (not shown) that may be positioned beneath star wheel 118 to rotate with star wheel 118 and to receive items diverted through star wheel apertures 602. For example, a bucket may be positioned beneath one or more star wheel apertures 602 to receive items diverted through each aperture 602. Moreover, each bucket may include a cam follower that engages a cam track as each bucket rotates with star wheel 118. The cam track may be positioned adjacent to star wheel 118 and may comprise at least one cam. Engagement of the cam follower of each bucket and the at least one cam of the cam track causes each bucket to discharge the diverted items from each bucket to a rejection system, e.g., to a rejection conveyor, to a rejection chute, or the like. For example, each bucket may be mounted pivotally beneath star wheel 118, such that engagement of the cam follower of each bucket and the at least one cam of the cam track may pivot each bucket to discharge diverted items contained within each bucket to a rejection system. Moreover, the at least one cam may comprise a plurality of cams positioned along the cam track, so that each of the buckets may discharge diverted items at a plurality of locations.
The rejection system may transport the diverted items discharged by each bucket to a rejection bin, where the items may be collected. The rejection system may comprise a conveyor, a chute, or the like to transport diverted items to the rejection bin.
In operation, rotary, vibratory dispenser receives a plurality of items delivered by bulk delivery apparatus 104 to feeder bowl 101. Feeder bowl rotation drive 105 and feeder bowl vibration device 106 respectively rotate and vibrate feeder bowl 101, so that feeder bowl 101 supplies items uniformly to each of a plurality of dispensing paths 102 positioned around feeder bowl 101. Dispensing path vibration devices 107 vibrate each dispensing path 102 and associated item-dispensing channel(s), so that each dispensing path 102 and channel(s) may dispense items singularly.
Sensing units 109 measure a physical characteristic of each item dispensed from each dispensing path 102 or channel and transmit each measurement to a control unit. Control unit determines whether the measured physical characteristic of each item is within a predetermined range of physical characteristics for that item, or whether the measured physical characteristic of an item is greater than or less than the predetermined range of physical characteristics. Control unit counts each dispensed item to provide an exact count of items dispensed from each dispensing path 102 and channel. In one embodiment of the invention, control unit counts only items, the measured physical characteristic of which is within a predetermined range of physical characteristics.
A dispensing head 110 receives items dispensed from each respective dispensing path 102 and channel. Bifurcation device 112 directs items to one of a first chamber 113 or a second chamber 114 of dispensing head 110. Control unit activates bifurcation device 112 once a predetermined quantity of items is received within a respective chamber of dispensing head 110, so that the items may exit the chamber and flow to holding chambers 115. If any of the items in a predetermined quantity of items has a measured physical characteristic of which that is greater than or less than a predetermined range, control unit activates the holding chamber 115 of the respective dispensing head 110 to divert the items away from a container and toward a diversion chute 120, so that the items may pass through diversion chute 120 and star wheel 118 to a rejection conveyor. Rejection conveyor transports the items to a rejection bin. If each of the items in the predetermined quantity of items has a measured physical characteristic that is within a predetermined range of physical characteristics, control unit activates holding chamber 115 of dispensing head 110 to direct the predetermined quantity of items to a container chute 119, so that items may pass through container chute 119 to a container positioned at a container-receiving groove 601 of star wheel 118.
Control unit may activate bifurcation device 112 to release items in a chamber as soon as an item with a measured physical characteristic that is greater than or less than a predetermined range is received in dispensing head 110. In another embodiment of the invention, control unit may increment a count of a predetermined quantity of items for each item the measured physical characteristic of which is greater than or less than a predetermined range, so that dispensing head 110 may direct a predetermined quantity of items, the measured physical characteristic of which of which is within a predetermined range of physical characteristics, to a container.
Referring to
While the invention has been described in connection with preferred embodiments, it will be understood by those of ordinary skill in the art that other variations and modifications of the preferred embodiments described above may be made without departing from the scope of the invention. Moreover, other embodiments of the present invention will be apparent to those of ordinary skill in the art from a consideration of the specification or a practice of the invention disclosed herein, or both.
This application claims priority from U.S. Provisional Patent Application No. 60/390,371 entitled “Dispensing and Diversion Systems and Methods,” and filed on Jun. 24, 2002, and U.S. Provisional Patent Application No. 60/454,596 entitled “Dispensing and Diversion Systems and Methods,” and filed on Mar. 17, 2003, the disclosures of which are incorporated herein by reference in their entirety.
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