TECHNICAL FIELD
In general, the present invention relates to a napkin folding apparatus, and in particular to an apparatus that positions flatware within a napkin, folds the napkin, and then applies an adhesive strip.
BACKGROUND OF THE INVENTION
A table setting, such as a table setting used in a restaurant, is often wrapped in a napkin. The table setting can include flatware, such as a fork, a knife, and a spoon, and can be held together by an adhesive strip.
SUMMARY OF THE INVENTION
In accordance with an aspect of the present application, a napkin folding apparatus for folding a napkin around at least one piece of flatware forming a flatware bundle is provided. The apparatus includes a napkin cartridge for receiving a plurality of napkins, at least one flatware cartridge for receiving a plurality of pieces of flatware, a folding assembly having a deck assembly for receiving one of the plurality of napkins and at least one of the plurality of pieces of flatware, and a rolling assembly for rolling the one of the plurality of napkins and the at least one of the plurality of pieces of flatware into the flatware bundle, and a transport assembly including an actuator and a gripper assembly movable by the actuator for transporting the flatware and the flatware bundle.
In accordance with an aspect of the present application, a napkin folding apparatus for folding a napkin around at least one piece of flatware forming a flatware bundle is provided. The apparatus includes a napkin cartridge for receiving a plurality of napkins; at least one flatware cartridge for receiving a plurality of pieces of flatware, a folding assembly having a deck assembly for receiving one of the plurality of napkins and at least one of the plurality of pieces of flatware, and a rolling assembly for rolling the one of the plurality of napkins and the at least one of the plurality of pieces of flatware into the flatware bundle, a transport assembly including an actuator and a gripper assembly movable by the actuator for transporting the flatware and the flatware bundle, a taping assembly including a roll holder for receiving a roll of tape, a cutting mechanism for cutting the tape, and a transport mechanism for transporting the tape once cut to the deck assembly, a first lifting assembly having a first lever arm for lifting the plurality of napkins, and at least one second lifting assembly having a second lever arm for lifting the plurality of pieces of flatware.
In accordance with another aspect of the present application, a method of creating a flatware bundle is provided. The method includes rotating a napkin pickup assembly from a first position to a second position to pick up a napkin, rotating the napkin pickup assembly from the second position to the first position, transporting at least one piece of flatware via a transport assembly from a flatware cartridge to a receiving position over the napkin, and rotating the napkin and at least one piece of flatware via a grip assembly to create the flatware bundle.
These and other objects of this invention will be evident when viewed in light of the drawings, detailed description and appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention may take physical form in certain parts and arrangements of parts, a preferred embodiment of which will be described in detail in the specification and illustrated in the accompanying drawings which form a part hereof, and wherein:
FIG. 1 is a front perspective view of an exemplary napkin folding apparatus.
FIG. 2 is a rear perspective view of the napkin folding apparatus.
FIG. 3 is a front perspective view of the napkin folding apparatus with plates removed.
FIG. 4 is a rear perspective view of the napkin folding apparatus with plates removed.
FIG. 5 is a perspective view of a deck assembly.
FIG. 6 is another perspective view of the deck assembly.
FIG. 7 is a perspective view of a rolling assembly.
FIG. 8 is a perspective view of a taping assembly.
FIG. 9 is another perspective view of the taping assembly.
FIG. 10 is still another perspective view of the taping assembly.
FIG. 11 is yet another perspective view of the taping assembly.
FIG. 12 is a further perspective view of the taping assembly.
FIG. 13 is a perspective view of a transport assembly.
FIG. 14 is another perspective view of a transport assembly
FIG. 15 is a perspective view of a lifting assembly.
FIG. 16 is a perspective view of a cartridge.
FIG. 17 is a perspective view of another cartridge.
FIG. 18 is a perspective view of still another cartridge.
FIG. 19 is a perspective view of yet another cartridge.
FIG. 20 is a perspective view of the apparatus with a frame removed.
FIG. 21 is another perspective view of the apparatus with a frame removed.
FIG. 22 is still another perspective view of the apparatus with a frame removed.
FIG. 23 is yet another perspective view of the apparatus with a frame removed.
FIG. 24 is a further perspective view of the apparatus with a frame removed.
FIG. 25 is another perspective view of the apparatus with a frame removed.
FIG. 26 is still another perspective view of the apparatus with a frame removed.
FIG. 27 is a further perspective view of the apparatus with a frame removed.
FIG. 28 is a perspective view of a deck assembly.
FIG. 29 is another perspective view of the deck assembly.
FIG. 30 is a perspective view of a rolling assembly.
FIG. 31 is a perspective view of a taping assembly.
FIG. 32 is another perspective view of a taping assembly.
FIG. 33 is a perspective view of a transport assembly.
FIG. 34 is another perspective view of a transport assembly.
FIG. 35 is a perspective view of a gripper assembly of the transport assembly.
FIG. 36 is another perspective view of the gripper assembly.
FIG. 37 is a perspective view of a lifting assembly.
FIG. 38 is a perspective view of a cartridge.
FIG. 39 is a perspective view of another cartridge.
FIG. 40 is a perspective view of still another cartridge.
FIG. 41 is a perspective view of yet another cartridge.
FIG. 42 is a perspective view of the apparatus with a frame removed.
FIG. 43 is another perspective view of the apparatus with a frame removed.
FIG. 44 is still another perspective view of the apparatus with a frame removed.
FIG. 45 is yet another perspective view of the apparatus with a frame removed.
FIG. 46 is a further perspective view of the apparatus with a frame removed.
FIG. 47 is another perspective view of the apparatus with a frame removed.
FIG. 48 is still another perspective view of the apparatus with a frame removed.
DETAILED DESCRIPTION OF THE INVENTION
With reference to the drawings, like reference numerals designate identical or corresponding parts throughout the several views. However, the inclusion of like elements in different views does not mean a given embodiment necessarily includes such elements or that all embodiments of the invention include such elements. The examples and figures are illustrative only and not meant to limit the invention, which is measured by the scope and spirit of the claims.
Turning initially to FIGS. 1-4, an exemplary napkin folding apparatus is shown at reference numeral 10. The apparatus 10 includes a housing 12 formed by one or more plates coupled to a frame 14 in a suitable manner, such as by fasteners. The housing 12 can include one or more openings, such as openings at its top closed by respective removable access panels 16 and 18, one or more openings at its front for receiving respective cartridges 20, 22, 24, and 26, an opening at its front closed by a bezel 28 to which a control, such as a human machine interface mounts, an opening at one side closed by a removable access panel 30, and an opening at another side through which a chute 32 extends. One or more handles 34 may be provided for transporting the apparatus, and a plurality of feet 36 may be provided for elevating the apparatus above a surface. A switch assembly 38 may also be provided on a side of the housing for connecting to a power source and turning the assembly on/off.
Disposed in the housing 12 is a folding assembly 40, a transport assembly 42 for delivering flatware to the folding assembly 40 and the chute 32, a taping assembly 44 for cutting strips of tape from a roll and delivering it to the folding assembly 40, and a plurality of lifting assemblies 46 for lifting the contents of the cartridges 20, 22, 24, and 26. The folding assembly 40 includes a deck assembly 50 for receiving the napkin and flatware and a rolling assembly 52 for rolling the napkin and silverware into a bundle. It will be appreciated that the apparatus also includes suitable circuitry, fans, connectors, wiring, etc. for controlling the apparatus.
Turning additionally to FIGS. 5 and 6, the deck assembly 50 will be described in detail. The deck assembly 50 includes a base 60 configured to be positioned on and coupled to a base of the taping assembly 44, a motor bracket 62 coupled to the base 60, a motor assembly 64 coupled to the motor bracket 62, and pivot brackets 66 and 68 coupled to the motor bracket 62 and the base 60 respectively. The motor bracket 62 may be coupled to the base 60 in a suitable manner, such as by suitable fasteners 70, and the pivot brackets 66 and 68 may be coupled to the motor bracket 62 and the base 60 in a suitable manner, such as by fasteners 72 and 74.
The motor assembly 64 includes a motor 80 having a shaft 82 coupled to a first pulley wheel 84, a second pulley wheel 86, and a belt 88 rotatable by the first pulley wheel 84 to drive the second pulley wheel 86. Coupled to the second pulley wheel 86 is a pivot rod 92 rotatable relative to the pivot brackets 66 and 68 by the motor assembly 64, and coupled to the pivot rod 92 and rotatable with the pivot rod 92 is a deck 90.
The deck 90 includes a base 100 having a first receiving area or napkin and flatware receiving area 102, a second receiving area 104, a slot 106 for receiving a vacuum bar 108, and a pair of ears 110 extending from its bottom through which the pivot rod 92 extends. A cradle assembly 112 is provided that includes a bottom portion 114 positioned in the first receiving area 102 and a top portion 116 positioned in the second receiving area 104. The top portion 116 is rotatable over the bottom portion 114 to effect a fold of the napkin and surround the flatware bundle. A motor 118 is coupled to the bottom of the deck 90 to effect movement of the top portion 116. The motor 118 has a shaft 120 coupled to a pulley wheel 122. A belt 124 coupled to the pulley wheel 122 and the top portion 116 is rotatable by the motor to drive the top portion 116 from its open position in the second receiving area 104 to its closed position over the bottom portion 114. The bottom portion 114 can include a gap 126 through which a cut strip of tape is fed.
The vacuum bar 108 is received in the slot 106 and secured in the slot 106 in a suitable manner. The vacuum bar 108 includes a port connected to a connector 130 for connecting to a source of vacuum, and one or more vacuum openings 132, and as show three openings, in communication with the connector 130. When the deck assembly 50 is rotated to pick-up a napkin, the vacuum is engaged to grab a side of the napkin while allowing the napkin to unfold as the deck assembly 50 is returned to its original position. It will be appreciated that the vacuum bar 108 may be integral with or formed in the deck 90.
Turning additionally to FIG. 7, the rolling assembly 52 will be described in detail. The rolling assembly 52 includes a base 150 configured to be positioned on and coupled to the base of the taping assembly 44, a first motor bracket 152 coupled to the base 150, a linear drive assembly 154 coupled to the first motor bracket 152, a second motor bracket 156 coupled to the linear drive assembly 154, a motor assembly 158 coupled to the second motor bracket 156, and a grip assembly 160 coupled to the motor assembly 158.
The linear drive assembly 154 includes a motor 162 having a shaft coupled to a linear actuator 164 to effect movement of the linear actuator 164. The second motor bracket 156 and motor assembly 158 are coupled to the linear actuator 164 such that movement of the linear actuator 164 effects movement of the grip assembly 160 toward and away from the deck 90. The motor assembly 158 includes a motor 166 having a shaft 168 coupled to a first pulley wheel 170, a second pulley wheel 172, and a belt 174 rotatable by the first pulley wheel 170 to drive the second pulley wheel 172 thereby rotating the grip assembly 160. The grip assembly 160 includes a body 180 coupled to the second pulley wheel 172 and a plurality of pins 182 or other suitable mechanism for engaging the flatware bundle. The linear actuator 164 moves the pins 182 toward and around the flatware bundle.
Turning now to FIGS. 8-12, the taping assembly 44 will be described in detail. The taping assembly 44 includes a deck support 186 for supporting the deck 90, a base 190 configured to be coupled to the housing 12, a roll holder 192 disposed on the base 190 for receiving a roll of tape 194, feed plates 196, a guide rail 188 for guiding the tape 194 to the feed plates 196, a cutting and transport assembly 198, and a feed mechanism 200. The tape 194 can have adhesive on both sides in non-overlapping zones.
The feed mechanism 200 includes a motor 202 having a shaft coupled to a pulley wheel 204, a first drive wheel 206, a belt 208 rotatable by the pulley wheel 204 to drive the first drive wheel 206, and a second drive wheel 210. The drive wheels 206 and 210 extend through respective openings 212 in the feed plates 196 to drive the tape 194 toward the cutting and transport assembly 198. The tape is driven until it contacts a stop 228 in an end plate 214. The end plate 214 also includes an area 216 spaced from the stop 228 for receiving a motor assembly and an area 218 spaced from the area 216 for receiving a cutting assembly. A sensor may be provided to verify the position of the tape.
The cutting and transport assembly 198 includes a cutting drive assembly 220, a support 222 coupled the base 190 and the cutting drive assembly 220, a cutting mechanism 224, and a motor assembly 226 coupled to the support 222.
The cutting drive assembly 220 includes a motor 230 having a shaft coupled to a linear actuator 232 to effect movement of the linear actuator 232. The linear actuator 232 is coupled to the cutting mechanism 224, which includes one or more cutting devices 234, such as a wheel or blade, movable vertically by the linear actuator 232 to cut the tap 194. The motor assembly 226 includes a motor 236 (FIG. 6) having a shaft coupled a first pulley wheel 238, a pair of second pulley wheels 240, and a belt 242 rotatable by the first pulley wheel 238 to drive the second pulley wheels 240. The second pulley wheels 240 are in contact with the tape 194 in the area 216 to move the cut tape 244 vertically to the rolling assembly 52. The tape 194 may include adhesive on one or more sides, and in one implementation, on both sides of the tape 194.
Turning now to FIGS. 13 and 14, the transport assembly 42 will be described in detail. The transport assembly 42 includes drive assembly 250 and a gripper assembly 252 coupled to the drive assembly 250. The drive assembly includes a first motor 254 having a shaft coupled to a linear actuator 256 to effect movement of the linear actuator 256 horizontally. The gripper assembly includes a support 258 coupled to the linear actuator 256 to move with movement of the linear actuator 256, a second motor 260 coupled to the support 258, a vacuum bar 262, support rods 264 coupled to the vacuum bar 262 and movable relative to the support 258, a third motor 266 coupled to the vacuum bar 262, a support arm 268 movable by the third motor 266, and guide pins 248 coupled to the vacuum bar 262.
The second motor 260 includes a drive screw 270 coupled to the vacuum bar 262 to effect vertical movement of the vacuum bar 262. The third motor 266 includes a shaft coupled to the support arm 268 to move the support arm 268, which may be substantially L-shaped, from a first position allow for retrieval of flatware and bundles, and a second position below the flatware and bundles. The guide pins 248 extend downward from the vacuum bar 262, for example on opposites sides thereof, to serve as guides to the flatware and bundles. The vacuum bar 262 includes a port coupled to a connector 272 for connecting to a source of vacuum, and one or more vacuum openings in communication with the port. When the vacuum bar 262 is lowered to position above the flatware or bundle, the vacuum is engaged to grab a single piece of flatware or the bundle.
The transport assembly 42 can also include one or more sensors 274 that senses an elevation of a stack of utensils. If the one or more sensors 274 verifies that the flatware is at the proper height for retrieval, then the flatware is retrieved. If the one or more sensors senses that the flatware is not at the proper height, the one or more sensors communicates with the respective lifting assembly to move the flatware to the proper height.
Turning now to FIG. 15, one of the plurality of lifting assemblies 46 will be described in detail. The apparatus 10 can include a lifting assembly 46 for each piece of flatware/napkin utilized. For example, the apparatus can include a lifting assembly 46a for a knife 280, a lifting assembly 46b for a fork 282, a lifting assembly 46c for a spoon 284, and a lifting assembly 46d for a napkin 286. The lifting assembly 46d may be substantially the same as the lifting assemblies 46a-c except for the height of the assembly.
The lifting assembly 46 includes a frame 290, a motor assembly 292 coupled to the frame, a bracket 294 movable in a track 296 coupled to the frame 290, and a lever arm 298 that moves the bracket 294. The motor assembly 292 includes a motor 300 having a shaft coupled to a drive screw 302, which is coupled to the lever arm 298 to raise the lever arm 298. The drive screw 302 is configured such that one revolution of the drive screw 302 raises the corresponding flatware stack one utensils height or alternatively, another predetermined height, and designed to not be back driven serving as a failsafe, for example if power is lost. The lifting assembly 46 can also include a sensor 304, such as a displacement sensor to measure the height of the flatware. It will be appreciated that the sensor 304 and the plate to which it is attached may be removed. It will also be appreciated that the sensor 304 may be used in addition to the sensor 274, or either sensor 274 or 304 may be used individually.
Turning now to FIGS. 16-19, the cartridges 20-26 will be described in detail. The cartridges may be made of suitable material, such as food-safe materials, and are designed to be efficiently loaded and washable in an industrial washer.
Referring initially to FIG. 16, the cartridge 20 will be described in detail. The cartridge 20 is configured to hold a stack of flatware, such as forks, spoons, knives, etc., and as shown a stack of knives 280. The cartridge includes 20 a frame 320, a top and bottom 322 and 324 coupled to the frame 320, and a handle 326 coupled to a front of the frame 320 for loading and unloading the cartridge 20. The frame, top, and bottom define a receiving area 328 for the flatware and for a movable plate 330 that moves vertically in the receiving area by movement of the lever arm 298. The flatware is disposed on the plate movable 330 such that movement of the plate 330 effects upward movement of the flatware. The frame 320 can include one or more openings 332 on its sides, and the top 322 can include an opening 334 for receiving the lifting assembly 46a to allow one piece of flatware to be picked up for transport to the deck assembly 50.
Referring now to FIG. 17, the cartridge 22 will be described in detail. The cartridge 22 is configured to hold a stack of flatware, and as shown a stack of forks 282. The cartridge includes a frame 340, a top and bottom 342 and 344 coupled to the frame 340, and a handle 346 coupled to a front of the frame 340 for loading and unloading the cartridge 22. The frame, top, and bottom define a receiving area 348 for the flatware and for a movable plate 350 that moves vertically in the receiving area by movement of the lever arm 298. The flatware is disposed on the movable plate 350 such that movement of the plate effects upward movement of the flatware. The frame 340 can include one or more openings 352 on its sides, and the top 342 can include an opening 354 for receiving the lifting assembly 46b to allow one piece of flatware to be picked up for transport to the deck assembly 50.
Referring now to FIG. 18, the cartridge 24 will be described in detail. The cartridge 24 is configured to hold a stack of flatware, and as shown a stack of spoons 284. The cartridge includes a frame 360, a top and bottom 362 and 364 coupled to the frame 360, and a handle 366 coupled to a front of the frame for loading and unloading the cartridge 24. The frame, top, and bottom define a receiving area 368 for the flatware and for a movable plate 370 that moves vertically in the receiving area by movement of the lever arm 298. The flatware is disposed on the movable plate 370 such that movement of the plate 370 effects upward movement of the flatware. The frame can include one or more openings 372 on its sides, and the top 362 can include an opening 374 for receiving the lifting assembly 46c to allow one piece of flatware to be picked up for transport to the deck assembly 50.
FIGS. 16-18 show various positions of the respective movable plates of the cartridges 20-24. For example, FIG. 16 shows the movable plate 330 in a first position where the stack of flatware is full, FIG. 17 shows the movable plate 350 in a second position where approximately half of the stack of flatware has been used, and FIG. 18 shows the movable plate 370 in a third position where approximate three quarters of the stack of flatware has been used.
Referring now to FIG. 19, the cartridge 26 will be described in detail. The cartridge 26 is configured to hold a stack of napkins, such as paper napkins or cloth napkins. The cartridge includes a frame 380, a top and bottom 382 and 384 coupled to the frame, and a handle 386 coupled to a front of the frame for loading and unloading the cartridge 26. The frame, top, and bottom define a receiving area 388 for the napkins and for a movable plate 390 that moves vertically in the receiving area by movement of the lever arm 298. The napkins are disposed on the movable plate 390 such that movement of the plate 390 effects upward movement of the napkins. The frame can include one or more openings 392 on its sides, and the top 382 can include an opening 394 through which the stack of napkins extends to be picked up by the deck assembly 50. As illustrated, the stack of napkins includes a stack of paper napkins having its fold positioned on the right side of the cartridge 26 closest to the deck assembly 50.
Turning additionally to FIGS. 20-27, the operation of the apparatus will be described in detail. FIG. 20 illustrates the apparatus in a home position, where the knife 280, fork 282, spoon 284, and napkin 286 are in the pick-up position or can be driven to their respective pick-up positions as needed. FIG. 21 shows the apparatus as it begins the folding process. In FIG. 21, the deck 90 has rotated from a first position to a second position to pick up a napkin. In the second position, the motor 80 has rotated the pivot rod 92 thereby rotating the deck 90 to position the base against a napkin 286. Suction is applied through the vacuum openings 132 in the vacuum bar 108 to grab and retain the napkin 286. With the suction engaged, the deck 90 is rotated back to the first position, where the napkin 286 will unfold and rest on the base 100. The linear drive assembly 154 is then activated to move the grip assembly 160 towards the deck 90 below the napkin.
Turning now to FIG. 22, the transport assembly 42 is then engaged to pick up at least one piece of flatware and transport it to the deck 90. The linear actuator 256 is moved to, or is already positioned above, one of the cartridges 20-24. Once positioned, the second motor 260 rotates to move the vacuum bar 262 downward to position it above the piece of flatware, with the guide pins 248 being on the sides of the flatware. Suction is applied through vacuum openings in the vacuum bar 262 to grab and retain the flatware. The second motor 260 then rotates to move the vacuum bar 262 upward and then the linear actuator 256 moves to the deck 90 above the first receiving area 102. The vacuum bar 262 can then be moved downward and the suction released to position the flatware on the napkin 286, moving part of the napkin into the first receiving area 102. In this position, the pins 182 act as a wall turning up a corner of the napkin at a handle end of the flatware. The process can then be repeated, if desired, to obtain additional pieces of flatware. As illustrated, the bundle includes one knife, one fork, and one spoon.
Turning now to FIG. 23, after the desired flatware has been positioned, the linear drive assembly 154 is activated to move the grip assembly 160 further toward the deck 90 such that the pins 182 encapsulate and end of the bundle. The grip assembly 160 allows for various types of flatware to be utilized and reduces machine size by encapsulating the end of the bundle rather than the whole bundle. The top portion 116 of the cradle assembly 112 can then be rotated by the motor 118 toward the bottom portion 114. The movement of the top portion 116 over the bottom portion 114 folds the napkin over the top of the flatware. The grip assembly 160 can then be rotated by the motor 166 to create a flatware bundle 400 including the desired flatware, such as the knife 280, fork 282, and spoon 284 rolled within the napkin 286 as shown in FIG. 24. During rotation, the cradle assembly 112 provides surfaces to control the wrapping of the napkin 286.
After the bundle 400 has been created, the tape is applied to hold the bundle 400 together. Referring again to FIGS. 9-12, FIG. 9 illustrates the tape 194 being feed to the stop 228, and then the motor 230 is activated to move the linear actuator 232 upward allowing the cutting mechanism 224 to cut the tape 194 as shown in FIG. 10. The cutting mechanism 224 then returns to its home position as shown in FIG. 11, and the second pulley wheels 240 are rotated by the motor 236 to drive the cut tape 244 upward through the gap 126 in the bottom portion 114 of the cradle assembly 112. The grip assembly 160 can continue to rotate the bundle 400 as the cut tape 244 is being fed through allowing the tape 244 to surround the bundle 400 and adhere to itself to secure the bundle 400. The top portion 116 can then be rotated back to position in the second receiving area 104.
Turning now to FIG. 25, the linear actuator 256 is moved back toward the deck 90 above the bundle 400 and then lowered and the vacuum engaged to grab the bundle 400. The third motor 266 can then move the support arm 268 below the bundle 400. The gripper assembly 252 is then raised and the linear actuator 256 moves the bundle 400 towards the chute 32 as shown in FIG. 26. As shown in FIG. 27, the vacuum is then removed and the support arm 268 moved from below the bundle 400 and the bundle 400 drops down the chute to a storage container or the like.
Turning now to FIGS. 28-48, an exemplary embodiment of the napkin folding apparatus is shown at 510. The napkin folding apparatus 510 is substantially the same as the above-referenced napkin folding apparatus 10, and consequently the same reference numerals but indexed by 500 are used to denote structures corresponding to similar structures in the napkin folding apparatuses. In addition, the foregoing description of the napkin folding apparatus 10 is applicable to the napkin folding apparatus 510 except as noted below.
Turning initially to FIGS. 28 and 29, a deck assembly 550 is shown. The deck assembly includes a base 600 having a first receiving area or napkin and flatware receiving area 602 and a second receiving area 604, and a napkin pickup assembly 594 having a vacuum 608. The napkin pickup assembly 594 is rotatable relative to the base 600. A cradle assembly 512 is provided that includes a bottom portion 614 positioned in the first receiving area 602 and a top portion 616 positioned in the second receiving area 604. The top portion 616 is rotatable over the bottom portion 614 to effect a fold of the napkin and surround the flatware bundle. The bottom portion 614 can include a gap through which a cut strip of tape is fed. Provided on the top of the deck are one or more air jet blocks, and as shown two air jet blocks 596 that assist with the napkin flow into the roll up, and a napkin separator air blast 598 (FIG. 42) on top of the napkin cartridge. The air jet blocks 596 and napkin separator air blast 598 may utilize the exhaust of the vacuum generators to create the desired air flow.
Turning next to FIG. 30, a rolling assembly 552 will be described. The rolling assembly 552 includes a base 650, a guide rail 652, a linear drive assembly 654, and a grip assembly 660.
The linear drive assembly 654 includes a motor 662 having a shaft coupled to a linear actuator 664 to effect movement of the linear actuator 664. The grip assembly 660 is movable toward/away from the deck assembly 550 and rotatable around the flatware bundle. The grip assembly 660 includes a body 680 and a plurality of pins 682 or other suitable mechanism for engaging the flatware bundle. The linear actuator 664 moves the pins 682 toward and around the flatware bundle.
Turning now to FIGS. 31 and 32, a taping assembly 544 will be described in detail. The taping assembly 544 includes a base 690 configured to be coupled to the housing, a roll holder 692 disposed on the base 690 for receiving a roll of tape 694, feed plates 696, a guide rail 688 for guiding the tape 694 to the feed plates 696, a cutting and transport assembly 698, and a feed mechanism 700. The feed mechanism 700 includes a motor 702 coupled to a drive wheel 706 having a geometry allowing it to flex and compress to tension the tape. The cutting and transport assembly 698 includes a motor having a shaft with a gear that causes two feed rollers to turn via gears on the rollers geometry.
Turning now to FIGS. 33-36, a transport assembly 542 will be described. The transport assembly 542 includes drive assembly 750 and a gripper assembly 752 coupled to the drive assembly 750. The drive assembly includes a first motor 754 having a shaft coupled to a linear actuator 756 to effect movement of the linear actuator 256 horizontally. The gripper assembly may be an integrated unit, for example formed by 3D printing, that utilizes cam paths to actuate grippers 768 up and out of the way or down and surrounding the silverware bundle. The grippers 768 are driven by a linear actuator, and the gripper assembly is movable up and down by a ball screw assembly.
Turning now to FIG. 37, one of the plurality of lifting assemblies 546 will be described in detail. The apparatus 510 can include a lifting assembly 546 for each piece of flatware/napkin utilized. For example, the apparatus can include a lifting assembly for a knife 780, a lifting assembly for a fork 782, a lifting assembly for a spoon 784, and a lifting assembly for a napkin 786. The lifting assembly 546 includes a frame 790, an actuator assembly 792 coupled to the frame, and a lever arm 798 that moves relative to the frame. The actuator assembly 792 includes a motor 800 and plane bearings that effect movement of the lever arm 798.
Turning now to FIGS. 38-41, the cartridges 520-526 will be described. The cartridges may be made of suitable material, such as food-safe materials, and are designed to be efficiently loaded and washable in an industrial washer.
Referring initially to FIG. 38, the cartridge 520 is configured to hold a stack of flatware, such as forks, spoons, knives, etc., and as shown a stack of knives 780. The cartridge includes 520 a frame 820, such as a bent piece of stainless steel, with inserts 822 and a handle 826 coupled to a front of the frame 820 for loading and unloading the cartridge 520. The frame defines a receiving area 828 for the flatware and for a movable plate that moves vertically in the receiving area by movement of the lever arm 798.
Referring now to FIG. 39, the cartridge 522 will be described in detail. The cartridge 522 is configured to hold a stack of flatware, and as shown a stack of forks 782. The cartridge includes a frame 840, such as a bent piece of stainless steel, with inserts 842 and a handle 846 coupled to a front of the frame 840 for loading and unloading the cartridge 522. The frame defines a receiving area 848 for the flatware and for a movable plate that moves vertically in the receiving area by movement of the lever arm 798.
Referring now to FIG. 40, the cartridge 524 will be described in detail. The cartridge 524 is configured to hold a stack of flatware, and as shown a stack of spoons 784. The cartridge includes a frame 860, such as a bent piece of stainless steel, with inserts 862 and a handle 866 coupled to a front of the frame for loading and unloading the cartridge 524. The frame defines a receiving area 868 for the flatware and for a movable plate that moves vertically in the receiving area by movement of the lever arm 798.
Referring now to FIG. 41, the cartridge 526 will be described in detail. The cartridge 526 is configured to hold a stack of napkins 786, such as paper napkins or cloth napkins. The cartridge includes a frame 880, such as a bent piece of stainless steel, with inserts 882 and a handle 886 coupled to a front of the frame for loading and unloading the cartridge 526. The frame defines a receiving area 888 for the napkins and for a movable plate that moves vertically in the receiving area by movement of the lever arm 798.
The cartridges 520-524 are positioned on a drawer 910 and the cartridge 526 is positioned on a drawer 912 that are coupled to respective slides 914 and 912 to move relative to the assembly. To load the cartridges, the drawers are pulled out and the cartridges loaded vertically. The drawers and/or cartridges may then be locked in place. The cartridges may be keyed to the machine so the machine knows which utensil is loaded, for example a knife, fork, and spoon arrangement or a knife and fork arrangement. For example, the machine may include configurable pins and the cartridges may include holes that receive the pins. If the wrong cartridge is inserted into a slot, the pins will not mate and a home sensor will not detect the cartridge.
Turning additionally to FIGS. 42-48, the operation of the apparatus will be described in detail. FIG. 42 illustrates the apparatus in a home position, where the knife 780, fork 782, spoon 784, and napkin 786 are in the pick-up position or can be driven to their respective pick-up positions as needed. FIG. 43 shows the apparatus as it begins the folding process. In FIG. 42, the napkin pickup assembly 594 has rotated from a first position to a second position to pick up a napkin. In the second position, suction is applied through the vacuum 608 to grab and retain the napkin 786. With the suction engaged, the napkin pickup assembly 594 is rotated back to the first position shown in FIG. 43, where the napkin 886 will unfold and rest on the base 600.
Turning now to FIG. 44, the transport assembly 542 is then engaged to pick up at least one piece of flatware and transport it to the deck assembly 550. Turning now to FIG. 45, after the desired flatware has been positioned, the grip assembly 660 is moved toward the deck assembly 550 such that the pins 682 encapsulate and end of the bundle. The napkin pickup assembly 594 can then be rotated to fold the napkin over the top of the flatware, and the grip assembly 660 can then be rotated to create a flatware bundle 900 including the desired flatware, such as the knife 780, fork 782, and spoon 784 rolled within the napkin 786 as shown in FIG. 46. After the bundle 400 has been created, the tape is applied to hold the bundle 400 together.
Turning now to FIG. 47, the transport assembly 542 is moved back toward the deck assembly 550 above the bundle 900 and then lowered to grab the bundle 400, and then the bundle 900 moved toward a chute as shown in FIG. 48.
The aforementioned systems, components, (e.g., motors, belts, actuators, among others), and the like have been described with respect to interaction between several components and/or elements. It should be appreciated that such devices and elements can include those elements or sub-elements specified therein, some of the specified elements or sub-elements, and/or additional elements. Further yet, one or more elements and/or sub-elements may be combined into a single component to provide aggregate functionality. The elements may also interact with one or more other elements not specifically described herein.
While the embodiments discussed herein have been related to the apparatus, systems and methods discussed above, these embodiments are intended to be exemplary and are not intended to limit the applicability of these embodiments to only those discussions set forth herein.
The above examples are merely illustrative of several possible embodiments of various aspects of the present invention, wherein equivalent alterations and/or modifications will occur to others skilled in the art upon reading and understanding this specification and the annexed drawings. In particular regard to the various functions performed by the above described components (assemblies, devices, systems, circuits, and the like), the terms (including a reference to a “means”) used to describe such components are intended to correspond, unless otherwise indicated, to any component, such as hardware, software, or combinations thereof, which performs the specified function of the described component (e.g., that is functionally equivalent), even though not structurally equivalent to the disclosed structure which performs the function in the illustrated implementations of the invention. In addition although a particular feature of the invention may have been disclosed with respect to only one of several implementations, such feature may be combined with one or more other features of the other implementations as may be desired and advantageous for any given or particular application. Also, to the extent that the terms “including”, “includes”, “having”, “has”, “with”, or variants thereof are used in the detailed description and/or in the claims, such terms are intended to be inclusive in a manner similar to the term “comprising.”
This written description uses examples to disclose the invention, including the best mode, and also to enable one of ordinary skill in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that are not different from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
In the specification and claims, reference will be made to a number of terms that have the following meanings. The singular forms “a”, “an” and “the” include plural referents unless the context clearly dictates otherwise. Approximating language, as used herein throughout the specification and claims, may be applied to modify a quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term such as “about” is not to be limited to the precise value specified. In some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Moreover, unless specifically stated otherwise, a use of the terms “first,” “second,” etc., do not denote an order or importance, but rather the terms “first,” “second,” etc., are used to distinguish one element from another.
As used herein, the terms “may” and “may be” indicate a possibility of an occurrence within a set of circumstances; a possession of a specified property, characteristic or function; and/or qualify another verb by expressing one or more of an ability, capability, or possibility associated with the qualified verb. Accordingly, usage of “may” and “may be” indicates that a modified term is apparently appropriate, capable, or suitable for an indicated capacity, function, or usage, while taking into account that in some circumstances the modified term may sometimes not be appropriate, capable, or suitable. For example, in some circumstances an event or capacity can be expected, while in other circumstances the event or capacity cannot occur—this distinction is captured by the terms “may” and “may be.”
The best mode for carrying out the invention has been described for purposes of illustrating the best mode known to the applicant at the time and enable one of ordinary skill in the art to practice the invention, including making and using devices or systems and performing incorporated methods. The examples are illustrative only and not meant to limit the invention, as measured by the scope and merit of the claims. The invention has been described with reference to preferred and alternate embodiments. Obviously, modifications and alterations will occur to others upon the reading and understanding of the specification. It is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims or the equivalents thereof. The patentable scope of the invention is defined by the claims, and may include other examples that occur to one of ordinary skill in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differentiate from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
Patent Application
20240367938
