Parts sorter

Abstract

An apparatus for sorting a plurality of substantially identical parts has a holding bin having a volume for holding a plurality of substantially identical parts and an opening for releasing some of the parts; a spring-mass system for translating the parts forward; a channel having a width of approximately nx, where n is an integer greater than one and x is the width of a characteristic dimension of the parts based on a preferred orientation due to translation of the parts; and a fluted chute having n rounded bottom, downwardly extending, diverging flutes each of a width of at least x, for separating remaining stacked parts and dividing a single plane of parts into n one dimensional lines of parts, such that the parts may be individually handled. The channel accepts a plurality of parts from the opening in the holding bin, and together with the vibrating spring-mass system which is preferably a second order system, arranges the parts into a substantially single plane of parts of no more than n abreast in the channel and forwards the parts towards a chute. The parts pass through the chute, over optical sensors and to a gate section having accumulator and deflector gates. A gate controller coupled to the optical sensors is provided to permit gates to be opened and closed based on the part count, and the locations to which the parts are being deflected.

Description

BACKGROUND

The invention generally relates to a parts sorter, and more particularly to an optical tablet and capsule counter for use in the pharmaceutical industry.

Optical counters for counting tablets and/or capsules have been known in the pharmaceutical industry for some time. Such counters take various forms. It is generally the common goal of such counters to reduce a pile of tablets or capsules to a single one-dimensional row so that they may be counted as they move past an optical sensor. Some of the various systems for accomplishing the same include rotational and linear vibrators, rotating discs, air jets, gravity feeds, moving belts, etc. Each system has its benefits and drawbacks.

Among the difficulties encountered by optical tablet or capsule counter systems are the requirements of: having a high throughput and accuracy; allowing different size tablets and capsules to be accommodated without undergoing extensive or difficult adjustments in the machine; providing an automatic feed and collection of tablets and capsules in excess of a selected or desired quantity; and providing for the tablets and capsules to be deposited directly into a final container, all with the goal of providing a relatively small sized, reliable counter. In the past, in order to obtain some of the goals, various other goals have been ignored or highly compromised. Typically, high count rate and highly accurate machines have been large in size, while smaller machines have been less accurate or have suffered from low throughput. Moreover, the art has not provided any small, high count rate, accurate machines capable of accommodating various tablet and capsule sizes without difficult machine adjustments.

Among the various sorters and counters known are those found in the following patents which are representative of the prior art:

______________________________________U.S. Pat. No. Inventor U.K. Patent No. Inventor______________________________________3,095,960 Luginbuhl 565,275 Thomson3,355,003 Wayne et al. 584,227 Hurst3,444,980 Wiseman 617,693 Bayes3,730,386 Monsees 671,821 Daniels3,767,027 Pund et al. 761,553 Gregory4,029,195 Hartness et al. 838,230 Packman4,129,207 Cupp 931,124 Nobel-Bozel 1,013,533 Korber 1,079,174 Fox et al. 1,093,800 Cutler 1,290,961 AMF, Inc. 1,318,988 Blanchaud et al.______________________________________ Of particular interest among the listed patents are the U.S. Pat. Nos. 4,129,207, to Cupp and 3,730,386 to Monsees. The Cupp patent discloses a sorter for hamburger buns which are forced to assume an hexagonal close pack arrangement before being divided into one-dimensional streams. The Cupp patent assumes that the buns are in a two-dimensional arrangement (i.e. unstacked) when they reach a diverging descending chute section, and no means for eliminating stacked buns is provided. Moreover, in the Cupp patent, means for counting the buns coming off of the chute in a parallel manner is not provided, nor are means for directing the parallel buns to single locations in desired numbers.

The patent to Monsees U.S. Pat. No. 3,730,386 discloses a counting machine for egg rolls. Successive conveyors at higher rates are used to separate the egg rolls into a single one-dimensional stream. The single stream is accommodated in a single V-shaped channel which has low enough sides to permit any egg rolls which may be atop other egg rolls to fall over the side of the channel. The Monsees patent suffers from low throughput, as only a single channel is provided.

SUMMARY OF THE INVENTION

It is therefore an object of the invention to provide a high throughput parts counter which is small in size, accurate, and simple to use;

It is another object of the invention to provide a parts detector which is capable of counting parts of various sizes without difficult adjustment in accommodating for different part types.

It is a further object of the invention to provide an optical parts counter for pharmaceuticals, capable of counting tablets and capsules of various sizes with automatic adjustment to accommodate the same;

It is yet a further object of the invention to provide an automatically size-adjustable optical tablet and capsule counter of small size, high throughput, and high accuracy.

In accord with the objects of the invention, the parts sorter of the invention broadly comprises:

(a) a holding bin having a holding area for holding a plurality of substantially identical parts and an opening for releasing some of said parts; (b) a means of forward translation of the parts; (c) a channel having a width of approximately nx, where n is an integer greater than one and x is the width of a characteristic dimension of said parts based on a preferred orientation of the parts due to translation, where said channel accepts a plurality of parts from said opening in said holding bin, and together with said means for forward translation arranges the parts substantially into a single two-dimensional plane of parts of no more than n abreast in said channel and forwards the parts towards a chute; and (d) a fluted chute having n flutes each of a width of at least x, each having a substantially rounded bottom surface along at least part of its length, and each descending as its extends away from said channel, for dividing said substantially two dimensional plane of parts into n one dimensional lines of parts, such that said parts sorter includes an optical counter, the sorter preferably further includes an optical sensor for counting the parts travelling in or exiting each flute of said fluted chute. Preferably, at least n sensors are used, with one sensor for each flute of the chute. Also, where the parts sorter is used for counting tablets or capsules or the like, preferably, the sorter includes and exit gate array for directing the tablets or capsules to their appropriate destinations.

In accord with a further aspect of the invention, the parts sorter is adjustable for handling parts of different dimensions. In order to make the sorter adjustable, the channel width and chute geometry or channel width and length are adjustable, the fluted chute has diverging flutes, and the relationship between the channel and the fluted chute is arranged such that the width of the end of the channel and the width of the portion of the fluted chute which first receives the parts are substantially equal. In providing such an arrangement, the fluted chute is provided with adjustable fingers defining the flutes or the flutes are fixed (non-adjustable) and the channel can be lengthened or shortened so that the end of the channel is located where the width of the diverging fluted chute is equal to the channel width. If automatic adjustment is desired, the optical sensors should preferably be sensitive to the dimensions of the parts. Then with feedback from the sensor to a servo system, the fingers of the chute or the channel floor may be automatically adjusted by the servo system.

Other preferred aspects of the invention include: use of a vibrating platen as a means of forward translation; provision of adjustable width walls or fences to define the channel; use of an adjustable venturi or throttle to help reduce the three dimensional parts arrangement in the bin into a two dimensional parts arrangement on the vibrating platen; a microprocessor for automatic control of the channel width and finger arrangement as well as for permitting a simplified interface for human input; gate control to permit a plurality of containers to be filled simultaneously or in a programmed sequence; a return tray for capturing parts which remain in the system after additional filling of containers is not desired; a controller for varying the amplitude and/or frequency of the platen vibration to accommodate different speeds and different size parts; and a double spring-mass platen system for obtaining higher throughput. The various aspects of the invention all permit the parts sorter to have all of the desired features aforestated in the Background section herein.

Other objects, features, and advantages of the invention will become apparent to those skilled in the art upon reference to the following detailed description of the invention and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1a is a top plan view of the invention;

FIG. 1b is a side plan view, partially in section, of the invention;

FIG. 2 is a partially cut-away perspective view of the parts sorter invention;

FIG. 3 is a part schematic part block diagram of the control system of the invention;

FIGS. 4a1, 4a2, 4b1 and 4b2 are flow diagrams of the control algorithm for the microprocessor of the sorter invention;

FIG. 5 is a side plane view of the double spring-mass system of an alternative embodiment of the invention; and

FIG. 6 is a top plan view of an alternative embodiment of the invention with fixed chute fingers and an adjustable channel length.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The essence of sorting and/or counting parts is to take a plurality of parts which are in a three-dimensional arrangement, and reduce the three-dimensional arrangement into a one-dimensional arrangement such that each part may be handled separately. One preferred embodiment of the invention for accomplishing this task is seen generally in FIGS. 1a and 1b and 2. The parts sorter apparatus 10 basically includes a holding bin 20, a means of forward translation 30 for the parts, a channel 40, and a fluted chute 50. The holding bin 20, as is best seen in FIG. 1b, provides a volume (three-dimensional) for accepting a plurality of parts. The bin is preferably supported by the chassis 100 of the apparatus 10 so that the weight of the bin and the parts do not apply an excessive force to the forwarding means 30. Indeed, the only force applied is by the parts which are directly above an opening 24 which is provided at the bottom of the bin 20. The size of the opening and the clearance of the bin opening 24 over the forwarding means 30 are chosen in a manner to accommodate the range of sizes of the parts and the throughput of the apparatus. Indeed, if desired, both the opening 24 and the clearance may be adjustable. It is of note, however, that it is not critical immediately upon leaving the bin that the parts establish a two-dimensional arrangement. This is so because the forwarding means 30 and the channel 40 are preferably arranged to enable parts to establish such a two-dimensional arrangement. Moreover, the fluted chute 50 is arranged to provide instabilities to and to divide any stacked parts which reach the fluted chute in a stacked manner and in so doing establish single streams of parts.

Directly below the bin 20 is the entry to the channel 40 which will be described in greater detail hereinafter. Parts are advanced along the channel 40 by the means of forward translation 30. While many different means of forward translation (hereinafter "forwarding means") are known in the art, the forwarding means 30 herein is preferably a vibrating platen assembly. The vibrating platen assembly of FIGS. 1A, 1B, and 2 is comprised of a spring-mass system with an upper plate (or vibrating platen 31 on which the channel 40 is formed) as the mass, and cantilever spring supports 34 as the springs. The spring supports 34 are arranged to connect the upper plate of the spring-mass system to the chassis 100 but are flexible enough to allow the upper plate 31 to move in a vibratory manner relative to the chassis. In order to vibrate the upper plate, an electromagnetic shaker is used such as is manufactured under #CV-1 by General Automation of San Diego, Calif. The shaker preferably includes the magnetic coil 36 which is attached to the chassis, and a magnetic armature 38 which is attached to the upper plate 31. The magnetic coil 36 is arranged to have current flowing therethrough to alternately attract and release the armature 38, thereby causing the armature 38 and platen 31 which is attached thereto to vibrate. Those skilled in the art will recognize that the speed and amplitude of vibration are thereby controllable. It will also be recognized that the vibrating platen may be arranged such that parts which are to be sorted will be driven to uniformly have one axis (the preferred axis) in a given direction thereby providing a characteristic dimension of width x, perpendicular to the direction of travel. Further, it should be appreciated that second and higher order spring-mass systems may be stacked atop the vibrating platen if desired by locating a compliant (rubber) strip atop the vibrating platen, and attaching another plate thereto which will act as the surface for the channel. Such an arrangement is seen in FIG. 5, where compliant strips 34a are provided as the second spring member, and top plate 31a is provided as the second mass. The second spring-mass system is preferably tuned to act as an amplifier.

Also, because of the compliant nature of the upper plate 31a and the sponginess of the springs of the second spring-mass system, parts which bounce onto the channel are quickly dampened. The resulting increase contact between the parts and the channel further acts to increase the system throughput. If desired, higher order spring-mass systems may be utilized. Regardless, the respective spring-mass systems are preferably tuned in a manner consistent with a dynamic mechanical system to obtain optimal results.

While the forwarding means 30 is helpful in eliminating parts from sitting atop each other, the channel 40 is also arranged to do the same. Thus, the channel is preferably comprised of a low friction surface (shown as 31a in FIG. 5) which is either identical to or integral with the top plate 31 of the vibrating platen assembly, a venturi or throttle 44 for restricting flow, and sides or fences 46 for establishing a channel width. When parts descend through the bin opening 24 onto the channel surface 31, they are vibrated along the channel by the forwarding means 30. However, the venturi 44 restricts the flow thereby limiting the number of parts which may proceed over a measured period of time. Once the parts proceed through the venturi, they typically establish a two-dimensional arrangement due to gravity. The vibrating action tends to aid the process of reducing the parts into the minimum energy two-dimensional configuration.

The channel is preferably arranged with fences 46 which define a channel width of nx+e, (e being a width greater than or equal to zero, and less than x) where n is an integer determined by the number of flutes in the fluted chute 50 and x is the characteristic dimension of the parts which are to be sorted. Thus, the parts tend to proceed n abreast within the channel towards the fluted chute 50 with their axis of the characteristic dimension perpendicular to their direction of movement. Because the channel width is only slightly larger than nx (i.e. not as large as (n+1)x), there is no opportunity for a row of more than n parts to arrive at the end of the channel simultaneously. Also, because of the venturi arrangement and the vibrating platen provide a substantially two-dimensional arrangement of parts (occasionally parts may sit atop each other in a stable arrangement), it is unlikely that more than n parts would attempt to settle into the n slots available. It will be appreciated that the size of the venturi may be controlled as desired. Also, as will be discussed hereinafter with regard to another aspect of the invention, the width of the channel may be automatically controlled.

At the end of channel 40, the parts reach a fluted chute 50. For purposes herein, the "chute" 50 shall be defined to be that area which: receives the parts from the channel 40; divides the parts into one-dimensional lines of parts; introduces instability into stacked parts not arranged in a one-dimensional line so as to cause such parts to assume a minimum energy; and then forwards the parts for handling as desired. The "flutes" 52 shall be defined to be the individual channels in the chute 50 through which the lines of parts traverse. The "fingers" 54 shall be defined to be the objects which separate the flutes 52 one from another. It will be recognized that the fingers 54 can be of minimal thickness. As seen best in FIG. 1a, the fluted chute is preferably comprised of n flutes 52a, 52b . . . , the exact number of flutes required being dependent on the loading of the system, the size of throat 44, etc. Each flute preferably has a width where it meets the channel 40 of approximately x (but not smaller than x). The n flutes are preferably separated and defined by n+1 fingers 54-1, 54-2 . . . , which effect the dividing of the leading row of n parts exiting the channel into n separate streams. The fingers 54 which also act to guide the parts down the fluted chute preferably have a minimal thickness where they meet the channel 40. Thus, the width of the fluted chute where it meets the channel 40 is preferably just slightly greater than nx, with the sum of the widths of the flutes preferably comprising a width of nx. As will be described hereinafter with reference to another aspect of the invention, the fingers 54 are preferably controllable such that the width of the flutes 52 may be changed automatically to accommodate a change in parts.

In order to introduce instability to stacked parts for the purpose of unstacking the same, the flutes are arranged to introduce a differential force to any remaining stacked parts. It is therefore desirable to introduce geometrical limitations which cause the respective stacked parts to translate the forward motion introduced by the spring-mass systems into different movements. The preferred flutes accomplish this in three ways, although any one of the three might suffice depending on the nature of the parts being counted. First, the flutes 52 are arranged with a rounded bottom such that stacked parts will typically engage the walls of the flute at different times and at different relative locations, thereby introducing instability. Second, the flutes are sloped downward in the direction of travel, thereby adding a forward component of the gravity force vector which will accelerate the stacked parts away from each other. The sloping of the fluted chute relative to the channel 40 also causes the stacked parts to change planar direction which helps promote separation of parts as the distance traversed by the lower and upper stacked parts differs. Third, instability is further introduced by causing the flutes to diverge and widen along the direction of travel, thereby adding a lateral component to the force vector applied to the stacked parts due to interaction with the side wall of the flute as the parts move through the flute.

Where the parts sorter is a counter, such as for tablets or capsules, the sorter 10 preferably further includes a sensor for counting the parts exiting each flute 52 of the fluted chute 50. In the preferred embodiment, the counter is an electronic counter and the sensor is an optical sensor 60. Preferably, n sensors 60 are used, with one sensor for each flute of the chute. The sensor 60 typically comprises an infrared source 62 and a photodiode 64 (or photovoltaic or photoresistor or other). As a part such as a tablet or capsule interrupts the infrared beam generated by the infrared source 62, the photodiode 64 senses the interruption (shadow) and updates a counter. As will be described in more detail hereinafter with regard to the automatic control of the apparatus 10, the detector 64 may also be arranged to detect the size of the part interrupting the infrared beam by measuring the size and time of the shadow.

Also, where the parts sorter apparatus 10 is used for counting tablets or capsules or the like, preferably, the sorter 10 includes an exit gate array 70 for directing the tablets or capsules towards appropriate locations. The gate array may comprise various gates for sorting the tablets or capsules as desired: One preferred arrangement provides an accumulator gate 72 which accumulates the tablets or capsules so that a certain number may all be released simultaneously to a container or bottle arranged at an exit manifold 79. A second gate may be a return gate 74 which permits the tablets or capsules remaining in the system to be captured and returned to a return bin 75 via a return manifold 76 after all desired containers have been filled. Finally, a diverter gate 78 may be provided so that the capsules or tablets may be directed to a desired exit manifold leading to the bottles. In this manner, more than one bottle may be simultaneously or sequentially filled with tablets or capsules. For simultaneous filling, all that is required is that the tablets or capsules be properly controlled to direct them to different desired locations such as by having tablets exiting different flutes be diverted to different exit manifolds 79. For sequential filling, all diverter gates 78 may be arranged to first send the tablets to a first manifold and then to toggle individually or simultaneously as required to divert the tablets to a second manifold. In particular, where a plurality of flutes handle capsules or tablets in parallel, and where the number of capsules or tablets having been diverted to an exit manifold approaches the total number of capsules or tablets required for a single bottle, one or more of the accumulator gates 72 are closed to prevent a plurality of simultaneously arriving capsules or tablets from exceeding the desired number of capsules or tablets. Then one or more accumulator gate which is holding the exact total of capsules or tablets required to complete the bottle count are opened selectively in a temporary manner (to prevent newly arriving capsules or tablets from slipping through). The number of capsules or tablets being accumulated behind the other accumulator gates are tracked so that when the all the accumulator gates are reopened for filling the next bottle, the number of capsules or tablets that will fall into the next bottle is known.

Those skilled in the art will appreciate that other gates may be supplied as desired to provide additional functions. Likewise, with additional diverter gates 78 and exit manifolds 79, the simultaneous filling of additional bottles or containers may be established. Indeed, if desired, the bottles or containers can be on a movable belt for increased automation.

In accord with a further aspect of the invention, the parts sorter apparatus 10 is adjustable for handling parts of different dimensions. In order to make the sorter adjustable, the channel 40 is arranged to have an adjustable width by having fences 46 be movable. Thus, as the characteristic dimension of the parts changes, the width of the channel may change. However, solely a change in the channel width will not fully accommodate a change in the parts to be sorted. Because the relationship between the channel 40 and the fluted chute 50 is such that the width of the end of the channel and the width of the portion of the fluted chute which first receives the parts are substantially equal, if the channel width is changed, the width of the receiving portion of the fluted chute must change. Preferably, in order to provide a fluted chute 50 with an adjustable width receiving section, the fluted chute 50 is provided with adjustable fingers 54 which define and divide the flutes 52. It will be appreciated that with moving fingers 54, the fingers other than the center finger (which need not be movable) will not always have their tips exactly abutting the edge of the channel. In order to accommodate the arc length change which results from the rotation of the fingers, either a small gap must be allowed between the end of the channel 40 and the defined flutes 52 in some circumstances, and/or the fingers must be allowed to extend beyond the edge of the channel 40. Thus, in the preferred embodiment of the invention, the fingers 54 extend under the channel 40, thus providing a small ledge 49 at the end of the channel 40. In this manner, the fingers 54 may be moved closer together or further apart to accommodate the channel width. Also, in this manner, the tips of the fingers are advantageously concealed from the tablets or capsules. Preferably, the end of the fingers 54 furthest from the bin 20 are stationary but pivotally attached to the chassis 100, and the tips of the fingers are moved by rotating the fingers about the stationary end.

It will be appreciated that the outer fingers (e.g. 54-1 and 54-5) of the fluted chute 50 will extend the furthest under the channel 40, as a change in the smaller dimension of the parts will cause the outer fingers to be rotated the most. In fact, if the dimension of the part decreases by length d, and the outer fingers are two fingers away from the middle finger, the tips of the outer fingers must be moved in by a distance 2d. However, even though the thickness of the fingers may increase in the direction away from the bin 20, the outside fingers do not add additional thickness to the nx thickness, as the thickness of the fingers may be arranged to be on the outside of the nx width, as shown in FIG. 1a. It will also be appreciated, as seen in FIG. 2, that the outside fingers may be directly connected to the channel fences 44. Thus, the movement of the chute fingers will automatically move the channel fences 44 and keep the widths equal.

Another manner of guaranteeing that the width of channel 40 is equal to the width of the fluted chute 50 where the two meet, is to extend the channel 40 over the a set of geometrically fixed diverging flutes until the same is accomplished, as seen in FIG. 6. In FIG. 6, the apparatus invention is provided with a flexible fence 46a, fence supports 13a and 13b, a platen 31a, sliding surface 31b which vibrates with platen 31a, flexible plates 31c with angled slots 51a-51d, locator pins 53a-53d, and fixed fingers 54-1 through 54-5 which define the fluted chute area. Locator pins 53a-53d are fixed in position, while sliding plates 31c, which are attached to flexible fence 46a are slidable forward or backward relative to platen 31a. As sliding plates 31c are slid backward, angled slots 51a-51d move relative to the fixed locator pins 53, and the movement of plates 31c cause flexible fence 46a to deform as shown. When sliding plates 31c are slid in a particular direction, sliding surface 31b, which is attached to and above platen 31a, but below sliding plates, 31c is also slid forward or backward as necessary such that where the channel as defined by the sliding surface meets the fluted chute, the width of each flute equals the characteristic dimension width of the parts to be sorted. This may be accomplished by lining up the flexible fence 46a with the fixed outer fingers 54-1 and 54-5 of the fluted chute. Sliding plates 31c and sliding surface 31b are then fastened by fasteners (not shown). Also in another arrangement, sliding plates 31c may be suspended above platen 31a so as not to vibrate therewith.

Turning to FIG. 3, it is seen that the apparatus invention preferably includes control means 110 for controlling various mechanical aspects of the apparatus. The control means includes a microprocessor 114 such as an Intel 8031 which preferably has a RAM, EPROM, address latch, data bus, and bidirectional bus driver (all not shown) associated therewith. The EPROM is provided to hold a desired program (which will be described with reference to FIG. 4) and the address decoders which permits the microprocessor to interface with peripherals. Thus, the microprocessor is arranged to interface with a user via a keyboard input means 116. The microprocessor also interfaces with a display 118, such as an alphanumeric LED array, for displaying information to the user. In conjunction with the commands of the user, and information received from return tray detector 122, bottle detectors 124, and other desired logical conditions if provided, the microprocessor is seen to control the mechanical gates 72, 74 and 78 via the gate interface 126. Likewise, in conjunction with the commands of the user, the microprocessor 114 can control the amplitude and frequency of the platen vibrations via platen control interface 128. Also, in conjunction with the commands of the user or as a result of information received from optical sensors 60 via a buffer 132, the microprocessor can actively control the width of the channel 40 and the movement of the fingers of the fluted chute 50 (or in the FIG. 6 embodiment, the sliding of the sliding plates) via commands to a servo-controller 150.

In order to provide for automatic adjustment of the apparatus to accommodate a change in the parts dimensions, either the user must inform the microprocessor 114 of the parts dimensions by feeding the new dimension to the microprocessor via keyboard 116, or additional means must be provided to sense the characteristic dimension of the parts. In accord with the preferred embodiment of the invention, an array of photodiodes with associated logic and circuitry are arranged to provide exactly that function. Thus, each sensor 60 not only includes an infrared source 62, but, for example, an array of sixteen integrated circuit chips which have a photodiode thereon. Chips such as the TRW OPC0812 can be used for such purposes. With such an arrangement, a determination of the characteristic dimension of the part may be had by sending the results to the microprocessor 114 and then averaging the results over a desired number of samples. Of course, refinement and active adjustment may be continually accomplished.

With a determination of the characteristic dimension of the parts to be sorted, the microprocessor 114 can send directions to a servo-controller 150. The servo-controller 150 may then provide signals for automatically adjusting the widths of the flutes 52 of the fluted chute 50 and the width of the channel 40 by the movement of the fingers 54. In order to adjust the widths of the flutes 52 and the channel 40, a servo-controller system preferably comprises the servo-controller 150, a control cam 154, lever arms 156 which follow the tracks in the control cam and which rotate the fingers of the fluted chute accordingly, a motor 158 for turning the control cam 154, and a potentiometer 162 for determining the position of the control cam. Thus, as seen in schematic form in FIG. 1b, in cut-away perspective form in FIG. 2, and in block form in FIG. 3, the instructions of the microprocessor 114 are interpreted by the servo-controller 150 which causes a voltage to be seen by the motor 158. In response the motor drives the control cam 154 by rotating it in the desired direction. The control cam 154 is preferably arranged with tracks which are slightly inclined relative to the rotational axis of the cam to form a cylindrical spiral, with the inclination or pitch of the tracks for the outer arms being proportionately larger than those of the inner arms. As the control cam 154 rotates, the lever arms 156 follow the tracks or grooves and force the fingers 54 of the fluted chute 50 to rotate accordingly. A potentiometer 162 monitors the rotation of the control cam 154 and provides a feedback signal to the servo-controller 150 so that the voltage to the motor 150 can be correspondingly changed. Again, as aforementioned, because the channel fences 46 are preferably attached to the outer fingers 54, the rotation of the control cam 154 causes the channel width to change along with the movement of the outer fingers.

A representative operation of the sorting apparatus 10 is best understood with reference to FIGS. 4a and 4b which set forth in flow diagram format the algorithm of a control program contained in the EPROM of the microprocessor. For purposes of understanding, the program of the EPROM of the microprocessor of the apparatus 10 will be described with reference to a tablet or capsule counter.

Upon powering up of the apparatus at 200 by plugging into a standard outlet and toggling a switch, the default parameters of the apparatus 10 are initialized at 202. The apparatus is then ready to accept set up information from the user and checks at 204 to see whether any buttons on the keyboard 116 have been pressed. If no buttons have been pressed, the apparatus waits at 206 until the user enters information.

The keyboard 116 preferably comprises three sets of buttons; a numeric pad; a set up control set; and an operation control set. The numerical pad includes the standard ten numerals which permit the user in the set up mode to choose the number of tablets or capsules to be packaged into an individual bottle, and the number of individual bottles to be filled. The set up control buttons permit the user to clear the display if an incorrect number of bottles or tablets have been chosen and if desired, to roughly prearrange the apparatus for tablets or capsules of different sizes. The operation control buttons permits the user to start and stop the operation of the apparatus, and to place the apparatus in a pause mode where the programmed parameters are retained but the apparatus is not actively processing tablets.

Once the keyboard has been pressed, a decision is made at 208 as to whether a set up mode button (including numeric) or an operation control button has been pressed. If a set up mode button has been pressed, a decision is made at 210 as to whether the button is a number or not. If it is a number, a decision is made at 212 as to whether the bottle number button has been pressed or not prior to the number. If the bottle amount button has not been pressed, the number being entered is for the tablet quantity. The number is displayed on the display 118, and the tablet quantity is then stored at 214 in memory. The apparatus then awaits the pressing of another button at 204. If, on the other hand, the bottle amount button had been pressed, the number being entered is considered to indicate the number (or amount) of bottles to be filled. That number is also displayed on the display 118 with a light next to the bottle amount button, and the number is stored at 216 in memory.

If the set up button pressed at 208 was not a number, it is assumed to be a set up control. Thus, at 222 a decision is made as to whether the control button was a bottle amount, a capsule choice, a size choice, or a clear display command. If the button was a bottle amount, the program continues at 224 and waits for additional information at 204. If a capsule choice is made (default=tablet), the information is stored in memory at 226 and the program returns to await the pressing of another button at 204. If a tablet or capsule size button is pushed (small, medium, or large), the size is recorded in memory at 228 and the program likewise returns to 204. On the other hand, if the clear button is pressed, the display is cleared (a "0" appears) at 230, and a decision is made at 232 as to whether the bottle amount button has been pressed. If the bottle amount was pressed, the memory for the bottle amount is reset at 234. Otherwise, the quantity of tablets or capsules is reset at 236. The program then returns to 204 to await additional instructions.

If the button pressed at 204 is found at 208 to be an operation control, a decision is made at 240 as to whether the operation control is the start control. If it is, a determination is made at 242 as to whether the tablet or capsule quantity has been set, and whether a size has been chosen. If one or the other has not been accomplished, an appropriate error message is sent at 246 to the display, and the program is returned to 204. If everything is in order, the system waits at 244 while the microprocessor 114 instructs the servo system 150 to arrange the channel 40 and fluted chute 50 to accommodate the proper size tablet or capsule. The microprocessor may also set the frequency of platen oscillation based on the stated rough size of the tablet or capsule, open the accumulators, and close the return chute the sorting and counting operation commences. Once the operation commences, the keyboard is constantly monitored for additional instructions.

If the control button pressed at 204 is not a start button, a determination is made at 248 as to whether the cancel (stop) button has been pressed. When the stop button has been pressed, if operation of the system has commenced, it is stopped. Regardless, the entire programming is started anew as the program returns to the initialization step 202. If the stop button was not pressed at 248, it is assumed at 252 that the pause command has been issued. Thus, the microprocessor brings the platen vibration to a halt and awaits at 204 another command such as "start" or "cancel". If desired, other commands such as "jog" may be provided to permit a manual control of the operation of the system.

Turning to FIG. 4b, the flow chart of the EPROM program which controls the apparatus is shown. Once the start button has been pressed the servo system is initialized. At 260, information from optical sensor 60 is read via a buffer 132, and a determination is made at 262 whether an object is being sensed. If a tablet is being sensed a no-sensing (empty) timer is reset to zero at 264. Then, at 266 a decision is made as to whether the tablet being sensed is a new tablet; i.e. the previous time through the loop, was no object sensed? If the tablet is not a new tablet, a running tabulation is made at 368 of the tablet's size through a knowledge of the amount of light being received to determine width, and/or length of time it is taking for the tablet to pass the sensor. If the tablet is a new tablet, a determination is made at 270 as to whether the tablet is being accumulated by the accumulator or is being permitted to go to a bottle. If the tablet can go to the bottle, a quantity index for the bottle is incremented at 271. Then the tablet's size is integrated (averaged) as aforestated at 268. If the tablet is being accumulated, a counter keeps track at 272 of the number of tablets at the accumulator and then the size is integrated at 268.

If no tablet is sensed at 262, a determination is made at 276 whether any object has been seen over a period of time T. If a period of time T has elapsed without a tablet being sensed, a determination is made at 278 as to whether the tasks have been accomplished. If yes, the program is returned to the initialize step 202. If the task has not been accomplished, it is assumed that the apparatus is empty and an empty signal is flashed at 279 on display 118. Then the program is returned to step 204 where user input is desired.

If no tablet is seen, but the time T has not elapsed, a determination is made at step 280 as to whether the appearance of no tablet is indicative of the end of the tablet, i.e. is it the first run through the code after the tablet is no longer sensed. If the tablet has immediately passed the sensor, a determination is made at 282 as to whether the tablet was one of a predetermined number of first tablets through the system. If it was, the size of the tablet is added at 283 to a running average which is used to fine tune the channel width and chute fingers via the servo mechanism. If the tablet was not one of the first number of tablets through, the size of the tablet may be compared at 284 to twice (or integer or non-integer greater than one) the predetermined running average and if it exceeds the multiplier times the average, an extra tablet(s) may be counted by returning the program to step 270.

Once each sensor has been checked for tablets exiting the flute of the chute with which it is associated and the program has looped through steps 260 to 284 for each sensor, the program continues by checking to see whether the bottles have been filled and whether the order has been filled. Thus at 290, a determination is made as to whether any more tablets are expected at the accumulator or diverter gate, by ascertaining whether a tablet is being sensed at the sensor. If no tablets are coming, the program returns to step 260 to check the sensors. If tablets are expected, a determination is made at 292 as to whether the tablet is to be the last tablet for the bottle. If it is, a timing mechanism is started at 294 for the diverter gate, as it takes some time from the moment the last tablet is sensed until it reaches the diverter and the diverter should not be toggled until that occurrence. Once a preset time has passed, as determined at 297, a determination is made at 298 as to whether the last bottle of the order is being filled. If not, at 302 the diverter gate is toggled, the bottle amount (count) is incremented and the accumulator is opened (if closed). The program then returns to step 260 to check the sensors. If the last bottle is being filled, at 304 the return chute is opened, the servo mechanism opens the channel to its maximum size and the program returns to step 260 until all the tablets are returned to the return tray and the sensors do not sense tablets for the predetermined amount of time.

If a decision is made at 292 that the tablet was not the last tablet for the bottle, a determination is made at 306 whether the tablet would exceed the number for the bottle. If yes, the accumulator is closed at 296 thus blocking the flow of additional tablets to this bottle and the program continues as aforedescribed. If the tablet is not the last and would not exceed the number for the bottle, the program continues at step 260.

It should be appreciated that the microprocessor of the invention is preferably able to step through the flow chart of FIGS. 4a and 4b at least on the order of the second power of ten repetitions each second. Such a speed permits an accurate determination of the size of the tablets being processed and quickly enables the servo mechanism to adjust chute finger locations and the size of the channel. It should also be appreciated that many other desirable features may be provided with the microprocessor and associated circuitry as so described. For example, the microprocessor could check to see that the return tray is in place prior to permitting the apparatus to fill an order. Likewise, the toggling of the accumulator may be timed in much the same manner as the timing of the diverter gate, as it takes some time for a last tablet for a bottle to travel from the sensor past the accumulator gate. Of course, the timing must be coordinated with the fact that with mechanical gates, there is a finite time to accomplish opening and closing. Further, sensors to determine bottle size can be implemented and the microprocessor could issue commands to adjust the bottle sizes in response thereto. Also, detection of foreign objects may be accomplished by comparing the sensed object size to a continuous running average, and warning of foreign objects may be given to the user.

There has been described and illustrated an apparatus for sorting a plurality of substantially identical parts, and especially a tablet or capsule counter. While particular embodiments of the invention have been described, it is not intended that the invention be limited thereby, as it is intended that the invention be broad in scope and that the specifications be read likewise. Thus, it will be understood by those skilled in the art that while a particular means for forward translation (vibrator) was described, many different such means are known in the art. For example, the means for forward translation could comprise means for tilting the channel such that gravity will act as a forwarding force. Or, if desired, a moving belt, air jet, or other means or combination of means could be used for forwarding the objects and still be within the scope of the invention, as the terminology "means for forward translation" is intended to be extremely broad in scope.

Further, it will be understood that the number and shape of the fingers and flutes of the fluted chute can be changed without deviating from the invention, provided that the row of n parts exiting the channel including any remaining stacked parts is separated by the fluted chutes into n one dimensional lines of parts. For example, the flutes could decline away from the channel such that gravity rather than the vibrating platen which extends through the chute area would cause the objects to proceed. Likewise, the bin, channel, and servo mechanism could all be substantially changed. The bin opening need not be on the bottom of the bin. Indeed, the bin itself need not be a conventional bin, but rather a source for the parts to be sorted. The channel, while preferably having parallel walls, could have slightly diverging walls, flexible walls, and/or no venturi. Also, the channel width which was described as being controlled by the servo control system by having the outer fingers attached to the channel fences, may be controlled by separate means with the fences not being attached to the outer fingers. The servo mechanism could utilize gears or the like rather than a control cam and lever arms.

Further yet, the sensors, gate arrangement and microprocessor programming and control could be substantially changed. For example, rather than causing all the accumulator gates to close when the desired parts count is neared, and then toggling appropriate gates to permit the desired number of parts through in order to complete the count, if the throughput of the system is not excessive, the gates can be closed only as the last part for a desired location passes. Or, upon reaching the ninety-eighth or ninety-ninth part for a one hundred part count, one or more gates can be temporarily closed while other gates remain open until the desired count is reached. Of course, other gating arrangements could be provided to perform fewer or more desired functions. The microprocessor and related circuitry could subsume the functions of the servo-controller by generating voltages for the motor operating the control cam. Or, if desired, a computer can be appended to the system. Thus, the determination of part widths for controlling the adjustability of the system could be accomplished in the servo or in an appended computer. Moreover, the program controlling the microprocessor and various aspects of the apparatus invention could take numerous forms. Also, the sensor for the parts counter could take different forms, and needs not be optical. Therefore, it will be apparent to those skilled in the art that other changes and modifications may be made to the invention as described without departing from the spirit and scope of the invention as so claimed.

Claims

1. An apparatus for sorting a plurality of substantially identical parts, comprising:

(a) a source of parts for said apparatus;

(b) a means of forward translation for forwarding said parts;

(c) a channel having a width of approximately nx, where n is an integer greater than one and x is the width of a characteristic dimension of said parts based on a preferred orientation of said parts due to translation, where said channel accepts a plurality of parts from said source of parts, said plurality of parts assuming a three-dimensional configuration including some parts in a stacked configuration, and said channel together with said means for forward translation causes said plurality of parts to assume a configuration of a substantially two dimensional plane of parts of no more than n abreast in said channel while forwarding the parts towards a chute; and

(d) a fluted chute having n flutes each of a width of at least x, each having a substantially rounded bottom surface along at least part of its length, and each descending as it extends away from said channel, for separating any of said parts still in said stacked configuration and dividing said substantially two dimensional plane of parts into n one dimensional lines of parts, such that said parts may be individually handled.

2. An apparatus according to claim 1, wherein:

said flutes diverge one from another as they extend away from said channel.

3. An apparatus according to claim 2, further comprising:

(e) means for adjusting the width of said channel to accommodate a change in the width x of said characteristic dimension of said parts.

4. An apparatus according to claim 3, further comprising:

(f) means for adjusting the widths of said flutes where said fluted chute accepts said parts from said channel, wherein

said fluted chute includes finger means for defining said flutes, and said finger means is adjustable.

5. An apparatus according to claim 4, further comprising:

(g) means for sensing the width of said parts and outputting a signal representative thereof, wherein

said means for adjusting the width of said channel includes means for automatically adjusting the width of said channel in response to a signal related to said signal output by said means for sensing.

6. An apparatus according to claim 5, wherein:

said means for adjusting the widths of said flutes includes means for automatically adjusting the locations of said fingers of said chute in response to a signal related to said signal output by said means for sensing.

7. An apparatus according to claim 1, further comprising:

(e) means for adjusting the length of said channel; wherein

said flutes diverge one from another with widths increasing as they extend away from said channel.

8. An apparatus according to claim 7, wherein:

said means for forward translation comprises a vibrating platen,

said fluted chute includes finger means for defining said flutes, said finger means being fixed in place, and

said means for adjusting the length of said channel comprises a sliding surface coupled to said vibrating platen and extending over at least a portion of said fluted chute, and means for adjusting the width of said channel to substantially equal the width of said fluted chute at an intersection of said sliding surface and said fluted chute.

9. An apparatus according to claim 1, wherein:

said means for forward translation comprises a vibrating second order spring-mass system.

10. An apparatus according to claim 9, wherein:

said second order spring-mass system comprises a first plate and means for vibrating said first plate, and at least one compliant strip atop said first plate and a second plate atop said at least one compliant strip.

11. An apparatus for sorting a plurality of substantially identical parts, comprising:

(a) a holding bin having a volume for holding a plurality of said substantially identical parts and an opening for releasing some of said parts;

(b) a means of forward translation for forwarding said parts;

(c) a channel having a width of approximately nx, where n is an integer greater than one and x is the width of a characteristic dimension of said parts based on a preferred orientation of said parts due to translation, where said channel accepts a plurality of parts from said opening in said holding bin, said plurality of parts assuming a three-dimensional configuration including some parts in a stacked configuration, and said channel together with said means for forward translation causes said plurality of parts to assume a configuration of a substantially two dimensional plane of parts of no more than n abreast in said channel while forwarding the parts towards a chute; and

(d) a fluted chute having n flutes each of a width of at least x, each having a substantially rounded bottom surface along at least part of its length, and each descending as it extends away from said channel, for separating any of said parts still in said stacked configuration and dividing said substantially two dimensional plane of parts into n one dimensional lines of parts, such that said parts may be individually handled; and

(e) a means for counting said parts after said parts have been divided into n one dimensional lines.

12. An apparatus according to claim 11, wherein:

said means for counting said parts includes at least one optical sensor.

13. An apparatus according to claim 12, wherein:

said flutes diverge one from another as they extend away from said channel.

14. An apparatus according to claim 13, further comprising:

(f) means for adjusting the width of said channel to accommodate a change in the width x of said characteristic dimension of said parts.

15. An apparatus according to claim 14, further comprising:

(g) means for adjusting the widths of said flutes where said fluted chute accepts said parts from said channel, wherein

said fluted chute includes finger means for defining said flutes, and said finger means is adjustable.

16. An apparatus according to claim 15, further comprising:

(h) means for sensing the width of said parts and outputting a signal representative thereof, wherein

said means for adjusting the width of said channel includes means for automatically adjusting the width of said channel in response to a signal related to said signal output by said means for sensing.

17. An apparatus according to claim 16, wherein:

said means for adjusting the widths of said flutes includes means for automatically adjusting the locations of said fingers of said chute in response to a signal related to said signal output by said means for sensing.

18. An apparatus according to claim 11, further comprising:

(f) means for adjusting the length of said channel; wherein

the widths of said flutes increase as they extend away from said channel.

19. An apparatus according to claim 16, wherein:

said means for automatically adjusting the width of said flutes where said chute accepts said parts from said channel comprises a servo control system including a servo-controller for receiving signals related to said signal output by said means for sensing and for providing signals related to said received signals, and a motor responsive to the signals output by servo-controller, wherein the motor causes said fingers to be adjusted.

20. An apparatus according to claim 19, further comprising:

(i) a microprocessor for receiving signals from at least said means for sensing, said microprocessor for processing signal information, and for providing signals to at least said servo-controller.

21. An apparatus according to claim 12, further comprising:

(f) a gate section including means for receiving said parts and means for directing said parts to a desired location after said parts have been counted by said at least one optical sensor.

22. An apparatus according to claim 21, wherein:

said means for receiving said parts includes a plurality of accumulator gates, and said means for directing said parts includes a plurality of deflector gates for deflecting said parts towards desired locations when said accumulator gates are not accumulating said parts.

23. An apparatus according to claim 22, further comprising:

(g) means for controlling said gate section; wherein

said optical sensor outputs information to said means for controlling said gate section, and

said means for controlling said gate section keeps count of the number of parts having been sensed by said at least one optical sensor and having passed through said plurality of accumulator gates.

24. An apparatus according to claim 23, wherein:

said means for controlling said gate section keeps count of the number of parts behind each accumulator gate when one or more accumulator gate is closed;

when parts passing by at least two of said accumulator gates are being sent to the same destination, said means for controlling said gate section closes at least one accumulator gate when the number of parts having passed through said at least two of said accumulator gates approaches a desired number.

25. An apparatus according to claim 24, for the sequential filling of containers at different locations, wherein:

said means for controlling said gate section toggles at least one deflector gate after a last part for a given destination as defined by said desired number passes said deflector gate.

26. An apparatus according to claim 25, further comprising:

(h) a return tray for capturing parts in said apparatus having a destination other than said containers, wherein,

said gate section further includes a return gate for directing said parts having a destination other than said containers to said return tray.

27. An apparatus according to claim 11, wherein:

said means for forward translation comprises a vibrating second order spring-mass system.

28. An apparatus according to claim 27, wherein:

said second order spring-mass system comprises a first plate and means for vibrating said first plate, and at least one compliant strip atop said first plate and a second plate atop said at least one compliant strip.

29. An apparatus for sorting a plurality of substantially identical parts, comprising:

(a) a holding bin having a volume for holding a plurality of substantially identical parts and an opening for releasing some of said parts;

(b) a means of forward translation for forwarding said parts;

(c) a channel having a width of approximately nx, where n is an integer greater than one and x is the width of a characteristic dimension of said parts based on a preferred orientation of said parts due to translation, where said channel accepts a plurality of parts from said opening in said holding bin, said plurality of parts assuming a three-dimensional configuration including some parts in a stacked configuration, and said channel together with said means for forward translation causes said plurality of parts to assume a configuration of a substantially two dimensional plane of parts of no more than n abreast in said channel while forwarding the parts towards a chute; and

(d) a fluted chute having n flutes each of a width of at least x, each having a substantially rounded bottom surface along at least part of its length, and each descending as it extends away from said channel, for separating any of said parts still in said stacked configuration and dividing said substantially two dimensional plane of parts into n one dimensional lines of parts, such that said parts may be individually handled;

(e) a means for counting said parts after said parts have been divided into n one dimensional lines;

(f) a gate section for receiving said parts and directing said parts to a desired location after said parts have been counted by said counting means, said gate section including a plurality of accumulator gates for accumulating parts; and

(g) means for controlling said gate section, wherein said means for counting outputs information to said means for controlling said gate section, and said means for controlling said gate section keeps count of the number of parts having been sensed by said means for counting and having passed through said accumulator gates, and open and closes said accumulator gates accordingly.

30. An apparatus according to claim 29, wherein:

when parts passing by at least two of said accumulator gates are being sent to the same destination, said means for controlling said gate section closes at least one accumulator gate when the number of parts having passed through said at least two of said accumulator gates approaches a desired number.

31. An apparatus according to claim 30, wherein:

said gate section further comprises a plurality of deflector gates for deflecting said parts to a desired location, said means for controlling said gate section controlling the opening and closing of said deflector gates.

32. An apparatus according to claim 29, wherein:

said means for controlling said gate section keeps count of the number of parts behind each accumulator gate when one or more accumulator gate is closed;

33. An apparatus according to claim 31, for the sequential filling of containers at different locations, wherein:

said means for controlling said gate section toggles at least one said deflector gate after a last part for a given destination as defined by said desired number passes said deflector gate.