Patent Grant
8662314
The present invention relates to a sorting apparatus and method, and more specifically to a sorting apparatus and method for separating articles in a product stream using a mechanical diverter responsive to a machine vision system. The present invention also includes, in one form of the invention, a combination of a sorting apparatus that uses an air ejector for foreign material removal and a mechanical diverter for redirecting undesirable articles from a product stream.
Sorting methods and machines have been known and practiced for many years in the production of goods including comestible articles. The machines found in the art include types that utilize reflecting electromagnetic radiation in the form of light to determine the optical reflective characteristics of the articles in the product stream using color as a determinant followed by an ejector to successfully remove offending articles. A notable example of such a sorter is the High Speed Mass Flow Sorting Apparatus for Optical Inspection and Sorting Bulk Food Products as shown in U.S. Pat. No. 5,887,073, and which is assigned to Key Technology, Inc.
Successful removal of offending or undesirable articles has been practiced to varying degrees of efficiency using several different approaches including air ejection and mechanical diversion. Experience has shown that air ejection techniques are suitable for a wide range of article types, but is best applied for smaller, less dense articles that can be easily influenced by a jet of fluid. Examples of articles suitable for air ejection include peas, corn, potato strips, potato crisps, and foreign material. Air ejection as commonly practiced utilizes a plurality of electrically controlled valves that are individually controlled by a machine vision system, and targeted toward offending or undesirable articles in a product stream. Thus, the undesirable articles are dislodged from their course of travel and caused to take an alternate path, removing them from the product stream.
Alternatively, mechanical diversion is similarly suitable for a wide range of articles, however, it is best applied for larger articles that are less susceptible to the physical influence caused by a jet of fluid. Examples of articles suitable for mechanical diversion include oranges, grape fruit, onions, and potatoes. Mechanical diverters are known in the art to require more frequent maintenance than air ejectors. In addition, mechanical diverters are more prone to undesirably bruised articles during a diversion.
An example of a sorter using a mechanical diversion arrangement is found in U.S. Pat. No. 5,979,667, where a rigid paddle is taught, and which selectively strikes articles from the product stream thereby forcing them into another path of travel. In this reference, a pulsed light sensor receives reflected light from a product stream of articles such as tomatoes. A color comparator utilizes information supplied from the pulsed light sensor to identify undesirable articles in the product stream. A pneumatically operated, and electrically controlled paddle is positioned so that undesirable articles are expelled from the product stream by striking them during their movement along a path of travel to send them to an alternate location. This reference also teaches the option of reversing the logic so that the moveable paddle is used to divert acceptable articles. Unfortunately, the striking action of the paddle upon the article during its course of travel has the potential to bruise the articles, thereby reducing their perceived value.
Another example of relevant art is found in U.S. Pat. No. 5,509,537 where a flexible finger is used to selectively strike undesirable articles from the product stream. Here, the flexible finger is presented as an alternative to the paddle described, above. One might expect that the striking flexible finger might decrease any adverse effects caused by the impacts made to the articles traveling in the product stream. However, it would appear that a flexible finger would also decrease the accuracy of the ejection operation by nature of its flexibility.
The present invention overcomes this and other limitation of the prior art. For instance, none of the aforementioned teachings, or other examples in the art disclose a sorter that utilizes a mechanical diverter having a concave shape that can gently redirect undesirable articles to another path of travel for further processing. In addition, the art does not teach the combination of utilizing both an air ejection device, and mechanical diversion in a single sorter arrangement.
One aspect of the present invention relates to a sorting apparatus for separating articles in a product stream, and which includes an endless belt conveyor configured to launch articles from the product stream in a first trajectory; an inspection station coupled to the product stream and operable to provide a routing signal based on inspection of the product stream; and a diverter comprising a launching block having a concave surface, and located in downstream relation relative to the inspection station, and controlled by the routing signal, and wherein the diverter has a retracted position where articles extend their travel in the first trajectory, and an extended position where articles interact with the diverter in a gliding manner along the concave surface to effectively launch the articles into a second trajectory.
Another aspect of the present invention is to provide a sorting apparatus for separating articles in a product stream, and which includes a conveying means to transport and launch the articles in a product stream in a first trajectory; an inspection means coupled to the product stream to provide a first and second routing signal based upon the inspection of the product stream; and a diverter means having a concave member, and controlled by the first and second routing signals and located in downstream relation to the inspection station to pass articles in the first trajectory in response to the first routing signal, and to further urge articles to assume a second trajectory in response to the second routing signal by urging the articles to glide along the diverter so that the articles are effectively launched into a second trajectory.
Yet another aspect of the present invention is to provide a sorting apparatus for separating articles in a product stream having acceptable articles, unacceptable articles, and foreign material, and which includes an endless belt conveyor configured to launch the product stream in a first trajectory; an inspection station coupled to the product stream and operable to provide a plurality of routing signals based upon the inspection of the product stream; a first air ejection station located in downstream relation to the inspection station, and controlled by a first portion of the plurality of routing signals, and configured so as to expel the foreign material from the product stream product stream in a second trajectory; and a concave shaped diverter located in downstream relation to the inspection station and which is controlled by a second portion of the plurality of routing signals, and which is operable to launch undesirable articles from the product stream so that they become separated from the desirable articles moving in the product stream.
Still another aspect of the present invention relates to a sorting apparatus which includes a conveyor for transporting a multiplicity of articles in a continuous product stream, and which includes acceptable and unacceptable articles, and foreign material, and which further propels the product stream into a first path of travel; an inspection station positioned along the first path of travel, and wherein the inspection station visually inspects the product stream so as to identify the respective acceptable articles, unacceptable articles and foreign material, and further generates a plurality of routing signals following the inspection of the product stream; and a diverter assembly located downstream of the inspection station, and in spaced relation relative to the conveyor, and wherein the diverter assembly is controlled by the plurality of routing signals supplied by the inspection station, and further has a first and second plurality of selectively moveable launching blocks, and wherein the second plurality of launching blocks are located downstream of, and in substantially gravitationally feeding alignment with, the respective first plurality of selectively moveable launching blocks, and wherein the individual moveable launching blocks of the first and second plurality each have a first, retracted position, and a second, extended position, and wherein, when the individual launching blocks of the first and second plurality are both in the retracted position, the individual articles moving along in the product stream move along a second path of travel; and wherein when the individual moveable launching blocks of the first plurality are in the extended position, the individual articles moving along in the product stream move along a third path of travel; and wherein when the individual moveable launching blocks of the first plurality are in a retracted position, and the second plurality of launching blocks are in an extended position, the individual articles travelling along in the product stream move in a fourth path of travel, and wherein the second, third and fourth paths of travel effect the sorting of the articles in the product stream.
These and other aspects of the present invention will be described in greater detail hereinafter.
Preferred embodiments of the invention are described below with reference to the following accompanying drawings.
a is a perspective view of a launching block from the diverter employed in the first form of the invention.
b is an inverted perspective view of a launching block from the diverter employed in the first form of the invention.
This disclosure of the invention is submitted in furtherance of the constitutional purposes of the U.S. Patent Laws “to promote the progress of science and useful arts” (Article 1, Section 8).
Referring now to
A stream of articles, or incoming product stream 12 is introduced at an infeed end of the sorter 10. In practice, the product stream 12 may be composed of any article of manufacture or production, and often includes both desirable articles which meet the specification of quality, and undesirable articles which fall outside the specification of quality. Furthermore, the incoming product stream 12 may contain other materials which have a different nature than the articles and will hereinafter be referred to as foreign material. The product stream 12 is composed of individual articles traveling in a direction which is generally depicted by the flow arrow labeled 14. The product stream 12 may include individual articles that are moving in concert at a generally uniform speed and traveling in the product flow direction 14.
Articles in the product stream 12 are introduced to an endless belt conveyor 16 that is integrated into the sorter 10 for transporting the articles through the sorter 10. The conveyor 16 includes an endless belt selected to provide a sufficient amount of friction for stabilizing the articles in the product stream 12 as they are transported in the flow direction 14.
The sorter 10 includes a user interface 18 that enables an operator, (not shown), to observe and control various operational aspects of the sorter 10. From the user interface 18, an operator can view representations of the articles in the product stream 12 as they are processed in the sorter 10. In addition, the user interface 18 provides a means for the operator to configure the operation of the sorter 10 to enable the sorter to make a determination between acceptable articles, undesirable or unacceptable articles, and foreign material.
Articles in the product stream 12 are transported along a path of travel to the end of the conveyor 16 where they are launched into a given trajectory. The product stream 12 is composed of articles that are scattered across both a width and length of the conveyor 16, and are illustrated in a single-file manner in
A routing assembly 22 is positioned in downstream receiving relation relative to the inspection station 20, and is further configured to respond to directions provided by the inspection station 20. The routing assembly 22 includes a plurality of active diverters that are capable of urging articles, and foreign material in the product stream 12 to follow predefined paths of travel. One such path of travel is a foreign material path of travel 24. A second path of travel is an acceptable article path of travel 26 provided for acceptable articles in the product stream 12 to follow. Another such path of travel is an unacceptable article path 28 which is established for unacceptable articles moving in the product stream 12.
Referring now to
The inspection station 20 includes a first camera 36 which is positioned to view the product stream 12 as it is transported by the endless belt conveyor 16. A second camera 38 is positioned to provide a downwardly looking view of the product stream 12 after it has been launched off of the endless belt conveyor 16. A third camera 40 is positioned to provide an upwardly directed view of the product stream 12 after it has been launched off of the endless belt conveyor 16. It should be understood that the inspection station 20 may also be configured to include either a fewer, or a greater number of cameras, or other types of optical sensors including photodiodes, photomultiplier tubes, or other types of imaging or sensing devices known in the art without departing from the teachings of this invention.
The inspection station 20 also includes a sorting processor 42 that is connected to each of the above identified cameras 36, 38, and 40, and which is operable to process electrical signals produced by each of the cameras so as to provide resulting data indicative of the physical characteristics of the articles, and foreign material, which are present in the product stream 12. The sorting processor 42 compares these signals, or data, with guidance provided by an operator (via the user interface 18 (FIG. 1)), to provide a resulting plurality of routing signals 44 which command actuators in the routing assembly 22 whose structure and function will be discussed in further detail, below.
The routing assembly 22 also includes an ejector 46 which is positioned above, and directed toward, the product stream 12. It is also operably connected to one of the routing signals 44. The ejector 42 is composed of a plurality of solenoid valves, and associated fluid powered jets which are arranged across the width of the sorter 10, and which operate to direct a pulse of fluid (typically air) toward the product stream 12 to dislodge an article or foreign material targeted by the sorting processor in response to the received routing signal 44 which is derived from the product stream 12. Each of the plurality of jets in the ejector 42 are individually associated with one virtual lane 21 (
The routing assembly 22 also includes a mechanical diverter assembly 50 which operably receives the routing signals 44. The routing signals represent commands provided by the sorting processor 42 which is formed, in part, of a general purpose computer, not shown. The diverter assembly 50 is positioned beneath the product stream 12, and oriented in a manner so that it can physically interact with the product stream 12 so as to efficiently route articles in the product stream 12, to a lower slide 52, and an upper slide 54. An upper guide 56 is provided, and positioned above the upper slide 54 whose operation will be discussed in further detail, below.
In one form of the invention, acceptable articles 30 are routed through the region defined between the lower slide 52, and the upper slide 54, and follow the normal trajectory 100 until encountering the lower slide 52. Also in this first form of the invention, unacceptable articles 32 are routed through the region defined between the upper slide 54, and the upper guide 56, and follow either a gentle trajectory 106, or an aggressive trajectory 108. The diverter assembly 50 is shown in a retracted position 102 in
Now referring to
A plurality of actuators 66 are coupled in fluid transmission controlling relation relative to the plurality of solenoid valves in the valve assembly 64. They are further each borne by the mounting frame 62 on a plurality of actuator pivot pins 68. Each actuator has a rod 70 which is operable to positionally respond to fluid pressure. A bracket 72 is fastened to each rod 70.
A plurality of launching blocks 76 are pivotally positioned in juxtaposed relation between a plurality of pivot pins 70 that are located on the mounting frame 62, and between the bracket 72. A block pin 74 retains the launching block 76 to the bracket 72. Each launching block 76 is fastened in such a manner that an extension of the rod 70 of the actuator 66 effectively raises a portion of the launching block 76 thereby enabling a controllable physical interaction with the product stream 12, and which is effective in routing articles in response to the commands received from the sorting processor 42 (
In a preferred embodiment, the actuator 66 is a pneumatic cylinder having a sufficient piston area so as to accurately, and quickly position the launching block 76 in a given position in response to commands from the sorting processor 42.
Now referring to
Now referring to
Now referring to
The calculation step 122 is followed by a distance threshold decision 124 where the distance is compared with a predefined minimum distance value referred herein as dmin. If the distance threshold decision 124 is true, then a type decision 126 is made based upon the review of the tag of each of An and An−1. If the type decision 126 is true, then a delay step 128 is performed followed by an aggressive reject step 130.
Still referring to
The operation of the first form of the invention is believed to be readily apparent and is briefly summarized in the paragraphs which follow.
In operation, and referring to
Cameras 36, 38, and 40 provide a means for measuring physical characteristics of the objects in the product stream 12, and this measurement data is provided to the sorting processor 20 where it is compared, and contrasted with the sorting parameters discussed, above, so as to render or generate a series of sorting decisions which are manifested by a plurality of routing signals 44.
Now referring to
In this first form of the invention, a substantial portion of the acceptable articles 30 are detected, and then tagged by the sorting processor 42 by means of the diverter control routine 110 in the tag step 120 as ACCEPT, and further allowed to travel in the normal trajectory 100, uninfluenced by the ejector 46. Still further, the sorting processor 42, in the pass step 136, provides routing signals 44 to the diverter assembly 50 to move, or maintain it, in a retracted position as shown in
Now referring to
In the described methodology, if An−1 is ACCEPT and An is REJECT then the type decision 126 is true, and the delay step 128 will be performed. Here it should be understood that the routing signal 44 will be delayed, thereby holding the diverter assembly 50 in the retracted position 102, so as to allow An−1 to pass thereby. Then, after the delay step 128 is completed, the aggressive step 130 is performed, so that the diverter assembly 50 is moved to launch An into the aggressive trajectory 108 because the sorting processor 42 issues a routing signal 44 which causes the valve assembly 64 to supply fluid to the actuator 66 so as to cause the rod 70 to control the position of the launching block 76. In this process, the unacceptable articles 32 encounter the launching block 76 proximate to the contact surface 88 as it is moved from the retracted position 102 to the extended position 104. This movement imparts an upwardly directed force on the article, and causes it to deviate from the normal trajectory 100, and follow a path which is substantially similar to the aggressive trajectory 108. The unacceptable article 32, on the other hand, may encounter the upper guide 56, and/or the upper slide 54, where it is discharged for further processing. This aspect of the operation of the sorter 10 enables the efficient diversion of unacceptable articles 32 that are in the proximity of acceptable articles 30 in the same, or adjacent virtual lanes 21. This also allows the acceptable articles 30 to pass in the normal trajectory 100.
Alternatively, if the type decision 126 is false, or if the distance threshold decision 124 is true, then the reject decision 132 is performed by the sorting processor 42. If the reject decision 132 is true, that is, if An is tagged as REJECT, then the diverter assembly 50 is moved to the extended position 104 in a manner similar to that previously discussed, above. If the diverter assembly 50 was already in the extended position 104, then it is maintained in that position. In either case, the unacceptable article 32 will encounter the launching block 76 when it is already at the extended position 104, so that it encounters the contact surface 88. Once again, it will slide on or along the contact surface 88, and travel to the launching surface 90 which will then redirect the motion of same and which further provides a smooth translation so that it is launched into the gentle trajectory 108. This gentle trajectory has a minimal upwardly directed motion, and travels until it encounters the upper slide where it is discharged for further processing.
Referring now to
Referring now to
With respect to the second form of the invention 200, the invention further includes a first downwardly directed, multiple-laned article orienting ramp which is generally indicated by the numeral 210. This multiple-laned orientation ramp 210 causes the articles to be sorted, 204, to be moved into discrete lanes so that they may move through the inspection station, as will be described, below. In the case where the articles to be sorted 204 represent ears of corn, as depicted in
In
As seen in
The present invention 200 also includes a second plurality of launching blocks 250 which are located downstream relative to the second downwardly directed multiple-laned article orienting ramp 240. As will be recognized by studying the drawings, the length of the second multiple-laned article orienting ramp is typically less than the length of the articles 204 which are being sorted However, in certain forms of the invention, the length of these second multiple-laned article orienting ramp may be larger. In large measure, the length of these structures are used to maintain the alignment of the articles 204, and to further establish a given distance between the first and second ramps 301 and 302, respectively which will be discussed in greater detail hereinafter. The respective launching blocks of the second plurality 250 each have a first or proximal end 251 which is pivotally affixed to a frame, and a second, distal or moveable end 252. The respective launching blocks of the second plurality 250 further have an upwardly facing, concavely shaped surface 253, and a downwardly facing surface 254. As earlier discussed with respect to the first plurality of launching blocks 220, the second plurality 250 moves along an arcuately shaped path of travel 255, between a first, retracted or normally down position 256, and a second, extended or normally up position 257. As seen in
Referring more specifically to
With regards to the second form of the invention 200, it will be seen from the drawings in
As should be understood by studying the drawings, the second form of the invention 200 defines three courses, or paths of travel for the articles 204 to be sorted. In particular, the invention defines a first path of travel 212; a second path of travel 312; a third path of travel 313; and a fourth path of travel 314. It should be apparent, that as additional groups or pluralities of launching blocks are added to the structure that additional courses of travel could be defined. As will be appreciated, the second, third, and fourth paths of travel each represent a discrete sorting characteristic for the respective articles 204 which are sorted by the second form of the invention 200. As earlier discussed, the first path of travel 212 is defined by the first, downwardly directed multiple-laned article orienting ramp 210. The second course or path of travel 312 is defined when the individual launching blocks in the first and second plurality 220 and 250, respectively, are both in the first retracted position 226 and 256, respectively. This orientation of the aforementioned structures allows the individual articles 204 to move to the lowermost point based upon a first sorting characteristic as determined by the general purpose computer or processor which receives the routing signals 215. Further, the third path of travel 313 is defined when the individual launching blocks of the first plurality 220 are located in the first extended position 227, and the article 204 traveling along same is delivered onto the first article receiving ramp 301. Further, the fourth path of travel 314 is defined for the articles 204 traveling, therealong, when the individual launching blocks of the first plurality of launching blocks 220 are located in the first retracted position 226, and the second plurality of launching blocks are located in the second extended position 257. In this arrangement, the articles to be sorted 204 are received onto the second article receiving ramp 302. The first, second, third and fourth paths of travel are clearly understood by a study of
Referring now to
The operation of the described second form of the invention 200 is believed to be readily apparent, and is briefly summarized at this point.
With regards to the second form of the invention 200 which is seen in
Therefore it will be seen that the present invention provides a convenient means by which articles to be sorted may be readily diverted into various paths of travel based upon sorting criteria which is established by a user in a manner which has not been possible, heretofore.
In compliance with the statute, the invention has been described in language more or less specific as to structural and methodical features. It is to be understood, however, that the invention is not limited to the specific features shown and describe, since the means herein disclosed comprise preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted in accordance with the doctrine of equivalents.
This patent application is a Continuation-In-Part of U.S. patent application Ser. No. 12/383,199, and which was filed on Apr. 19, 2009.
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| Entry |
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| http://www.magnusoncorp.biz/ccm.html “Automatic Corn Cutter” 6 pages of website, printed Jun. 18, 2010. |
| Number | Date | Country | |
|---|---|---|---|
| 20120138512 A1 | Jun 2012 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 12383199 | Mar 2009 | US |
| Child | 13373961 | US |
