The present invention concerns systems and methods for conveying and sorting produce. More particularly, some embodiments of the present invention concern systems and methods for conveying produce under an inspection process and selectively ejecting the produce based on produce grade.
Conventional conveying and sorting systems typically comprise a conveyor having a continuous chain-like construction which moves in a line from a loading and singulating portion, to an inspection portion, and then to a sorting area where produce is selectively sorted based on inspection (which could include inspecting for color, shape, and size, among other characteristics). Conventionally, the rotation of the produce in the direction of conveyor travel (i.e., the produce rolls forward in the direction of conveyor travel), rather than perpendicular to the direction of travel. The produce is ejected by being selectively dropped by the system on to the appropriate exit station in the sorting area of the conveyor
For example, many types of conventional conveyance systems utilize a plurality of rollers arranged such that their rotational axes are perpendicular to the direction of conveyance, meaning the direction of rotation of the conveying surface is parallel to the direction of conveyance. Consequently, produce being conveyed on such systems is also rotated in the direction of conveyance. Furthermore, conventional conveying systems require relatively large amounts of space and are comprised of assemblies of many parts, which requires more maintenance to keep these systems functioning. For example, systems which utilize a plurality of rollers require a plurality of drive mechanisms to accommodate the rollers. Consequently, in addition to requiring more space, this requires these parts to be inspected and repaired or replaced more frequently.
Therefore, the need exists for a conveying system which can convey and rotate produce while utilizing less space and less materials. More particularly, the need exists for a conveying system which can rotate produce in a direction perpendicular to the direction of conveyance, without any hinderance of the conveying motion. Furthermore, the need exists for a conveying system which utilizes a single drive mechanism to rotate produce during conveyance.
The present invention generally concerns systems for conveying produce as well as methods for achieving the same. In some embodiments, a conveying system may include a conveying assembly which may have a continuous drive chain for driving the conveyance of produce. Produce may enter a loading portion, then a singulating portion, then an inspection portion, and then an unloading portion. Within the singulating portion, produce may be separated prior to reaching the inspection portion. After the inspection portion, produce may be conveyed until it reaches the unloading portion where it is ejected. In some embodiments, a conveying assembly may comprise a plurality of conveyance lanes.
According to some embodiments, the drive chain may be driven in a continuous motion by means of one or more sprockets. Within the conveying assembly, the direction of conveyance is generally from the loading portion to the unloading portion, with the direction of conveyance being opposite on a returning portion of the drive chain. The drive chain may be supported by, and slidably engaged with, a support track.
In some embodiments, produce may be conveyed on one or more fingers which may extend from a finger mounting bracket engaged with the drive chain. As a finger travels into the unloading portion, the finger may drop to allow the produce to be ejected onto a chute. As the finger reaches the end of the unloading portion, it may be returned to its original position, ready to receive produce. The finger may be guided onto a return track and eventually returned back to the loading portion for receiving produce.
According to some embodiments, a conveying assembly may include one or more augers which may extend in the direction of conveyance along one or more fingers. An auger may be driven (i.e., rotated) by an auger drive which may include a motor, a drive shaft, one or more pulleys, and one or more belts. An auger may be used to separate produce within the singulating portion. An auger may also aid with the inspection of produce within the inspection portion.
In accordance with some embodiments of the present invention, a finger of a conveying assembly may generally comprise an elongate body which may extend from the drive chain of the conveying assembly. A finger may comprise a receiving surface which may have a convex shape configured to retain produce therein during conveyance of the same. In accordance with some embodiments, a finger may have a cavity near an apex of the receiving surface within which a portion of an auger may be disposed. A cavity may induce contact between produce and an auger positioned within the cavity.
In some embodiments, a finger may be indirectly engaged to the drive chain by a finger mounting bracket which may be engaged to the drive chain. A finger mounting bracket may comprise a slot configured to receive and retain a portion of the drive chain. In some embodiments, a finger mounting bracket may comprise a pair of notches which may be configured to receive a portion of the drive chain. In some embodiments, a finger mounting bracket may be engaged with a drive chain by a pin which may be received through portions of the drive chain and finger mounting bracket. According to some embodiments of the present invention, a finger may be hingedly engaged with a finger mounting bracket. In some embodiments, a finger may be engaged to a finger mounting bracket by inserting a pivot pin through an opening in the finger mounting bracket and engaging the finger with the pivot pin.
In accordance with some embodiments, and as previously described, a conveying assembly may comprise one or more augers for rotating produce. An auger may be generally elongated, extending across a plurality of fingers. In some embodiments, an auger may have a longitudinal axis which may be about parallel to a drive chain. Additionally, the longitudinal axis of an auger may be about parallel to the direction of conveyance.
According to some embodiments, an auger may generally comprise a shank and/or fighting. In some embodiments, the fighting may be wound around the shank or may be integrally formed therewith. A fighting may formed as a ridge, protrusion, plate, or any other shape. A fighting may be formed in helical pattern. In some embodiments, an auger may comprise a shank without fighting or an auger may comprise fighting without a shank.
According to some embodiments of the present invention, an auger may be configured to rotate such that it may impart rotation on produce which may be in contact with the auger. In preferred embodiments, an auger may rotate about a longitudinal axis which may be oriented about parallel to a drive chain. In some implementations, a pair of adjacent augers may rotate in opposite directions. According to some implementations, a top surface of a pair of adjacent augers may rotate towards a drive chain. During rotation of a pair of augers, a top surface of produce may rotate away from a drive chain.
During operation of a conveying assembly, as a drive chain moves in the direction of conveyance, one or more fingers may be driven in a direction parallel to the direction of conveyance so as to convey produce toward the unloading portion of the conveying assembly. An auger may also assist with the conveyance of produce on one or more fingers by forcing the produce in the direction of conveyance. Furthermore, an auger may also assist with the retention of produce on one or more corresponding fingers.
In accordance with some embodiments of the present invention, during conveyance of produce by a conveying assembly, an auger may simultaneously rotate about its longitudinal axis to induce rotation on the produce. In some implementations, an auger may rotate in a counterclockwise direction while produce rotates in a clockwise direction, causing a top surface of the produce to rotate generally toward a drive chain. The concurrent motions of a drive chain and an auger may cause produce to be conveyed in a direction while simultaneously rotating about an axis which may be about parallel to the direction of conveyance.
According to some embodiments of the present invention, as a finger travels in the direction of conveyance, its orientation may be retained by a retention track engaged with the finger. In some embodiments, a finger may comprise a retention tab which may be housed in a finger retention track. As the finger moves toward the unloading portion of a conveying assembly, the retention tab may abut an inside surface of the finger retention track, thus preventing the finger from pivoting downward and ejecting produce. When the finger arrives at the unloading portion, openings in the retention track may allow the finger to change orientations. In some embodiments, an actuator may control a cam disposed adjacent to an opening of the retention track which may the finger to be released and eject produce. According to some embodiments, a free end of the ejection cam may be actuated such that it pivots inwardly toward the retention track and such that the retention tab of the finger, which is moving in the direction of conveyance, contacts the ejection cam, forcing the finger to pivot downward and eject produce.
In some embodiments of the present invention, a conveying assembly may comprise a plurality of gears disposed underneath a plurality of fingers and which may be aligned with an apex of the fingers. A gear may generally rotate in a direction of conveyance and a tooth pitch and width of a gear may correspond to a space between two adjacent fingers. In some embodiments, a plurality of gears may be arranged in a line and rotated slightly from a centerline. During operation of a conveying assembly, as the fingers move in the direction of conveyance, they may catch the teeth of a gears and drive the rotation thereof. As a gear rotates, the tips of the gear teeth may contact a peripheral surface of produce, causing it to rotate. Furthermore, and according to some embodiments, a gear may be configured to contact a finger, causing the finger to be moved in an upward direction which may assist with the rotation of produce.
According to some embodiments of the present invention, a system for the conveyance of produce may comprise: a drive chain; a finger retention track above the drive chain; a finger mounting bracket which may be engaged with the drive chain; a finger which may comprise a surface for supporting the produce and a retention tab, wherein the finger may be hingedly engaged with the finger mounting bracket, and wherein the finger surface may (i) distally extend from the finger mounting bracket, (ii) comprise a generally upwardly convex shape, and (iii) comprise a cavity near the apex thereof; and an elongate auger for rotating the produce and which may have a longitudinal axis that may be parallel to the drive chain, wherein the auger may (i) be at least partially positioned in the cavity of the finger surface, (ii) comprise a top surface which may be rotatable towards the drive chain, and (iii) comprise a shaft and flighting. In some embodiments, the system may further comprise a chain support below the drive chain. In some embodiments, the drive chain may slidably engage the chain support. In some embodiments, the finger may have a first orientation and a second orientation. In some embodiments, when the finger has the first orientation, the retention tab of the finger may be within the finger retention track. In some embodiments, when the finger has the second orientation, the retention tab of the finger may not be within the finger retention track. In some embodiments, the auger flighting may be around a portion of the auger shaft. In some embodiments, the auger flighting may be integrally formed with the auger shaft. In some embodiments, the auger fighting may be engaged with the auger shaft. In some embodiments, the auger fighting may have a helical shape. In some embodiments, the system for the conveyance of produce may further comprise an auger drive for rotating the auger and the auger drive may comprise a shaft. In some embodiments, the auger drive may comprise a pulley engaged with the auger shaft, a pulley engaged with the auger drive shaft, and a belt engaged to each of the pulley of the auger shaft and the pulley of the auger drive shaft. In some embodiments, the system for the conveyance of produce may further comprise a motor engaged to the auger drive shaft.
According to some embodiments of the present invention, a system for inspecting produce may have a loading portion, an inspection portion, and an unloading portion and may comprise a plurality of lanes, where each lane may comprise: a) a drive chain between a drive chain support and a finger retention track; b) a plurality of fingers on each side of the drive chain, wherein each of the fingers may be hingedly engaged with a corresponding one of a plurality of finger mounting brackets, wherein each of the finger mounting brackets may be engaged with the drive chain, and wherein each of the fingers (i) may comprise a surface for supporting the produce and may have a cavity therein, (ii) may comprise a retention tab, and (iii) may have a first orientation and a second orientation; c) and at least two augers, wherein a first auger may be on a first side of the drive chain and wherein a second auger may be on a second side of the drive chain, wherein each of the augers (i) may have a longitudinal axis that may be parallel to the drive chain, (ii) may be at least partially positioned in the cavities of the surfaces of at least two of the fingers, and (iii) may comprise a top surface which may rotate toward the drive chain. In some embodiments, in the loading portion, each of the fingers may have the first orientation and the retention tab of each of the fingers may be within the finger retention track. In some embodiments, in the inspection portion, each of the fingers may have the first orientation and the retention tab of each of the fingers may be within the finger retention track. In some embodiments, in the inspection portion, the auger may comprise fighting for rotating the produce for inspection. In some embodiments, in the unloading portion, each finger retention track may comprise a plurality of openings therein. In some embodiments, in the unloading portion, the retention tab of each of the fingers may be ejected from one of the finger retention track openings. In some embodiments, each lane may further comprise a plurality of ejection actuators which may have an ejection cam engaged thereto, and wherein the ejection cam may have a first orientation and a second orientation. In some embodiments, each of the ejection cams may be positioned near one of the finger retention track openings. In some embodiments, when the ejection cam has the first orientation, the cam may be outside of the finger retention track opening, and wherein when the ejection cam has the second orientation, a portion of the ejection cam may be through the finger retention track opening and in the finger retention track. In some embodiments, in the loading portion, (i) each of the fingers may have the first orientation and (ii) the retention tab of each of the fingers may be within the finger retention track; in the inspection portion, (i) each of the fingers may have the first orientation, (ii) the retention tab of each of the fingers may be within the finger retention track, and (iii) the auger may comprise fighting for rotating the produce for inspection; and in the unloading portion, (i) each finger retention track may comprise a plurality of openings therein, (ii) each lane may further comprise a plurality of ejection actuators which may have an ejection cam engaged thereto, wherein each of the ejection cams may be positioned near one of the finger retention track openings, (iii) the ejection cam may have a first orientation when the ejection cam may be outside of the finger retention track opening, and (iv) the ejection cam may have a second orientation when a portion of the ejection cam may be through the finger retention track opening and in the finger retention track.
According to some embodiments of the present invention, a method for conveying produce through a machine may comprise a drive chain and may have a loading, inspection, and unloading portion, wherein the drive chain may move from the loading portion to the inspection portion and from the inspection portion to the unloading portion, wherein the method may comprise the steps of: a) in the loading portion, (i) positioning a retention tab of each of a plurality of fingers within a finger retention track, wherein each of the plurality of fingers may be hingedly engaged with one of a plurality of finger mounting brackets, wherein each finger mounting bracket may be engaged with the drive chain, and (ii) placing the produce on a surface of at least one of the plurality of fingers; b) in the inspection portion, (i) positioning the produce to be engaged with an auger, wherein the auger may be at least partially positioned in a cavity of the finger surface and may have a longitudinal axis that may be parallel to the drive chain, and (ii) rotating the auger to cause the produce to rotate along an axis which may be parallel with the longitudinal axis of the auger; and c) in the unloading portion, (i) ejecting each retention tab through one of a plurality of openings in the finger retention track, and (ii) removing the produce from the surface of the finger.
The invention, in its various aspects, will be explained in greater detail below. While the invention will be described in conjunction with several exemplary embodiments, the exemplary embodiments themselves do not limit the scope of the invention. Similarly, the exemplary illustrations in the accompanying drawings, where like elements have like numerals, do not limit the scope of the exemplary embodiments and/or invention, including any length, angles, or other measurements provided. Rather the invention, as defined by the claims, may cover alternatives, modifications, and/or equivalents of the exemplary embodiments.
As further illustrated in
As further illustrated in
As illustrated, for example, in
In accordance with some embodiments of the present invention, a finger of a conveying assembly may generally comprise an elongate body which may extend from the drive chain of the conveying assembly. For example, and with reference to
As further illustrated in
According to some embodiments of the present invention, a finger may be hingedly engaged with a finger mounting bracket. For example, and with further reference to
In accordance with some embodiments, and as briefly described above, a conveying assembly may also comprise one or more augers for rotating produce. For example, referring back to
According to some embodiments, an auger may generally comprise a shank and fighting, the flighting of which may be wound around a portion of a length the shank or which may be integrally formed therewith, or otherwise engaged with the shank. For example, referring briefly to
According to some embodiments of the present invention, an auger may be configured to rotate such that it may impart rotation on produce which may be in contact with the auger. In preferred embodiments, an auger may rotate about a longitudinal axis which may be oriented about parallel to a drive chain. For example, referring back to
Referring now, generally to
In accordance with some embodiments of the present invention, during conveyance of produce by a conveying assembly, an auger may simultaneously rotate about its longitudinal axis to induce rotation on the produce. For example, as further illustrated in
According to some embodiments of the present invention, as a finger travels in the direction of conveyance, its orientation may be retained by a retention track engaged with the finger. For example, referring back to
Upon reaching an unloading portion of the conveying assembly, a finger retention track may become discontinuous (whereas, throughout other portions, the finger retention track may be continuous so that a retention tab of a finger is continuously retained to maintain an orientation of a finger). For example, referring now, generally, to
In some embodiments, as finger 731A approaches the opening in finger retention track 751, ejection actuator 752A may actuate ejection cam 753A such that a free end of ejection cam 753A may pivot in direction K. By this motion, retention tab 734A of finger 731A contacts an outer surface of ejection cam 753A and drives retention tab 734A away from finger retention track 752, thus causing the free end of finger 731A to pivot downward in direction L. When finger 731A pivots downward, this causes the ejection of produce 760 from finger 731A, in direction M, and onto an unloading chute 718 (with the positions of finger 731A and produce 760 after ejection shown in broken lines).
Referring now to
It is to be understood that variations, modifications, and permutations of embodiments of the present invention may be made without departing from the scope thereof. It is also to be understood that the present invention is not limited by the specific embodiments, descriptions, or illustrations or combinations of either components or steps disclosed herein. Thus, although reference has been made to the accompanying figures, it is to be appreciated that these figures are exemplary and are not meant to limit the scope of the invention.
The present application claims priority to, and the benefit of, U.S. Provisional Patent Application No. 63/252,591, filed Oct. 5, 2021, which is hereby incorporated by reference in its entirety.
Number | Date | Country | |
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63252591 | Oct 2021 | US |