Abstract:
The present invention includes a parts feeder system capable of being used in either a first mode without an auxiliary hopper or in a second mode with and auxiliary hopper. The parts feeder system includes an enclosure having an opening therein. In the first or manual-feed mode, the parts feeder system is replenished my manual filling thereof, and in the second or auxiliary hopper-feed mode the opening in the enclosure accommodates an auxiliary hopper. When the auxiliary hopper is used, the dispensing chute of the auxiliary hopper is positioned over the supply of the parts feeder. Additionally, the enclosure of the parts feeder system is configured with grooves so that it can be secured by a minimal number of fixation elements and can therefore be easily attached and removed.

Description:
This application is a division of U.S. application Ser. No. 09/059,972, filed Apr. 14, 1998 now U.S. Pat. No. 6,109,475. 
    
    
     FIELD OF THE INVENTION 
     The present invention pertains generally to parts feeding and sorting devices, especially a parts feeder system which may be supplied with parts either directly or via a detachable or portable matable auxiliary hopper. 
     BACKGROUND OF THE INVENTION 
     Automated devices and systems for providing individual parts at an output from a non-ordered supply are well known. Generally, such systems draw individual parts from a reservoir of disoriented parts, orient them as desired, and transport them singly to another machine or tool, which then uses or otherwise operates on the individual part. Such systems commonly include a parts feeder system, a parts transporting system, and may include a tool or other further processing machinery. 
     The parts feeder system is generally designed to orient the individual parts in a desired fashion and to move them one at a time away from the parts reservoir. For example, a feeder system may operate to remove individual screws from a reservoir, orient them so that the head of each screw is in the rear relative to the screws&#39; direction of motion, and move the individual screws to the input of a transporting system. Such feeder systems may include vibratory parts feeder machinery, such as that disclosed in U.S. Pat. No. 5,630,497 and/or in co-pending commonly-owned application Ser. No. 08/806,109. 
     Currently-available parts feeder systems are relatively small machines able to sit on a workbench, cart, or similarly sized surface. A bowl or similar container within the parts feeder system forms the reservoir of parts to be used. To keep the system operating, the supply of parts in the bowl must be renewed. Some known parts feeder systems can only be supplied by manual loading, wherein a person accesses the bowl of the feeder system by opening or removing a cover or access panel and replenishes the supply directly. This type of system has a limitation in that the supply of parts available to the feeder system is determined by the capacity of its bowl, which, given the relatively small size of parts feeder systems, is commonly small. Thus, only a relatively small number of parts may be manually loaded or fed into such a direct-feed parts feeder system at one time. Direct manual loading is labor-intensive and must be performed relatively often, with resultant machine down-time. 
     Feeder systems have also been developed which have an integral or permanently attached auxiliary hopper for supplying parts to the bowl of the parts feeder system. The auxiliary hopper generally has a larger capacity than the bowl and is fixed in the system so that it continuously feeds parts into the bowl. However, available parts feeder systems having such an auxiliary hopper usually fix the auxiliary hopper over the bowl of the feeder system. Access to the system, particularly the bowl and associated machinery, is consequently impeded or blocked by the auxiliary hopper. 
     A further limitation to currently-available parts feeder systems is that they are single mode systems that operate either as a direct manually-fed or as an auxiliary hopper-fed system, but cannot be switched from one mode to operate in the other mode. That is, such parts feeder systems do not have the capability of switching between direct manual feed and auxiliary hopper feed due to the integral nature of the auxiliary hopper in the feeder system. Manual-feed systems are not configured to allow use of an auxiliary hopper and cannot be retrofitted. Thus, a purchaser of a manual-feed parts feeder system cannot upgrade it to include an auxiliary hopper, and therefore must purchase a new parts feeder if an auxiliary hopper feed is desired. Conversely, the purchaser of a parts feeder system having an auxiliary hopper will have difficulty accessing the bowl of the feeder system, and cannot replace or interchange the auxiliary hopper component by itself. Instead, the purchaser must purchase an entirely new parts feeder system if an alternate auxiliary hopper, or no hopper at all, is desired. 
     SUMMARY OF THE INVENTION 
     One form of the present invention contemplates an apparatus comprising an auxiliary hopper adapted for receiving parts and a parts feeder system having a bowl for receiving parts, with the parts feeder system having a first mode wherein the auxiliary hopper is removably coupled with the parts feeder system and delivers parts to the bowl, and a second mode wherein the auxiliary hopper is uncoupled from the parts feeder system and does not deliver parts to the bowl. 
     Another form of the present invention contemplates a system comprising vibratory parts feeder machinery having a bowl adapted for receiving parts, an enclosure substantially surrounding the machinery and having an opening for allowing access to the bowl, and an auxiliary hopper comprising a container portion, a chute portion, a drive portion, and a base portion. In a first mode, the vibratory parts feeder machinery is interconnected to the auxiliary hopper by inserting the chute portion of the auxiliary hopper into the opening of the enclosure to deliver parts to the bowl, and in a second mode, the vibratory parts feeder is separated from the auxiliary hopper. 
     Another form of the present invention contemplates a method of replacing a first auxiliary hopper having a chute portion with a second auxiliary hopper having a chute portion in an apparatus comprising the first auxiliary hopper coupled to a parts feeder system. The method comprises uncoupling the first auxiliary hopper and the parts feeder system by withdrawing the chute portion of the first auxiliary hopper from an opening in the enclosure of the parts feeder system, and coupling the second auxiliary hopper and the parts feeder system by inserting the chute portion of the second auxiliary hopper into the opening. 
     Another form of the present invention contemplates a method of converting a parts feeder system having an enclosure with an opening therein from a first mode, in which said parts feeder system receives parts from an auxiliary hopper having a chute portion, with the auxiliary hopper being coupled to the parts feeder system by inserting the chute portion into the opening, to a second mode in which the parts feeder system does not receive parts from an auxiliary hopper. The method comprises separating the auxiliary hopper and the parts feeder system by withdrawing the chute portion from the opening. 
     Another form of the present invention contemplates a method of converting a parts feeder system having an enclosure with an opening from a first mode, in which the parts feeder system does not receive parts from an auxiliary hopper to a second mode in which the parts feeder system receives parts from an auxiliary hopper having a chute portion. The method comprises coupling the auxiliary hopper and the parts feeder system by inserting the chute portion of the auxiliary hopper into the opening. 
     Another form of the present invention contemplates a combination comprising a parts feeder system for individually dispensing parts having a bowl for receiving the parts and a base plate with at least one groove defined therein, a structure coupled to the base plate with at least one groove defined therein, and a side member having a first portion retained in the groove in the plate and a second portion retained in the groove in the structure. The structure or the side member has one or more openings allowing access to the bowl of the parts feeder system. 
     These and other aspects of the invention will be evident to those of skill in this art. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a partially-exploded perspective view of a parts feeder system and auxiliary hopper according to one embodiment of the present invention. 
     FIG. 2 is a side elevational view of the parts feeder system and auxiliary hopper of FIG. 1 coupled together. 
     FIG. 3 is a side elevational view of the auxiliary hopper comprising a portion of the apparatus of FIG.  1 . 
     FIG. 4 is a top view of the auxiliary hopper comprising a portion of the apparatus of FIG.  2 . 
     FIG. 5 is a side elevational view of the parts feeder system comprising a portion of the apparatus of FIG.  1 . 
     FIG. 6 is a side elevational view of the frame elements and control panel enclosure comprising a portion of the parts feeder system of the apparatus of FIG.  1 . 
     FIG. 7 is an enlarged sectional view of the frame elements of FIG. 6 taken along the line  7 — 7 . 
     FIG. 8 is a view as in FIG. 7, comprising an alternate embodiment of the frame elements of the present invention. 
     FIG. 9 is a perspective view of the frame elements and base comprising a portion of the parts feeder system of the apparatus of FIG.  1 . 
     FIG. 10 is a view as in FIG. 9, comprising an alternate embodiment of the frame elements of the present invention. 
     FIG. 11 is a rear elevational view of the parts feeder system of FIG. 1, with a covering plate coupled thereto. 
     FIG. 12 is a view as in FIG. 11 with the covering plate removed. 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     For the purposes of promoting an understanding of the principles of the present invention, reference will now be made to the preferred embodiments illustrated in the drawings and specific language will be used to describe the same. It will nevertheless be understood that no limitation of the scope of the present invention is thereby intended, such alterations and further modifications in the illustrated embodiments, and such further applications of the principles of the present invention as illustrated therein being contemplated as would normally occur to one skilled in the art to which the present invention relates. 
     With reference generally to FIGS. 1 and 2, there is illustrated an apparatus  20 , which includes a parts feeder system  22  and an auxiliary hopper  24 . Parts feeder system  22  and auxiliary hopper  24  are designed and constructed to be readily separable and interconnectable so that parts feeder system  22  can be used with a variety of auxiliary hoppers, or in a stand-alone mode with no auxiliary hopper. When used together, parts feeder system  22  and auxiliary hopper  24  are interconnected by moving them together, as indicated by arrow  23 , to form apparatus  20 . 
     Referring also to FIGS. 3 and 4, there is illustrated auxiliary hopper  24  which includes a base plate  26 , an enclosure  28 , a container portion  30 , and a chute portion  32 . Chute portion  32  includes spaced side wall members  34  and floor surface  36 . Container portion  30  holds components or parts for subsequent feeding by parts feeder system  22 . Such components may be, but are not limited to, screws. Enclosure  28  encloses a driving mechanism  37  and a stand  38  (shown in phantom), which act on container portion  30  to move components from container portion  30  into and through chute portion  32 . In a specific embodiment of the present invention, stand  38  and enclosure  28  are coupled to a base plate  26 . Container portion  30  is filled with components through opening  39  in the top of container portion  30 . 
     Referring now to FIGS. 2,  5  and  6 , there is shown parts feeder system  22  according to the present invention. In one embodiment, parts feeder system  22  includes side enclosure  40 , cover  41 , and base plate  44 . Base plate  44  and base plate  26  may be made of numerous materials, although a preferred material is aluminum. Base plate  44  includes a groove  45 , shown in FIG.  10 . In a specific embodiment of the invention, groove  45  is in proximity to and follows a substantial portion of the perimeter of base plate  44 , although other groove configurations, including multiple grooves or alternate placement of groove(s), are considered to be within the scope of the invention. 
     Also positioned on base plate  44  is machinery for feeding parts in a parts feeder system, shown in phantom in FIG.  2 . In one embodiment of the invention, the machinery may be a vibratory parts feeder system including a bowl  49  and associated drive mechanisms  50 . In a specific embodiment, bowl  49  and associated drive mechanisms  50  may be those described in U.S. Pat. No. 5,630,497 and/or co-pending patent application Ser. No. 08/806,019. As used herein, the term “bowl,” unless specifically referred to otherwise, refers to any reservoir or container used to hold components to be fed by a parts feeder system. Controls for the parts feeder machinery are generally located within control panel and enclosure  51 . 
     In one embodiment, base plate  44  includes a plurality of feet  46  on the underside of base plate  44 . Feet  46  may be integral with or otherwise affixed to base plate  44 , and in a specific embodiment are made of rubber or other similar material to minimize transmission of vibration and/or noise. Base plate  26 , with auxiliary hopper coupled thereto in one embodiment, may have feet receiving portions (not illustrated) formed therein to accommodate feet  46  when parts feeder system  22  is coupled with auxiliary hopper  24 . 
     On the upper side of base plate  44  there is attached a frame for holding an enclosure around the machinery of parts feeder system  22 . In the embodiments illustrated in FIGS. 6-10, the frame comprises frame elements  52 ,  54 ,  56  and  58 . Cover  41  is attached by a hinge  42  to frame element  52 . Cover  41  and hinge  42  are positioned to allow cover  41  to rotate between a closed position, shown in FIG. 5, and an open position (shown in phantom in FIG. 2) wherein cover  41  is substantially over frame element  52  and the space inside side enclosure  40  is accessible through the opening left when cover  41  is rotated to the open position. The angle θ between the top of cover  41  in the closed position and frame element  52  may be any angle such that cover  41  may be opened when parts feeder system  22  is used with an auxiliary hopper  24  without having interference or substantial restriction to access to the space inside side enclosure  40 . In one specific embodiment, the angle θ is about 159 degrees. 
     Referring to FIGS. 6,  7 , and  9 , frame elements  52 ,  54 ,  56 , and  58  include one or more grooves configured to receive therein at least a portion of side enclosure  40 . (For clarity, the grooves are not shown in FIG. 9.) In one specific embodiment, frame element  52  is a generally rectangular member, including two grooves  53  parallel to and proximate to the shorter ends of frame element  52 , and frame element  54  is a generally rectangular member, including two grooves  55  parallel to and proximate to the shorter sides of frame element  54 . Frame elements  56  may comprise two elongated members each including a groove  57  which runs substantially the entire length of the elongated member. Frame elements  58  may also comprise two elongated members, and also have longitudinal grooves  59  therein. 
     Other embodiments of the frame elements are within the scope of the present invention. Referring to FIGS. 8 and 10, a second embodiment comprises frame element  56 ′ in the form of a single substantially planar rectangular frame element, and frame element  58 ′ in the form of a single substantially rectangular frame element, each having one or more grooves configured to receive a portion of side enclosure  40 . In a specific embodiment, the groove(s) are near one or more edges of frame elements  56 ′ and/or  58 ′. Further, frame elements  56  and  58  or  56 ′ and  58 ′ may be integrally constructed or joined to form one or more L-shaped members. Also, the geometric shapes and depths of the groove(s) in a given frame element may be of a multitude of shapes and sizes as needed to accommodate alternate enclosure characteristics. 
     In the embodiments of the invention depicted in FIGS. 6-10, frame element  52  is coupled to frame element  54 , and frame element  54  is in turn attached to a rear portion of frame elements  56  or  56 ′. Upper portions of frame elements  58  or  58 ′ are attached to forward portions of frame elements  56  or  56 ′. As FIG. 7 shows, in one embodiment grooves  53  and  55  meet where frame elements  52  and  54  meet, and grooves  55  and  57  meet where frame elements  54  and  56  meet. In another specific embodiment, frame elements  56  or  56 ′ are generally parallel to frame element  52 , and frame elements  58  or  58 ′ are generally parallel to frame element  54 . 
     The present invention also includes a side enclosure  40 , best seen in FIGS. 1 and 5. Side enclosure  40  may be made of any desired material, but preferred materials are polyurethane, stainless steel and fiberglass. In one embodiment, side enclosure  40  is a single piece. Side enclosure  40  couples to frame elements  52 ,  54 ,  56 , and  58  and to base plate  44  by fitting portions of side enclosure element  40  into grooves  53 ,  55 ,  57 ,  59  and  45 . Side enclosure  40  may have any shape suited for coupling with the groove or grooves in the frame elements and base plate. As one example, in the embodiment shown in FIGS. 1 and 5, side enclosure  40  is an irregularly shaped element that wraps around the forward portion of parts feeder system  22 . In another embodiment, side enclosure  40  may include several pieces which are coupled to each other, and/or in one or more of the grooves in one or more of frame elements  52 ,  54 ,  56  and  58 . 
     In the embodiment in which side enclosure  40  is a single piece a single fixation device  70 , secures side enclosure  40  to frame elements  52 ,  54 ,  56 , and  58  and base plate  44 . Embodiments of side enclosure  40  which include more than one element may require additional fixation devices. 
     Referring now to FIGS. 11 and 12, there is shown the rear of one embodiment of parts feeder system  22 , with and without a covering plate, respectively. Frame element  54  has an opening  60  formed therein which allows access to the interior volume defined by, but not limited to frame element  52 , frame element  54 , and side enclosure  40 , and more specifically the interior volume in which bowl  49  and associated drive mechanisms  50  of parts feeder system  22  are located. Opening  60  is large enough to accommodate chute portion  32  of auxiliary hopper  24 , and may be of any shape, although a preferred shape for opening  60  is rectangular. In one embodiment, attachment holes  63  surround opening  60 . In a specific embodiment, six attachment holes  63 , threaded for screws, are provided, although it will be appreciated by one of ordinary skill in the art that alternate attachment elements can be provided. 
     The present invention can also include a cover plate  62 . Cover plate  62  is attached, by suitable elements, to frame element  54  over at least a portion of opening  60 . In the specific embodiment in which attachment holes  63  are threaded for screws, cover plate  62  includes threaded screw holes which correspond to the threaded screw holes  63  in frame element  54 , and is attached by screws  65  to frame element  54 . 
     Cover plate  62 , in one embodiment, may completely block opening  60 , or may only block a portion of opening  60 . As illustrated in FIG. 9A, cover plate  62  may include an opening  66 , which, when cover plate  62  is attached to rear frame element  54 , communicates with opening  60  and therefore with the interior of parts feeder system  22 . Opening  66  is of a proper dimension to accommodate chute portion  32  of auxiliary hopper  24 . 
     Parts feeder system  22  can therefore be used with auxiliary hoppers of various sizes, with auxiliary hoppers having variously sized or located chute portions, or alternatively with no auxiliary hopper at all. If an auxiliary hopper is to be used, a cover plate  62  having an opening  66  sized to correspond to the chute  32  of auxiliary hopper  24  is preferably attached to frame element  54  of parts feeder system  22 . However, cover plate  62  is not necessary to the interconnection and the operation of parts feeder system  22  and auxiliary hopper  24 . Auxiliary hopper  24  and parts feeder system  22  are connected so that chute portion  32  penetrates opening  60  of frame element  54  and is positioned above bowl  49 , yet still permits the opening of cover  41  to allow access to the machinery of parts feeder system  22 . 
     To replace a first auxiliary hopper that is interconnected with parts feeder system  22  with a second auxiliary hopper, parts feeder system  22  and the interconnected first auxiliary hopper must be separated. If the opening in covering plate  62 , if used, will not accommodate the chute portion of the second auxiliary hopper, then covering plate  62  must be removed and may be replaced with a different covering plate having an opening sized to accommodate the chute portion of the second auxiliary hopper. The chute portion of the second auxiliary hopper is then inserted through frame element  54  so that the chute portion is above bowl  49 . 
     If no auxiliary hopper system is desired, a covering plate having no opening may be attached to frame element  54  of parts feeder system  22 . Components may then be provided to the parts feeder system  22  by opening cover  41  and placing the components into bowl  49  of parts feeder system  22 . To convert parts feeder system  22  from use with an auxiliary hopper to a direct manual feed mode, parts feeder system  22  and interconnected auxiliary hopper  24  are separated. Covering plate  62 , if used, may be removed and replaced, if desired, with a different covering plate having no aperture therethrough. To reconvert the parts feeder system  22  from a direct manual feed mode for use with an auxiliary hopper, the covering plate having no aperture therethrough, if present, is removed, a covering plate having an aperture which will accommodate the chute portion of the desired auxiliary hopper may be attached to frame element  54 , and the chute portion of the desired auxiliary hopper is inserted through frame element  54  so that the chute portion is above bowl  49 . 
     The present invention thereby provides a parts feeder system capable of being used in an auxiliary hopper-fed mode, with one of a variety of auxiliary hoppers, or alternatively in a standalone manually-fed mode. It is understood that opening  60  may be placed in one of several places on the enclosure of the parts feeder system  22 , including frame elements  52  and  54  and side enclosure  40 , so long as cover  41  remains able to open. Accordingly, while the preferred embodiment of the invention places opening  60  and auxiliary hopper  24  at the rear of parts feeder system  22 , it is understood that many different configurations are within the scope of the invention. 
     While the present invention has been illustrated and described in detail in the drawings and foregoing description, the same is to be considered as illustrative and not restrictive in character, it being understood that the preferred embodiments have been shown and described and that all changes and modifications that come within the spirit of the present invention are desired to be protected.