Article feeding device

According to the present disclosure, an article feeding device that reliably and consistently outputs properly oriented articles includes an input configured to receive articles, an output configured to dispense properly oriented articles, an orientation alteration portion between the input and output, and an orientation control system. The orientation alteration portion includes a first track configured to allow properly oriented articles to pass therethrough without alteration and a second track configured to alter the orientation of improperly oriented articles. The orientation control system is configured to detect orientation of the articles at the input and to send the articles to either the first track or the second track depending upon the detected orientation.

TECHNICAL FIELD

This present disclosure relates to article feeding devices.

BACKGROUND

Article feeding devices are used to properly orient and advance articles passing through bottling lines, assembly lines, packaging lines, and the like. Vibration and shaking are commonly used as methods for moving and changing the orientation of articles as the articles pass through article feeding devices. For some article feeding devices, such as a cap feeder in a bottling line, vibration and shaking in bowl-type cap feeders still results in improperly oriented caps, which reduces throughput since the improperly oriented caps must be reprocessed through the feeder.

SUMMARY

The present disclosure provides an article feeding device that reliably and consistently outputs properly oriented articles and, in particular, provides a cap feeder that properly orients caps in a bottling line. The article feeding device according to the present disclosure comprises an input configured to receive articles, an output configured to dispense properly oriented articles, an orientation alteration portion between the input and output, and an orientation control system. The orientation alteration portion includes a first track configured to allow properly oriented articles to pass therethrough without alteration and a second track configured to alter the orientation of improperly oriented articles. The orientation control system is configured to detect orientation of the articles at the input and to send the articles to either the first track or the second track depending upon the detected orientation.

The article feeding device according to the present disclosure may further comprises a first orientation portion configured to arrange the articles in either a first orientation or a second orientation before being received at the input. The orientation control system may be configured to determine whether the articles are in the first orientation or the second orientation. The first orientation may corresponding to a properly oriented article, while the second orientation corresponds to an improperly oriented article.

According to the present disclosure, the orientation control system may include a camera configured to provide image data of the articles at the input and the orientation control system may determine whether the articles are in the first orientation or the second orientation by comparing the image data to a stored image. The orientation control system may control a servo dial to transport the articles from the input to the first track or the second track based on the determination.

According to the present disclosure, a cap feeder for providing bottle caps to a bottling line is described. The cap feeder comprises a bin configured to receive caps in bulk, a first orientation portion configured to receive the caps from the bin and to provide the caps to a second orientation portion in either a first orientation or a second orientation, and a second orientation portion configured to receive the caps from first orientation portion in the first orientation and the second orientation. The second orientation portion comprises an input, first and second output paths connected to the input, a servo dial located at the interface between the input and the first and second output paths, and an orientation control system configured to determine whether each individual cap at the input is in the first orientation or the second orientation and to control the servo dial to send the individual cap to the first output track or the second output track based on the determination.

According to the present disclosure, the second orientation portion of the cap feeder may further comprise an orientation alteration portion. The orientation alteration portion includes a chute connected to the first output track and a helical path connected to the second output track. The chute is configured to allow properly oriented caps to pass through without alteration and the helical path is configured to invert the caps passing therethrough.

According to the present disclosure, the orientation control system of the cap feeder includes a camera or similar imaging sensor configured to provide image data of each individual cap at the input. The orientation control system is configured to determine whether each individual cap is in the first orientation or the second orientation by comparing the image data to a stored image of a properly or improperly oriented cap.

These and other objects, features and advantages of the present disclosure will become apparent in light of the detailed description of embodiments thereof, as illustrated in the accompanying drawings.

DETAILED DESCRIPTION

Before the various embodiments are described in further detail, it is to be understood that the invention is not limited to the particular embodiments described. It will be understood by one of ordinary skill in the art that the article feeding device described herein may be adapted and modified as is appropriate for the application being addressed and that the components of the article feeding device described herein may be employed in other suitable applications, and that such other additions and modifications will not depart from the scope thereof.

Referring toFIGS.1and2, an article feeding device according to the present disclosure in the form of a cap feeder10is shown. The cap feeder10includes a bin portion12, a first orientation portion14, and a second orientation portion16arranged in series between an input18and an output20of the cap feeder10.

The bin portion12has an open upper end22forming the input18to the cap feeder10, side walls24, and a floor26forming an interior space configured received bottle caps28through the open upper end22. Referring toFIG.3, each cap28has the shape of a typical bottle cap, with a closed top29, cylindrical side wall30having internal threads, and open bottom31configured to receive the threaded mouth portion of a bottle to allow the internal threads of the cap28to engage the bottle.

ReferringFIGS.1and4, the bin portion12includes an exit32through one of the side walls24at the floor26. The floor26is moveable and configured to transport caps28from within the interior space of the bin portion12through the exit32to the first orientation portion14. For example, as shown, the floor26is a conveyor belt. However, other similar article transport systems are within the scope of the present disclosure and may be used in place of the conveyor belt. The exit32may have a height that is sized to allow only a single layer of caps28to pass therethrough to the first orientation portion14.

As seen inFIG.2, the first orientation portion14and second orientation portion16have a downward slope relative to the horizontal direction between the input18and the output20. Unless otherwise discussed herein, vibration is used to urge the caps28along this downward slope through the first orientation portion14and second orientation portion16.

Referring toFIGS.4and5, the first orientation portion14includes a plurality of straightening channels34followed by a plurality of exit holes36. Each straightening channel34has a semi-cylindrical shape, and the straightening channels34are parallel and adjacent to one another and extend away from the bin portion12toward the exit holes36. The exit holes36are vertically arranged cylindrical holes sized to be slightly larger than the caps28so that the caps28can only pass through the exit holes36with the closed cap top29or open cap bottom31facing downward. The exit holes36may include an inverted conical entry surface38to facilitate entry of the caps28into the exit holes36.

The straightening channels34are positioned to receive the caps28exiting the bin12through the exit32of the bin portion12and to pass the caps28to the plurality of exit holes36through vibration of the first orientation portion14. The semi-cylindrical shape of the straightening channels34orients the caps28with either their tops29or bottoms31facing the exit holes36as the caps move through the channels34. This results in the caps28dropping out of the channels34at the exit holes36with the top29or bottom31facing downward. The vibration of the first orientation portion14then causes the caps28to drop downward through the exit holes36onto the second orientation portion16.

The second orientation portion16includes a funneling tray40, a sorting tray42, an orientation tray44, and an exit tray46arranged in series and an orientation control system47configured to control the sorting tray42. The funneling tray40includes a track48having a bottom surface50and two side walls52. The track is configured to receive the caps28dropping through the exit holes36of the first orientation portion14, with the top29or bottom31of each cap28resting on the bottom surface50of the track. In a first portion54of the track48, the side walls52are angled toward one another along the length of the first portion54in order to reduce the width of the track48from an initial width sized to allow the plurality of caps28being received from the exit holes36of the first orientation portion14to fit within the track48to a final width, the final width being sized to fit only a single cap28within the track48. In a second portion56of the track48, the side walls52are parallel, so that the second portion56maintains the final width of the track48and only allows a single cap28to pass at a time. The output of the second portion56of the track48of the funneling tray40is connected to the sorting tray42.

Referring toFIG.6, the sorting tray42includes a branching track57having a bottom surface58and side walls59that form an input60, a first output track62, and a second output track64, all having widths sized to allow the caps28to pass serially through the respective tracks. The sorting tray42also includes a servo dial66positioned above the interface of the input60with the first output track62and second output track64at the upper end of the side walls59. The servo dial66has a circular disk shape with three transport notches68formed in the outer circumference thereof and is configured to be driven in rotational movement about its central axis by a servo motor. The transport notches68are equally spaced about the circumference of the servo dial66and each transport notch68is sized to fit a single cap28therein.

The input60is configured to receive the caps28from the funneling tray40as they serially exit the second portion56. The servo dial66is configured to accommodate each cap28from the input60in one of its transport notches68and to direct the cap28to either the first output track62or the second output track64depending upon an orientation of the cap28. The first output track62and the second output track64may be formed as cam paths having inner wall surfaces69that urge the caps28out of the transport notches68as the servo dial66rotates toward the respective first output track62or the second output track64in order to avoid jamming of the servo dial66. Each time the servo dial66rotates to transport a cap28within the transport notch68proximate the input to either the first output track62or the second output track64, the servo dial66does so through a 120 degree rotation so that another one of the transport notches68is located proximate the input60.

Referring toFIGS.6and7, the orientation control system47includes a camera70, or other similar sensor, positioned over the second portion56of track48, as seen inFIG.6, and a controller71operatively coupled to the camera70and to the servo motor that rotates the servo dial66. The camera70is configured to view each cap28as the cap28passes through the second portion56into the input60of the sorting tray44and to provide the image data to the controller for each cap28. The controller71is configured to use the image data from the camera70for each cap28to determine if the respective cap28is oriented correctly, with its top29facing up and its bottom31resting on the bottom surface50of the track48, or oriented incorrectly, with its bottom31facing up and its top29resting on the bottom surface50of the track48. For example, the controller71may make the determination by comparing the image data to a stored image of a cap top or bottom. Based on this determination, the controller71controls the servo motor to rotate servo dial66clockwise or counterclockwise to move the respective cap28within a transport notch68from the input60to either the first output track62or the second output track64. In particular, if the controller71determines that the cap28is oriented correctly, with its top29facing up and its bottom31resting on the bottom surface of the track, the servo dial66is rotated clockwise to deliver the respective cap28to the first output track62. Alternatively, if the controller71determines that the cap28is oriented incorrectly, with its bottom31facing up and its top29resting on the bottom surface of the track, the servo dial66is rotated counterclockwise to deliver the respective cap28to the second output track64.

The orientation control system47, including the camera70, controller71, and/or servo motor, includes all of the necessary electronics, software, memory, storage, databases, firmware, logic/state machines, microprocessors, communication links, and any other input/output interfaces to perform the functions described herein and/or to achieve the results described herein. For example, the controller71, may include, or be in communication with, one or more processors and memory, which may include system memory, including random access memory (RAM) and read-only memory (ROM). Suitable computer program code may be provided to the controller71for executing numerous functions, including those discussed in connection with the orientation control system47.

The one or more processors may include one or more conventional microprocessors and may also include one or more supplementary co-processors such as math co-processors or the like. The one or more processors may be configured to communicate with other networks and/or devices such as servers, other processors, computers, sensors, and the like.

The one or more processors may be in communication with the memory, which may comprise magnetic, optical and/or semiconductor memory, such as, for example, random access memory (“RAM”), read only memory (“ROM”), flash memory, optical memory, or a hard disk drive memory. Memory may store any data and/or information typically found in computing devices, including an operating system, and/or one or more other programs (e.g., computer program code and/or a computer program product) that are stored in a non-transitory memory portion and adapted to direct the orientation control system47, including the controller71, to perform according to the various embodiments discussed herein. The orientation control system47and/or portions thereof, and/or any other programs may be stored, for example, in a compressed format, an uncompiled and/or an encrypted format, and may include computer program code executable by the one or more processors. The executable instructions of the computer program code may be read into a main memory of the one or more processors from a non-transitory computer-readable medium other than the memory. While execution of sequences of instructions in the program causes the one or more processors to perform the process steps described herein, hard-wired circuitry may be used in place of, or in combination with, executable software instructions for implementation of the processes of the present invention. Thus, embodiments of the present invention are not limited to any specific combination of hardware and software.

The term “computer-readable medium” as used herein refers to any medium that provides or participates in providing instructions and/or data to the one or more processors of the orientation control system47(or any other processor of a device described herein) for execution. Such a medium may take many forms, including but not limited to, non-volatile media or memory and volatile memory. Non-volatile memory may include, for example, optical, magnetic, or opto-magnetic disks, or other non-transitory memory. Volatile memory may include dynamic random access memory (DRAM), which typically constitutes the main memory or other transitory memory.

Referring toFIGS.8-10, the orientation tray44includes a first orientation track72connected to the first output track62of the sorting tray42and a second orientation track74connected to the second output track64of the sorting tray42. The first orientation track72is formed as a straight chute that includes a bottom surface75and parallel guide walls76extending along the length of the orientation tray44. The first orientation track72is configured to receive caps28from the first output track62and to support the caps28on the bottom surface75while allowing the caps28to pass through the first orientation track72to exit tray46, for example, by vibratory motion of the like, without changing an orientation of the caps28. The second orientation track74is formed as a helix78within a tube80extending along the length of the orientation tray44. The helix78has an input opening82at an input end84of the tube80and an output opening86, also seen inFIG.4, at an output end88of the tube80. The cross section of the input opening82rotates 180 degrees along the length of the helix78such that the output opening86is a 180-degree inversion of the input opening82. The second orientation track74is configured to receive incorrectly oriented caps28from the second output track64and to invert the caps28by allowing the caps28to pass through the helix78, for example, by vibratory motion of the like. Thus, caps28enter the helix78with their bottoms31facing up and exit the helix78into the exit tray46with their bottoms31facing down.

Referring back toFIG.4, the exit tray46includes an exit tray track90extending from the orientation tray44to the output20of the cap feeder10, shown inFIG.1. The caps28exit the orientation tray44from either the first orientation track72or the second orientation track74into exit tray track90of the exit tray46and, in either case, are properly oriented. The caps pass through the exit tray track90to the output20of the cap feeder10, shown inFIG.1, for further use in the bottling process.

Thus, in operation, caps28may be dumped in bulk into the bin portion12of the cap feeder10. The caps28then pass through the first orientation portion14, where each cap is oriented on the track with either its top29or bottom31in contact with the track. The caps28are then fed into the second orientation portion16, where the caps28are sorted between those with their tops29in contact with the track and those with their bottoms31in contact with the track. Those with their bottoms31in contact with track are passed through the second orientation portion16to the output20of the cap feeder10without a change in orientation, while those with their tops29in contact with the track are inverted to have their bottoms31in contact with the track and then passed to the output20of the cap feeder10.

The present disclosure advantageously provides a cap feeder10that achieves 100% throughput, with all caps28being properly oriented after a single pass through the cap feeder10. This is a significant improvement over conventional bowl-type shaker cap feeders, in which a large percentage of caps must be reprocessed.

The present disclosure also provides a cap feeder10that is easily customizable to process different types of caps. In particular, the various channels, exit holes, and tracks of the first and second orientation portions14,16described herein, may be formed on removable trays so that appropriately sized channels, holes, and tracks may be selected and/or designed based on the cap being processed through the cap feeder10. Similarly, the image of the cap top or bottom stored in the controller71for comparison to the image data during processing may also be updated based on the cap being processed through the cap feeder10.

While the principles of the present disclosure have been described herein, it is to be understood by those skilled in the art that this description is made only by way of example and not as a limitation as to the scope of the disclosure. Other embodiments are contemplated within the scope of the present disclosure in addition to the exemplary embodiments shown and described herein. Modifications and substitutions by one of ordinary skill in the art are considered to be within the scope of the present disclosure. For example, while the article feeding device of the present disclosure has been described as a cap feeder, present disclosure is not limited to cap feeders and the orientation systems described herein may be implemented in various other forms of article feeding devices.