Divider system

A divider system for diverting objects from an infeed lane into one or more discharge lanes includes a dividing screw set, a discharge screw set, and a diverting mechanism. The dividing screw set conveys a sequence of objects to an output end of the screw set where the objects are divided by rotation of the dividing screw set and outputted alternately to first and second discharge screws of the discharge screw set to form a first series of objects conveyed by the first discharge screw and a second series of objects conveyed by the second discharge screw. The divider system includes a diverting mechanism which can be selectively actuated to divert objects from one discharge screw to the other discharge screw to form a diverted group.

TECHNICAL FIELD

The present disclosure relates to a divider system for dividing and diverting objects from an infeed lane into one or more discharge lanes.

BACKGROUND

Divider and diverting mechanisms are used in combination with conveyor mechanisms to convey objects received via an infeed such that the objects are divided between two or more discharge lanes and/or diverted to a selected one of the discharge lanes as required by the system including the divider, for example, to discharge the divided and/or diverted objects to one or more downstream processes, to balance the volume of objects fed to each of multiple downstream processes, to separate the objects by type and/or condition, etc. Divider systems which use a dividing force such as an air blast or mechanical force, such as a plunger force, to force an object on a conveyor to one side of the conveyor or the other to divide a sequence of conveyed objects between two discharge conveyors are known. The use of an air blast or plunger force to exert a dividing force on the object, especially taller and/or lightweight objects, can be destabilizing, potentially causing the object to tip or fall from the conveyor, which can result in a disruption of the conveyor operation. The dividing force in these systems may be triggered from an input signal received from a sensor, such as an electronic eye, which is configured to detect an objection condition. Delay associated with detection and transmission of the detection signal, additional delay associated with actuation delay of an air blast or plunger actuator, and/or variability in response time and/or dividing force associated with variability in pressure of the air blast due to environmental factors including temperature, humidity, etc., introduces variation into the response time and accuracy of such a dividing system. Changeover of such a divider system may require additional time for reprogramming of sensor eyes and pneumatic controls, air nozzle size, type and/or position adjustment, etc., for each different size, shape and/or weight of the object.

SUMMARY

A divider system for dividing and selectively diverting objects from an infeed lane into one or more discharge lanes is provided. The divider system described herein includes a dividing screw set, a discharge screw set, a diverting mechanism, and a conveying mechanism for conveying a sequence of objects received to the divider system from an infeed lane through the dividing and discharge screw sets to one or more discharge lanes. The divider system receives objects from an infeed channel for division into first and second series of objects by the dividing screw set. The first series of objects is output to a first discharge screw of the discharge screw set and onto a first discharge belt, and conveyed by the first discharge screw through a discharge channel defined by the discharge screw set. The second series of objects is output to a second discharge screw of the discharge screw set and onto a second discharge belt, and conveyed by the second discharge screw through the discharge channel.

The dividing screw set has an input end for receiving objects from an infeed lane, and an output end for outputting the objects in divided series into a discharge channel defined by the discharge screw set. The dividing screw set has an infeed portion and a dividing portion, where the lead of the screw form in the dividing portion is greater than the lead of the infeed portion. The infeed portion includes a plurality of infeed pockets for sequencing, stabilizing and conveying objects received from the infeed lane to the dividing portion on a conveyor including split and tilted first and second discharge belts, such that, when a sequence of objects are conveyed into the dividing portion, alternating objects in the sequence are tilted into the dividing pockets of the first and second dividing screws, such that a first object in the sequence is divided and tilted into a dividing pocket of the first dividing screw, the second object in the sequence is divided and tilted into a dividing pocket of the second dividing screw, a third object in the sequence is divided and tilted into a dividing pocket of the first dividing screw, a fourth object in the sequence is divided and tiled into a dividing pocket of the second dividing screw, and so on in alternating fashion, to divide the sequence of objects into a first series of objects divided into the dividing pockets of the first dividing screw which are outputted from the first dividing screw onto the first discharge belt to be received into alternating discharge pockets of the first discharge screw, and a second series of objects divided into the dividing pockets of the second dividing screw which are outputted from the second dividing screw onto the second discharge belt to be received into alternating discharge pockets of the second discharge screw.

As an object of the first series is outputted from the dividing pocket of the first dividing screw onto the first discharge belt, the divided object is received into a discharge pocket of a first discharge screw, for conveyance to a first discharge lane. Similarly, as an object of the second series is outputted from the dividing pocket of the second dividing screw, the divided object is received into a discharge pocket of a second discharge screw, for conveyance to a second discharge lane. The diverting mechanism is actuable to selectively divert one or more objects from the discharge pockets of one of the discharge screws into empty discharge pockets of the other of the discharge screws, to form a diverted group of objects which are conveyed to a selected one of the discharge lanes. In an illustrative configuration, the diverting mechanism includes diverter elements which can be actuated, for example, by one of a servo, hydraulic, pneumatic, or magnetic actuator, to contact and divert the object from one discharge belt to the other. In one example, the diverter element is configured as a pivoting arm, which can include a contact surface which is contoured to gradually contact the objects being diverted, so as to gradually apply a diverting force to the objects without destabilizing the objects. Movement and actuation of the diverter elements, the dividing screws, the discharge screws, and the conveyor is controlled by a controller. Advantageously, the pockets defined by the dividing screw set and the discharge screw set stabilize and support the objects as the objects are conveyed, divided, diverted and/or discharged. The system is further advantaged by coordination of the rotation speed of the dividing and discharge screws with the belt speed of the conveyor by a controller, where the rotation speed and the belt speed are coordinated so no loading force (no drag or acceleration) is imposed by the conveyor on the objects being conveyed through the divider system, such that each of the objects is conveyed in a stable and controlled position through the divider system. Advantageously, the support provided by the screw sets enables dividing and diverting of relatively taller and/or lighter objects such as empty containers, while minimizing and/or eliminating potential for object tip over or jamming in the system.

The divider system can include one or more sensors for sensing a condition and/or state of the object, such as a color, shape, label, bar code, weight, component presence, size, etc. and for outputting a sensor signal indicating the condition and/or state of the object to the controller. The controller is configured to receive and analyze the sensor signal and to selectively divert one or more objects from one of the discharge belts to the other in response to the sensor signal. The controller can be configured to receive input signals from other devices and/or sensors, which may be upstream and/or downstream of the divider system, including signals indicating object flow and line balancing information from downstream processes receiving the divided objects from the discharge lanes of the divider system. The controller can use the input signals to selectively divert one or more objects from one of the discharge belts to the other in response to the input signal. A method for dividing and diverting objects using the divider system described herein is provided.

The use of screw sets to divide and convey the divided objects, and the use of mechanical diverters to divert divided objects into a diverted group, as described in detail herein, while stabilizing those objects using a discharge screw set, provides a divider system which can divide and divert objects at high speeds and with high accuracy of position on the conveyor, uniform spacing, and position stability, as compared with known systems which first sense an object presence and/or condition, transmit a signal, and actuate a burst of air or plunger to divert an unsupported object on a conveyor.

DETAILED DESCRIPTION

Referring to the drawings wherein like reference numbers represent like components throughout the several figures, the elements shown inFIGS. 1-27are not necessarily to scale or proportion. Accordingly, the particular dimensions and applications provided in the drawings presented herein are not to be considered limiting. Referring toFIGS. 1-5, a divider system is indicated generally at100, and includes a conveying mechanism indicated generally at20, a dividing mechanism indicated generally at40, a diverting mechanism generally indicated at72, a drive mechanism indicated generally at110(seeFIGS. 19-20) and a controller104. The divider system100includes a frame assembly106to which the conveying mechanism20, the dividing mechanism40, the diverting mechanism72, the drive mechanism110and the controller104are attached. The divider system100can be at least partially contained by a housing102, as shown inFIG. 2.

The conveying mechanism20includes a conveyor generally indicated at22and driven by the drive mechanism110. The conveyor22includes an infeed belt24for conveying a sequence of objects10along an infeed lane16between infeed rails18A,18B to discharge belts26A,26B of the conveyor22. The discharge belts26A,26B include a flat portion28(seeFIG. 9) to receive the objects10from the infeed belt24, and a peaked portion30(seeFIGS. 10-12) for conveying the objects through the dividing mechanism100. In the peaked portion, the discharge belts26A,26B are tilted away and downward from a peaked center32and away from a longitudinal axis94of the conveyor22. The discharge belts26A,26B convey the sequence of objects10through the dividing mechanism40where the objects10are divided into two object series12A,12B, where, in the example shown inFIGS. 3-12and as described in further detail herein, the objects10in the first series12A are divided onto a first discharge belt26A and the objects10in the second series12B are divided onto a second discharge belt26B. The object series12A,12B are conveyed, respectively, on discharge belts26A,26B to, respectively, discharge lanes34A,34B of an outfeed portion90to exit the conveyor22at an outfeed end92. In the example shown inFIG. 1, the discharge lanes34A,34B are defined by discharge rails36A,36B and a lane separator38. The divider system100further includes a diverting mechanism72which, in the example shown inFIGS. 1 and 13-15and as explained in further detail herein, can be selectively actuated to divert the series12A,12B of the divided objects10onto one of the discharge belts26A,26B to form a diverted group14of objects10, where the diverted group14of objects10are then conveyed via a respective one of the discharge lanes34A,34B to the outfeed end92of the conveyor20.

Referring toFIGS. 3-12andFIG. 16, the dividing mechanism40includes a dividing screw set indicated generally at42, and a discharge screw set indicated generally at60. The dividing screw set42includes first and second dividing screws44A,44B connected to drive units118A,118B such that each of the dividing screws44A,44B is rotatable about a screw axis98(seeFIG. 9). The dividing screw set42includes an input end46for receiving objects10from the infeed belt24, and an output end48for outputting the divided objects10in two object series12A,12B. As shown inFIGS. 3 and 4, object series12A is outputted to discharge belt26A for conveyance to discharge lane34A, and object series12B is outputted to discharge belt26B for conveyance to discharge lane34B. The dividing screws44A,44B are configured to be driven by drive units118in opposing directions relative to a longitudinal axis94defined by the conveyor22. In the present example, dividing screw44A is configured to rotate clockwise, and dividing screw44B is configured to rotate counter-clockwise, as viewed from the output end48of the dividing screw set42. As shown inFIGS. 5 and 16, each of the dividing screws44A,44B is a variable lead screw, having an infeed portion52with a thread form having a first lead L1, and a dividing portion56with a thread form having a second lead L2, where the second lead L2is greater (longer) than the first lead L1. The second lead L2defines a predetermined interval at which objects10are outputted from the output end48of the dividing screw set42. In a non-limiting example, the first lead L1is equal to the pitch P of the screw thread form, and the second lead L2is twice the pitch P of the screw thread form.

As shown inFIGS. 5, 8 and 16, the dividing screws44A,44B are aligned such that the screw axes98of the dividing screws44A,44B are parallel to each other and to the longitudinal axis94, and are spaced laterally from the longitudinal axis94and relative to each other to define a dividing channel50including a plurality of infeed pockets54distributed along the longitudinal length of the infeed portion52of the dividing screw set42, and a plurality of dividing pockets58A,58B distributed along the longitudinal length of the dividing portion56of the dividing screw set42. The shape of each infeed pocket54is defined by the screw form of the infeed portion52of the dividing screws44A,44B. As shown inFIGS. 5, 9 and 16, in the infeed portion52, the thread forms of the dividing screws44A,44B are aligned to form the plurality of infeed pockets54, such that each object10in the infeed portion is supported in a substantially upright position in a respective infeed pocket54, as shown inFIGS. 3, 9 and 16, as the object10is conveyed through the infeed portion52from the input end46to the dividing portion56along a flat portion28of the conveyor22. In a non-limiting example, the height H of the dividing screws44A,44B can be adjusted for the height, shape, size, and/or weight distribution of the object10, to stabilize the object10in the upright position and as such, prevent tipping of the object10, jamming of the object10in the dividing channel50, etc. It would be understood that the divider system100can include multiple sets of dividing screws44A,44B, each set42having a different thread form, lead combination, number of starts, pocket size, etc., for use with objects10of different shapes and sizes.

As shown inFIGS. 5, 8, 10, and 16, in the dividing portion52, the thread forms of the dividing screws44A,44B are offset to form a plurality of dividing pockets58A,58B which are longitudinally offset from each other, such that, due to the offset formation of the dividing pockets58A,58B and the larger lead L2of the thread form in the dividing portion56, the objects10in the dividing portion56are spaced along the longitudinal axis94of the dividing channel50and singulated from each other prior to being outputted from the output end48of the dividing screw set42. As shown inFIGS. 8 and 10-12, the conveyor22, in the dividing portion56of the dividing channel58and continuing through the discharge channel68, is peaked such that each of the discharge belts26A,26B is tilted away and downward (as viewed on the page) from a central peak at a peak angle Ap. An object10in the dividing portion56will be tilted into one or the other of the dividing pockets58A,58B as the object10is conveyed into the dividing portion56, by the action of the dividing portion56of the one of the dividing screws44A,44B including the dividing pocket58a,58B into which the object10is received, in combination with the tilting action of the peaked discharge belts26A,26B urging the object10to tilt into the dividing pocket58A,58B. The photographic images shown inFIGS. 5-7and schematicFIGS. 8-12illustrate the progression of a sequence of objects10being divided by rotation of the dividing screw set42into two object series12A,12B and outputted into the discharge screw set60while being conveyed on the peaked portion30of discharge belts26A,26B of conveyor22.

Referring now toFIG. 5, shown is a sequence of objects10, which in the non-limiting example are containers sequentially labeled c1, c2, c3, c4, c5, c6, c6for illustrative purposes. The objects10have been received into the infeed portion52and conveyed sequentially through the dividing screw set42such that at the point in time shown inFIG. 5, objects c1and c2are located in the dividing portion56, object c3is transitioning from an infeed pocket54of the infeed portion52to a dividing pocket58A of the dividing portion56, and objects c4, c5, c6are located in infeed pockets54. The conveyor22(seeFIGS. 8 and 9) in the infeed portion52includes a flat portion28such that the discharge belts26A,26B in the infeed portion52are flat and such that the objects c4, c5, c6are supported in an upright position by the dividing screws44A,44B on the flat portion28, as shown inFIG. 9.

The conveyor22transitions from a flat portion28in the infeed portion52to a peaked portion30in in the dividing portion56of the dividing mechanism, where in the dividing portion56each of the discharge belts26A,26B is peaked at a peak angle Ap (seeFIGS. 8 and 10), such that, as object c3transitions into dividing pocket58A, object c3is tilted away from its upright position into the dividing pocket58A at a tilt angle At. The tilt angle At is a function of the peak angle Ap and the shape of the screw form and/or pocket depth in the dividing portion56of the dividing screw44A,44B. The tilt angle At can be increased by changing the shape of the dividing pocket58, for example, by increasing the depth of dividing pocket58in the dividing portion56. The tilt angle At can be affected by the shape, height, and center of gravity of the object10. In one example, the height H of the dividing screws44A,44B relative to the discharge belts26A,26B can be adjustable, such that the height H of the dividing screws44A,44B can be modified to adjust the tile angle At. As such, it would be understood that one or more of the shape (pitch, lead, pocket depth, etc.) of the divider screws44A,44B, the peak angle Ap of the discharge belts26A,26B, and the screw height H can be varied to establish the tilt angle At of the object10in the dividing pocket58, as the object10is progressed through the dividing portion56, to ensure the object10is stabilized in the respective one of the dividing pockets58A,58B and on the respective one of the discharge belts26A,26B to which the object10is divided, as it is conveyed along the conveyor22.

As shown inFIGS. 5 and 16, and as illustrated inFIG. 10, dividing pockets58A,58B are longitudinally offset from each other, such that, as the sequence c1, c2, etc. of objects10is conveyed from the infeed portion52to the dividing portion56of the dividing screw set42, the objects10are alternately divided between the first and second dividing screws44A,44B and first and second discharge belts26A,26B, such that every object10in the sequence is divided in a lateral direction which is opposite the previous and the subsequent objects10in the sequence. Referring to the sequence of objects10shown inFIGS. 5, 6, 17, and 21-22, object c1is divided onto discharge belt26A and into dividing pocket58A of dividing screw44A, and the next sequential object c2is divided onto discharge belt26B and into dividing pocket58B of dividing screw44B. This dividing pattern continues as the sequence of objects10progresses through the dividing screw set42, as illustrated inFIGS. 6 and 7, with object c3being divided onto discharge belt26A and into dividing pocket58A, and object c4being divided onto discharge belt26B and into dividing pocket58B, and as further illustrated inFIGS. 23-24, showing the division of the object sequence c1, c2, c3, c4, c5, c6, c7, c8into two object series12A,12B, where the first object series12A includes objects c1, c3, c5, c7(and so on) and is divided into dividing pockets58A and onto discharge belt26A, and the second object series12B includes objects c2, c4, c6, c8(and so on) and is divided into dividing pockets58B and onto discharge belt26B. As such, it would be understood that the division of the sequence c1, c2, c3, etc. of objects10into two object series12A,12B occurs by rotation of the dividing screw set42and lateral tilting of the object10on the conveyor22such that an object10in the sequence is singulated into one of the dividing pockets58A,58B and onto one of the discharge belts26A,26B, and the objects10which precede and are subsequent to that object10in the sequence are singulated into the other one of the dividing pockets58B,58A and onto the other one of the discharge belts26B,26A.

As shown inFIGS. 5 through 7and further illustrated inFIGS. 21 through 24, the objects10in each of the object series12A,12B are outputted from the dividing screw set42to a receiving end64of the discharge screw set60. As shown in the figures, objects10in the sequence of objects c1. . . cn are divided by rotation of the dividing screw set42and received alternately into a dividing pocket58A and a dividing pocket58B, where the divided objects10received into the dividing pocket58A are outputted at the output end48from the dividing pocket58A and received by the discharge screw62A to form a series of objects12A, and the divided objects10received into the dividing pocket58B are outputted at the output end48from the dividing pocket58B and received by the discharge screw62B to form a series of objects12B. The discharge screw set60includes first and second discharge screws62A,62B connected to a drive unit118such that each of the discharge screws62A,62B is rotatable about a screw axis98(seeFIG. 11) to define a longitudinal axis95therebetween. The first and second discharge screws62A,62B each define a respective thread form such that during rotation of the discharge screw set60, the thread forms of the first and second discharge screws62A,62B are mirror images to each other relative to the longitudinal axis94. The discharge screw set60includes the receiving end64for receiving the objects10outputted from the dividing screw set42, and a discharge end66from which the objects10are conveyed to the outfeed portion90of the conveying mechanism20. The discharge screws62A,62B are configured to be driven by drive units118in opposing directions relative to the longitudinal axis94defined by the conveyor22. In the present example, discharge screw62A is configured to rotate clockwise, and discharge screw62B is configured to rotate counter-clockwise, as viewed from the discharge end66of the discharge screw set60. In the example shown inFIGS. 4 through 7, each of the discharge screws62A,62B is a constant lead screw. In the example shown, the discharge screws62A,62B and the dividing screws44A,44B have the same pitch, and the discharge screws62A,62B have the same lead L1as the infeed portion52of the dividing screws44A,44B. It would be understood that the example shown is illustrative and non-limiting, and, for example, the discharge screws62A,62B could have a lead which is variable from the receiving end64to the discharge end66to change the spacing of the objects10along the longitudinal axis, e.g., longitudinally, as they are conveyed through the discharge screw set60.

As shown in the figures, and as illustrated byFIGS. 17-18, the discharge screws62A,62B are aligned such that the screw axes98of the discharge screws62A,62B are parallel to each other and to the longitudinal axis94, and are spaced laterally from the longitudinal axis94and from each other to define the discharge channel68including a plurality of discharge pockets70A,70B distributed longitudinally, e.g., along the length, of the discharge screw set60. The shape of each discharge pocket70A,70B is defined by the screw form of the discharge screws62A,62B. As shown inFIGS. 5-7andFIGS. 11 and 12, the conveyor22, in the discharge channel68is peaked such that each of the discharge belts26A,26B is tilted away and downward (as viewed on the page) from a central peak at a peak angle Ap. As such, and as shown inFIGS. 6 and 7and illustrated inFIG. 17, an object10being outputted from the output end48of the dividing screw set42will be tilted into one of the discharge pockets70A,70B and conveyed in the tilted position along the conveyor22. In the example shown, the root (minor) diameter and crest (major) diameter of the screw form of the discharge screws62A,62B is relatively smaller, respectively, than the root (minor) diameter and the crest (major) diameter of the screw form of the dividing screws44A,44B, such that, as the object10is outputted from the dividing screw set42into one of the discharge pockets70A,70B, the tilt angle At of the object10can increase, as shown inFIGS. 10-12, as compared to the tilt angle At of the object10in the dividing pocket58A,58B, and such that the object series12A is further divided laterally from the object series12B as the object series12A and12B are conveyed by the discharge screws62A,62B through the discharge channel68. As shown inFIGS. 6-7 and 17and in additional detail inFIGS. 22-23, objects c1, c3, c5, etc. of the object series12A are discharged from dividing pocket58A as indicated by the arrow120and fed into discharge pockets70A of discharge screw62A, and conveyed by rotation of the discharge screw62A and movement of the discharge belt26A through the discharge channel68for discharge into the first discharge lane34A. Likewise, objects c2, c4, c6, etc. of the object series12B are discharged from dividing pocket58B as indicated by arrow122and fed into discharge pockets70B of discharge screw62B, and conveyed by rotation of the discharge screw62B and movement of the discharge belt26B through the discharge channel68for discharge into the second discharge lane34B.

FIGS. 6 and 7andFIGS. 21-24illustrate object series12A being divided from the sequence of objects10, such that objects c1, c3, c5, c7etc. are, as previously described, divided into a dividing pocket58A of dividing screw44A and outputted into a pocket70A of the discharge screw62A. As illustrated by the figures, the objects c1, c3, c5, c7etc. are singulated in the dividing portion56and outputted to the discharge screw62A such that every other discharge pocket70A is left empty as the objects c1, c3, c5, c7etc. are received by the discharge screw62A. Referring toFIGS. 7 and 17andFIGS. 22 and 23, for example, the discharge pocket70A between the discharge pocket70A in which object c1is positioned and the discharge pocket70A in which object c3is positioned is an empty pocket X1. As shown beginning withFIG. 21, and illustrated inFIG. 17, the objects c1, c3, c5, c7are outputted to every other discharge pocket70A, such that the empty pocket X1is maintained between longitudinally adjacent objects c1and c3, an empty pocket X3is maintained between longitudinally adjacent objects c3and c5, and so on. Likewise, as object series12B is divided into a dividing pocket58B and outputted to the discharge screw62B, every other discharge pocket70B is left empty as the objects c2, c4, c6, c8etc. are received by the discharge screw62B. The rotation of discharge screws62A,62B is coordinated such that each object10in series12A is conveyed in a discharge pocket70A which is laterally opposite an empty discharge pocket70B, and each object10in series12B is conveyed in a discharge pocket70B which is laterally opposite an empty discharge pocket70A (seeFIGS. 22-23andFIG. 17). Referring toFIGS. 22 and 17, for example, an empty pocket X2is maintained in advance of object c2and an empty pocket X4is maintained between objects c2and c4output to discharge screw62B. Object c1is laterally opposite empty pocket X2, object c2is laterally opposite empty pocket X1, object c3is laterally opposite empty pocket X4, object c4is laterally opposite empty pocket X3, and so on. By dividing the object series12A,12B such that each object10in the series12A,12B is laterally opposite an empty pocket X in the discharge channel68, the objects10from series12A can be respectively diverted, by actuation of the diverter74A, into the respective laterally opposite empty pockets70B in discharge screw62B to form a diverted group14B, as shown inFIGS. 13, 14 and 25. Likewise, the objects10from series12B can be respectively diverted, by actuation of the diverter74B, into the respective laterally opposite empty pockets70A in discharge screw62A to form a diverted group14A, as shown inFIG. 27.

As shown inFIGS. 4 and 8andFIGS. 24 and 26, the object series12A is conveyed by the discharge screw62A and along the discharge belt26A to the discharge end66of the discharge screw set60, where the objects c1, c3, c5, etc. of the series12A are conveyed into the discharge lane34A for conveyance on the discharge belt26A through the conveyor outfeed portion90to the outfeed end92. Likewise, the object series12B is conveyed by the discharge screw62B and along the discharge belt26B to the discharge end66, where the objects c2, c4, c6, etc. of the series12B are conveyed into the discharge lane34B for conveyance on the discharge belt26B through the outfeed portion90to the outfeed end92. In a non-limiting example, the conveyor22in the outfeed portion90can be peaked as shown inFIG. 12, such that objects10on the respective discharge belts26A,26B are tilted against the respective discharge rails36A,36B, to urge the objects10to remain in their respective discharge lane34A,34B and to stabilize and/or support the objects10in their respective discharge lanes34A,34B as they are conveyed through the outfeed portion90.

Referring toFIGS. 3 and 4,FIGS. 13-15, andFIG. 27, the divider system100includes a diverting mechanism72. In the example shown, the diverting mechanism includes a first diverter74A and a second diverter74B. the diverting mechanism72is in communication with the controller104such that each of the first and second diverters74A,74B are selectively actuable to divert the series12A,12B of the divided objects10onto one of the discharge belts26A,26B to form a diverted group14of objects10, where the diverted group14of objects10are then conveyed via a respective one of the discharge lanes34A,34B to the outfeed end92of the conveyor20. In an illustrative example shown inFIGS. 13-15andFIG. 18, the diverter74A includes a diverter element76A which is configured, in a non-limiting example, as a pivoting arm connected at a first end84A via a pivotable joint82A to a connecting member80A, such that the diverter element76A is pivotable about a pivot axis96A between a non-actuated position shown inFIGS. 3 and 4and an actuated position shown inFIGS. 13-16andFIG. 27. In the actuated position the diverter element76A is pivoted to a diverter angle Ad as shown inFIGS. 13, 14 and 18, such that a second end86A of the diverter element76A pivots into the discharge channel68to contact objects10in the series12A and divert the objects in series12A from discharge belt26A to discharge belt26B, where each of the diverted objects in series12A is received into a respective empty pocket X in the discharge screw62B and conveyed by the discharge screw62B and discharge belt26B out of the discharge channel68to the discharge lane34B of the outfeed portion90. The diverter74A includes an actuator108A for actuating and de-actuating the diverter element76A. The diverter element76A, in the illustrative example, is connected to the actuator108A by a linkage88A actuable by the actuator108A to pivot the diverter element76A between the actuated and non-actuated positions. The linkage88A shown inFIG. 15includes a rod and cylinder assembly for moving the diverter element76A. This example is non-limiting and it would be understood that other configurations of linkage88A could be used. The actuator108A can be, by way of non-limiting example, one of a hydraulic actuator, a pneumatic actuator, a magnetically actuated servo mechanism, or other like actuator.

Each of the diverters74A,74B can include a respective second diverter element78A,78B, as shown inFIGS. 11 and 13. In the example shown, the first (upper) diverter element76A pivots into the discharge channel68to contact the upper portion (as viewed on the page) of the object10protruding above the discharge screw62A, and the second (lower) diverter element78A pivots into the discharge channel68via a clearance gap G between the conveyor22and the discharge screw62A, to contact the lower portion (as viewed on the page) of the object10. By contacting the object10both above and below the discharge screw62A with, respectively, the upper and lower diverter elements76A,78A, the object10is stabilized and supported as it is diverted from discharge belt26A to discharge belt26B and as the object10is diverted into its corresponding pocket70B in discharge screw62B. It would be understood that, for objects10which are shaped and/or sized such that the upper portion of the object10does not protrude above the discharge screw, the object10can be diverted using the lower diverter element78A only. In a non-limiting example, the lower diverter element78A is a pivoting arm connected at a first end84A via the pivotable joint82A to the connecting member80A, such that the diverter element78A is pivotable about the pivot axis96A. As illustrated inFIGS. 15 and 21-27, each of the diverter elements76A,76B,78A,78B can include a contoured surface for contacting the objects10, such that, during selective actuation of any of the diverter elements76A,76B,78A,78B to divert the objects10, contact between the contoured surface and the diverted object10is gradual, such that the diverted object10remains stabilized through the diversion sequence.

FIGS. 13-14, 18 and 24-26illustrate actuation of the diverting mechanism72using the diverter74A to selectively divert objects10from discharge belt26A to discharge belt26B to form a diverted group14B of objects10conveyed to discharge lane34B, and de-actuation of the diverter74A to resume conveyance of the divided series12A on discharge belt26A and to discharge lane34A. InFIG. 24, after division of sequence c1, c2, c3, c4, etc. of objects10by the dividing screw set42into object series12A,12B, as previously described herein, and prior to actuation of the diverter74A, the first series12A of divided objects c1, c3, c5, etc. is shown being conveyed by discharge screw62A and discharge belt26A to discharge lane34A, and the second series12B of divided objects c2, c4, c6, etc. is shown being conveyed by discharge screw62B and discharge belt26B to discharge lane34B. InFIGS. 25 and 18, in an illustrative example, the diverter74A is actuated by the actuator108A to initiate pivoting of the diverter element76A using linkage88A into the discharge channel68, such that second end86A of the diverter element76A pivots into contact with object cG, to apply a lateral force to divert the objects10of series12A, beginning with object cG, from their respective pockets70A to respective empty pockets XB of discharge screw62B, and from discharge belt26A to discharge belt26A, to form a diverted group14B. The diverted group14B, beginning with object cG, cH, and so on, is conveyed from the discharge channel68on discharge belt26B to the discharge lane34B.FIG. 25shows the diverter element76A fully actuated, e.g., fully pivoted to the diverter angle Ad, such that in the fully pivoted position, the diverter element76A is contacting and diverting each object10of series12A as it is outputted from the dividing screw44A into an empty pocket XB in discharge screw62B.

InFIG. 26, in an illustrative example, the diverter74A is shown being de-actuated by the actuator108A such that the diverter element76A is pivoted away from the diverted group14and out of contact with objects10in series12A, such that the objects10in series12A remain on discharge belt26A as they are conveyed, undiverted, through the discharge channel68to discharge lane34A, as shown inFIG. 26. Summarizing the example shown inFIGS. 25-26, the diverting mechanism72is actuated to divert objects10in object series12A from discharge screw62A to discharge screw62B and from discharge belt26A to discharge belt26B, such that the objects10in object series12B and the objects10in object series12A which have been diverted to discharge screw62B are discharged from discharge channel68to discharge lane34B as a diverted group14B, and the diverting mechanism72is subsequently de-actuated such that, as the diverter74A is retracted, the objects10in the object series12A remain on discharge belt26A and the object series12A,12B are again discharged on their respective discharge belts26A,26B. The example of diverting a plurality of objects10from a series12A,12B into a diverted group14is non-limiting, and it would be understood that the actuation and de-actuation of the diverting mechanism72can be controlled by the actuators108A,108B and/or the controller104to selectively divert, in a single actuation/de-actuation cycle, as few as a single object10or a plurality of objects10from one to another of the discharge screws62A,62B and discharge belts26A,26B.

Referring toFIGS. 1 and 4andFIGS. 13-14, the diverting mechanism72, in a non-limiting example, includes the first diverter74A and a second diverter74B. The second diverter74B is configured as described for the first diverter74A, such that the second diverter74B includes a diverter element76B which in a non-limiting example is configured as a pivoting arm connected at a first end84B via a pivotable joint82B to a connecting member80B, such that the diverter element76B is pivotable about a pivot axis96B between a non-actuated position shown inFIGS. 13 and 14and an actuated position shown inFIG. 27. In the actuated position the diverter element76B is pivoted to a diverter angle Ad as shown inFIG. 27, such that a second end86B of the diverter element76B pivots into the discharge channel68to contact objects10in the series12B and divert the objects in series12B from discharge belt26B to discharge belt26A, where each of the diverted objects in series12B is received into a respective empty pocket X (see XA, XB inFIG. 18) in the discharge screw62A and conveyed by the discharge screw62A and discharge belt26A out of the discharge channel68to the discharge lane34A of the outfeed portion90. The diverter74B includes an actuator108B, indicated generally inFIG. 4, for actuating and de-actuating the diverter element76B. In a non-limiting example the actuator108B is configured as described for actuator108A. The diverter74B can include a second diverter element78B (seeFIGS. 11 and 13), where, in the example shown, the first (upper) diverter element76B pivots into the discharge channel68to contact the upper portion (as viewed on the page) of the object10protruding above the discharge screw62B, and the second (lower) diverter element78B pivots into the discharge channel68via a clearance gap G between the conveyor22and the discharge screw62B, to contact the lower portion (as viewed on the page) of the object10. By contacting the object10both above and below the discharge screw62B with, respectively, the upper and lower diverter elements76B,78B, the object10is stabilized and supported as it is diverted from discharge belt26B to discharge belt26A and as the object10is diverted into its corresponding pocket70A in discharge screw62A. It would be understood that, for objects10which are shaped and/or sized such that the upper portion of the object10does not protrude above the discharge screw, the object10can be diverted using the lower diverter element78B only. In a non-limiting example, the lower diverter element78B is a pivoting arm connected at a first end84B via the pivotable joint82B to the connecting member80B, such that the diverter element78B is pivotable about the pivot axis96B.

The diverting mechanism72can be actuated and de-actuated, for example, by commands and/or signals selectively outputted from the controller104to the diverters74A,74B, for example, via actuators108A,108B. The controller104can be in communication with one or more devices which provide data and/or signals to the controller104, such that the data and/or signals received by the controller104can be used by the controller104to determine when and for how long one or the other of the diverters74A,74B should be actuated. By way of non-limiting example, the devices in communication with the controller104can include equipment and/or devices which are upstream and/or downstream from the divider system100, where signals received from the equipment can include commands to divert the objects10to one or the other of discharge lanes34A,34B in response to conditions of the upstream and/or downstream equipment, including conditions related to line balancing and/or capacity requirements of the downstream equipment, equipment downtime due to changeover, set-up or other reasons, etc.

In another example, the devices in communication with the controller104can include one or more sensors which can be located upstream and/or downstream from the divider system100, and/or can be included in the divider system100, for outputting signals to the controller104which can be used by the controller104to determine whether actuation and/or de-actuation of diverting mechanism72and/or the diverters74A,74B is required. By way of example, one or more of the sensors can be operable as a photosensor for detecting color, shape, object condition, etc., a scanner such as a bar code scanner, a sensor to detect a dimension, weight, or other quantifiable, e.g., measurable characteristics of an object10, etc. In a non-limiting example, the divider system100can include at least one sensor to sense a condition of the object10, and to output a condition signal to the controller104which is indicative of the condition of the object10. By way of example, the condition may be an indication of the shape, size, color, type, or other identifying condition of the object10that may differentiate the object10from other objects10in the sequence of objects10located, for example, in the infeed lane16and/or in the infeed portion52of the dividing screw set42. The controller104, in response to the condition signal, can selectively output a command to the diverting mechanism72to divert the object10associated with the condition signal to one or the other of the discharge lanes34A,34B. In one example, the condition may be a color, label, bar code or other distinguishing feature of the object10which identifies the object10as one of a first type to be diverted to discharge lane34A or one of a second type to be diverted to discharge lane34B. In another example, the condition may be a feature of the object10which is used to determine if a standard for the object10has been met. For example, the object10can be configured as a liquid container enclosed by a cap, as shown in the photographs ofFIGS. 21-27, and the sensor can be configured to sense presence of the cap. The controller104can be configured to divert objects10with missing caps to one of the discharge lanes26A as rejected objects, and to divert objects10with caps present to the other of the discharge lanes26B as acceptable for further processing. In another example, the sensor can be configured to sense a fill condition of the container, for example, to detect a partially filled or empty container, such that the partially filled or empty container can be diverted to one of the discharge lanes26A,26B as a rejected object10. The examples provided herein are non-limiting, and it would be understood that one or more sensors can be included in the divider system100to sense object conditions which can cause the controller104to selectively actuate and/or de-actuate the diverting mechanism72.

The controller104, in a non-limiting example, is configured to control the drive mechanism110of the divider system100. In the example shown inFIGS. 19 and 20, the drive mechanism110includes a drive motor112, synchro bars114and gearing116, which is arranged to concurrently drive rotation of the dividing screws44A,44B, rotation of the discharge screws62A,62B, and movement of the conveyor22including discharge belts26A,26B. The controller104controls the drive mechanism110, including controlling the rotation speed of the dividing screws44A,44B, the rotation speed of the discharge screws62A,62B and the belt speed of the conveyor22, such the conveying force imposed by the conveyor22on the objects10being conveyed in the dividing pockets58through the dividing channel50and/or on the objects10being conveyed in the discharge pockets70through the discharge channel68is at equilibrium with the conveying forces imposed on the objects10by the dividing pockets58and the discharge pockets70. It would be understood that when the forces imposed by the dividing pockets58, the discharge pockets70, and the discharge belts26(being driven by the conveyor22) are controlled such that the forces are at equilibrium, the objects10are conveyed with no destabilizing drag force or destabilizing accelerating force imposed on the objects10relative to the conveying forces of the dividing pockets58and the discharge pockets70, such that the objects10are stabilized in the dividing pockets58and discharge pockets70and are retained in their respective pockets58,70as they are conveyed through the dividing channel50and discharge channel68. In one example, the rotation rate and pitch of each of the dividing screws44A,44B and the discharge screws62A,62B is proportional to the conveyor speed such that there is no forward or reverse drag or force exerted by the screw face on the object10, e.g., such that the object10is moved through the divider mechanism100at the conveyor speed, and therefore remains upright and stable with the feeding force exerted on the object10by the screw form equivalent in direction and magnitude to the conveying force exerted on the object10by the conveyor. In one example, the controller104determines and controls the speed of the conveyor22and the revolution speed of the dividing screws44A,44B and the discharge screws62A,62B, based on the pitch of the dividing screws44A,44B and the pitch of the discharge screws62A,62B, such that the linear speed of the conveyor22, the linear speed of the discharge belts26A,26B, the linear speed of the dividing screws44A,44B and the linear speed of the discharge screws62A,62B are the same.

The illustrative example of a divider system100shown inFIGS. 1-27is not intended to be limiting. It would be understood that the divider system100, including the dividing mechanism40and/or the diverting mechanism72can be configured within the scope of the description provided herein to divide and/or divert objects10of shapes, sizes and configurations other than those shown in the figures by modifying one or more of the dividing screw set42, the discharge screw set60, the diverting mechanism72, and/or the conveyor20including the infeed belt24, the flat and peaked portions28,30, the discharge belts26A,26B, and/or the outfeed portion90. By way of example, modifications anticipated within the scope of the description including various combinations of double and single lead screw forms, combinations and modification of screw pitch and pocket depth to accommodate the shape of the object10, modification of the width of the dividing channels50and/or the discharge channels68and/or the height of the dividing screw sets42and/or the discharge screw sets60relative to the conveyor20to accommodate and/or optimize stabilization of the object10, etc. By way of example, modifications anticipated within the scope of the description including various configurations of the diverting mechanism72, which can include modifications and/or variations of the shape and size of the diverter elements76A,76B,78A,78B, which can include arm configurations which are bent, curved, or otherwise shaped to adapt to the shape, size, weight, and/or other condition of the objects10being diverted. Further, the linkage88A,88B and/or the actuators108A,108B can be modified as required to accommodate the conditions of the objects10being diverted and/or modifications of the diverter elements76A,76B,78A,78B. for example, the actuators108A,108B can be actuated by one or more of hydraulic, pneumatic, magnetic, and electrical means, and the linkage88A,88B can be modified, for example, to actuate a diverter74A,74B configured other than a pivoting arm, for example, a plunger type diverter. The example of the conveyed object10shown in the figures is not limiting, and it would be understood that the object10can be other than a container, and could be one or more of a container, a carton, a case, a bottle, a can, etc., which could be positioned in and conveyed via the infeed pockets54, the dividing pockets53A,58B, and the discharge pockets70A,70B.

As used herein, the terms “a,” “an,” “the,” “at least one,” and “one or more” are interchangeable and indicate that at least one of an item is present. A plurality of such items may be present unless the context clearly indicates otherwise. All numerical values of parameters, quantities, or conditions in this disclosure, including the appended claims, are to be understood as being modified in all instances by the term “about” or “approximately” whether or not “about” or “approximately” actually appears before the numerical value. “About” and “approximately” indicate that the stated numerical value allows some slight imprecision (e.g., with some approach to exactness in the value; reasonably close to the value; nearly; essentially). If the imprecision provided by “about” or “approximately” is not otherwise understood with this meaning, then “about” and “approximately” as used herein indicate at least variations that may arise from methods of measuring and using such parameters. Further, the terminology “substantially” also refers to a slight imprecision of a condition (e.g., with some approach to exactness of the condition; approximately or reasonably close to the condition; nearly; essentially). In addition, disclosed numerical ranges include disclosure of all values and further divided ranges within the entire disclosed range. Each value within a range and the endpoints of a range are all disclosed as separate embodiments. The terms “comprising,” “includes,” “including,” “has,” and “having” are inclusive and therefore specify the presence of stated items, but do not preclude the presence of other items. As used in this disclosure, the term “or” includes any and all combinations of one or more of the listed items.

The above features and other features and advantages of the present invention are readily apparent from the detailed description of the best modes for carrying out the invention described herein, when taken in connection with the accompanying drawings. While some of the best modes and other embodiments for carrying out the claimed invention have been described in detail, various alternative designs and embodiments exist for practicing the invention.