Apparatus and method for pick and placement of bulk items

An assembly and method for moving bulk items from a first location to a second location is disclosed. The items are moved from the first location to the second location through a pick-up head. Vacuum pressure is supplied to the head to pick-up an item at the first location and carry the item to the second location. A detector is located between the first location and the second location to detect if an item has been picked up by the head. If no item is detected, the head is closed to the vacuum pressure through a control mechanism or closure element.

BACKGROUND

The present application relates to an apparatus for handling bulk items. Irregular shaped items stored in bulk in an overlapping fashion can be difficult to handle and sort. For example in the food industry, bulk food items such as meat, chicken and poultry are separated and sorted for weighing, cutting, and packaging operations. Automation of this process can reduce labor costs and increase efficiency. However, the irregular shape and features of such items can introduce challenges and interfere with automation.

SUMMARY

The present application relates to an assembly for handling bulk items. As described, the assembly includes a plurality of heads to pick up items from a bin or conveyor. Vacuum pressure is supplied to the plurality of heads to pick up the items. A detector is used to detect or confirm if an item has been picked up by the head. A vacuum control mechanism is coupled to the heads to close the heads to the vacuum pressure if no item is picked up by the head. In illustrated embodiments a closure element is coupled to each of the plurality of heads and is operable between an opened position and a closed position. If no item is detected an actuator element or device is used to close the closure element to preserve vacuum pressure. Closure elements of closed heads are opened via a passive control device to provide vacuum pressure to the heads at a pick-up location of a closed loop path.

It should be understood that the FIGS. are not necessarily drawn to scale and that like numbers have been used to identify like parts in the sequence of FIGS.

DETAILED DESCRIPTION OF ILLUSTRATIVE EMBODIMENTS

The present application relates to an assembly and method for handling bulk items as schematically shown inFIG. 1A. As shown, the assembly includes a plurality of pick-up heads100coupled to a vacuum pressure source102to supply vacuum pressure to pick-up items from a pickup location104and transport the items to a drop-off location106. In the embodiment shown, the heads100move or rotate along a closed loop path between the pick-up location104and drop-off location106as illustrated by arrows108. In the embodiment shown, the heads100are rotated in a clockwise direction along a circular path via a drive mechanism110(illustrated schematically). Application, however, is not limited to a particular direction or circular closed loop path. For example, the path can be oval or elliptical shaped. Although a particular number and arrangement of heads is schematically shown, application is not limited to any particular number or arrangement of heads.

As shown, the assembly includes a detector114in the path between the pick-up location104and the drop-off location106to determine whether the head100has picked up an item from the pick-up location104. If the head100has not picked-up an item then the detector114provides a “no-item detected” output to a controller116. The controller116uses the output from the detector114to operate a vacuum pressure on-off control mechanism118coupled to the heads to control vacuum pressure supplied to the heads from the vacuum pressure source102. In response to the “no-item detected” output from the detector114, the vacuum pressure on-off control mechanism118closes the vacuum pressure to the head110to limit pressure loss from an opened head110with no item and preserve vacuum pressure for the heads carrying items from the pick-up location104to the drop-off location106.

In an illustrated embodiment, the detector114includes a transmitter and receiver aligned in the path between the pick-up location104and the drop-off location106. In an illustrative embodiment, the detector114uses optical or infrared sensors or receivers to detect items. The controller116is an electronic controller device including one or more hardware or circuit components, logic components and/or a processor and one or more memory devices to provide a control signal to the vacuum pressure on-off control mechanism118to close the head100if no item is detected.

FIG. 1Bis a flow chart illustrating steps incorporating the features of the present application schematically shown inFIG. 1A. As shown inFIG. 1B, one of the plurality of heads100is position proximate to the pick-up location104and vacuum pressure is supplied to the head100as illustrated in steps120and122. In step124, the detector114detects if an item is attached to or has been picked-up by the head100. If no item is detected in step126, the head is closed to the vacuum pressure source so that no vacuum pressure is supplied to the head100as illustrated in step128. The head is moved or rotated from the pick-up location104to the drop-off location106as shown in step130. In step132, if the head has picked up an item, the item is released at the drop-off location106. In particular, the item is released through the application of positive pressure, gravity or through physical contact. For example, in an illustrative embodiment the item is released or “knocked off” the head106through a mechanical device or mechanism (not shown). Thus as described, if no item is detected, the head100is closed to the vacuum pressure source before moving to the drop-off location106.

FIG. 2Aschematically illustrates another embodiment of an assembly of the present application similar toFIG. 1A. In the embodiment shown, the heads100are coupled to a support structure140to move the heads100along the closed looped path between the pick-up location104and the drop-off location106. The vacuum pressure on-off control mechanism118includes closure elements142operably coupled to the heads100having an opened position to supply vacuum pressure to the heads and a closed position to close the head to the vacuum pressure source102. As previously described, detector114is located aft of the pick-up location104to detect if an item has been pick-up by the heads100. Output from the detector114is provided to the controller116which is coupled to a feedback control device144to shift the closure element142to the closed position if no item is detected. Forward of the pick-up location, the assembly includes a passive control device146to open the closure element142closed by the feedback control device144in response to the no item detection.

In the illustrated embodiment, the support structure140is a rotating disc to form a circular closed loop path. As illustrated inFIGS. 2A-2B, vacuum pressure is supplied to the heads100from the vacuum pressure source102through a manifold150. The heads100are coupled to an obverse surface of the support structure140and the manifold150is supported relative to a reverse surface of the support structure140. The manifold150includes multiple manifold chambers152a,152b,152cwhich in the illustrated embodiment includes a chamber152aconnectable to the vacuum pressure source102to supply vacuum pressure to the heads100between the pick-up location104and the drop-off location106, chamber152bconnectable to a positive pressure source154to release items at the drop-off location106and chamber152cconnectable to a cleaning or sanitizing solution source156to clean or sanitize the heads100during operation. The heads are coupled to the manifold chambers through supply passages158extending through the support platform140between the obverse and reverse sides as shown inFIG. 2B. The support platform140rotates relative to the manifold150through drive mechanism110to sequentially position the heads100proximate to the manifold chambers152a,152b,152c, to supply vacuum pressure at the pick-up location104, positive pressure to release an item at the drop-off location106and water or other solution during the rotation cycle of the heads100after the drop-off location106and before the pick-up location104.

In an illustrative embodiment shown inFIG. 2C, the first chamber152aincludes a circumferential dimension to continuously supply vacuum pressure as the head100moves between the pick-up location104and the drop-off location106. The circumference dimension of the second chamber152bis aligned to provide positive pressure to release an item at the drop-off location106and the circumferential length of the third chamber152cis designed to provide solution to the head after the drop-off location106and before or prior the pick-up location104. In the embodiment shown inFIG. 2C, the drop-off location106is orientated generally 90 degrees from the pick-up location104, however application is not limited to a particular orientation or placement. Although a manifold with three chambers is described, application is not limited to any particular number of manifold chambers.

FIG. 3Aillustrates an embodiment of an assembly of the present application where the support platform140is rotationally coupled to a base structure160and rotated through a drive shaft162coupled to a drive motor164. Manifold150is supported below the support platform140to provide vacuum pressure to the plurality of heads as previously described. As comparatively shown inFIGS. 3A-3B, the heads100are coupled to the manifold and vacuum pressure source through a flexible hose166. As shown, a support fixture170movably supports the heads100relative to the base structure160and support platform140to raise and lower the heads between the pick-up location104and drop-off location106.

In particular the support fixture170as shown inFIG. 3Bincludes a support arm172rotationally coupled to support platform140through stand174. The support arm172rotates as illustrated by arrow175to move the head100from the raised position to the lowered position so that the head can pick-up and drop items. The position of the support arm174is adjusted during a rotation or closed loop cycle through guide structure176coupled to the base structure160of the assembly as shown inFIGS. 3A and 3C. As shown inFIG. 3C, the guide structure176includes a guide track178along the closed loop path. Guide pins180on the plurality of heads100move along the guide track178to control the elevation of the heads100relative to the support platform140and base structure160. In particular, the guide track178includes raised and lowered track portions to move the heads100between the raised and lowered positions along the closed looped path of the heads100.

FIG. 4Ais a top view of an embodiment of the assembly for picking up items from the pick-up location104and placing items at the drop-off location106. As shown inFIG. 4A, items are provided to a pick-up bin or conveyor182through an input conveyor184. For example, the pick-up conveyor is a recirculating conveyor (not shown). The items are transferred from the bin182to compartments185along an output conveyor186via rotation of the heads100. Prior to bin182, the closure elements142are opened via the passive control device146to provide vacuum pressure to the head100at the pick-up location104. In particular, as previously described, before the head100reaches the pick-up location104, the passive control device146opens the closed head100to provide vacuum pressure to the heads100. After bin182, the detector114detects if the head100has an item and if not the feedback control device144operates the closure element142to close vacuum pressure to the head100prior to rotation of the head to the output conveyor186. Otherwise if an item is detected, the closure element142remains open to provide vacuum pressure to carry the item on the head100to the drop-off location106.

In the embodiment shown, the output conveyor186includes side-by-side product compartments185a,185balong a length of the conveyor186. As shown inFIGS. 4B-4C, the assembly includes a diverter mechanism190to alternately place one item in a first side-by-side compartments185aand another item in an adjacent side-by-side compartment185b. The diverter mechanism190as shown includes a diverter192to sequentially place items in the side-by-side compartments185a,185b. In the embodiment shown, the diverter192is rotationally coupled to the base structure and is rotated between a first position as shown inFIG. 4Band a second position as shown inFIG. 4Cto place the items in the side-by-side compartments185a,185b. As shown the diverter192is rotated through actuator194operably coupled the diverter192through one or more linkages. In an illustrated embodiment, the actuator194is a pneumatic cylinder which is coupled to a pneumatic pressure source to move or rotate the diverter192between the first and second positions as shown inFIGS. 4B-4C.

As shown, a motor198drives or moves the output conveyor186for continuous operation. Operation of the motor198and diverter192is controlled via the controller116to time movement of the conveyor186with the cycle of the diverter192so that each of the side-by-side compartments185a,185bis filled prior to moving the conveyor186to position the next side-by-side compartments185a,185bat the drop-off location106. As illustrated, in the process steps ofFIG. 4D, if no item is detected in step200, operation of the conveyor motor198is paused while the drive mechanism110rotates the support platform140to advance the next head at the drop-off location106as shown in step202. If an item is detected, the item is released from the head at the drop-off location fill one of the side-by side compartments185a,185bas shown in step204. If both compartments185a,185bare filled in step206, the conveyor motor198advances the conveyor186to the next side-by-side compartments185a,185bin step208and the support platform for the heads is rotated in step210. If both sides are not filled, the actuator194operates the diverter192to shift the diverter192to the unfilled compartment as shown in step212to place the next item in the rotation cycle in the unfilled compartment and the support platform is rotated to position the next head at the conveyor186.

Thus, as described for a double sided conveyor186, the conveyor is advanced or moved in sequence with the rotation of two heads unless one or both of the heads has no item detected and the operation sequence for the motor198and diverter192is paused to wait for the items to fill the adjacent compartments185a,185b. In another embodiment, the head drops off items along a single row conveyor (not shown). Operation of the conveyor is sequenced with rotation of the heads100and support platform140. If no item is detected operation of the conveyor motor198is paused so that the conveyor186is not advanced in sequence with the rotation of the support structure140until an item is dropped onto the conveyor at the drop-off location106.

FIGS. 5A-5Billustrate an embodiment of the closure element142operably coupled to the head100to close vacuum pressure to the head in response to no item detected on the head. As shown, the head includes a cylindrical body248having a flow passage250coupled to a nozzle tip252. The closure element142as shown is operable in a chamber of a branch structure256coupled to the cylindrical body248of the head100and is movable between a retracted position in the branch structure256spaced from the flow passage250and an extended position in the flow passage250to occlude or plug the flow passage250and close vacuum pressure to the nozzle252of the head. As shown, the closure element142is a plug-type valve element258.

The plug-type valve element258is moved between the retracted position and an extended through a plunger device260having an enlarged head262which form an interface structure or tool to move the plunger device260. The plunger device260is coupled to the valve element258and is moveable between a first position and a second position through operation of an actuator element272of the feedback control device144in response to no item detected input from the detector114. In particular in the illustrated embodiment, the enlarged head262of the plunger device260is movable in a control passage274of the feedback control device144between a forward position and an aft position via operation of the actuator element272. The actuator element272is moved between a retracted position and an extended position via actuator275to interface with the enlarged head262to move the valve element258from the retracted position to the extended position to plug the flow passage250to close the head. In an illustrated embodiment the actuator is a pneumatic cylinder operable to move the plunger device260to shift the valve element258between the open and closed positions as described.

FIGS. 5C-5Dillustrate operation of the passive control device146to open the plug-type valve element258on the head100prior to the pick-up location or bin. As shown, the passive control device includes a passive control passage280having an inlet282, an outlet284and a ramped surface286between the inlet282and the outlet284. The inlet282includes an opening sized to receive the enlarged head262of the plunger device260either in the retracted and extended positions. The ramped surface286extends from the inlet282to a smaller sized opening of the outlet284aligned with the opened position of the enlarged head262of the plunger device260. As progressively illustrated inFIG. 5D, as the closed head approaches the control passage280, the enlarged head262of the plunger device260is in the retracted position. Movement of the enlarged head262along the ramped surface286moves the plunger device260to the extended position to open the head to the vacuum pressure. If the head262of the plunger device approaches the inlet282in the extended position, the head is not affected by the ramped surface286and passes through the passive control passage280in the extended or opened position.

FIGS. 6A-6Billustrate an alternate embodiment of a closure element142of the present application operable relative to a closure structure300supported on the support platform140to close vacuum pressure to the heads100if no item is detected. In the embodiment shown, the closure structure300is operably coupled to the head100through the flexible hose166and includes an inlet coupled to the supply passages and outlet coupled to the flexible hose166. As shown inFIG. 6B, the closure element is a rotating valve element302which rotates in a valve chamber of the closure structure300between an opened position shown inFIG. 6Bto provide vacuum pressure to the head and a closed position shown in phantom. In the opened position shown inFIG. 6Ba valve passage304of the valve element302aligns with the inlet and outlet of the closure structure300to provide vacuum pressure to the head. In the closed position, the valve passage304is not aligned with the inlet and outlet of the closure structure300to close the head as shown inFIG. 6C.

InFIG. 6B, the closure structure300shown includes a plurality of arms310spaced about an outer circumference of the structure to form the interface structure or tool to open and close the valve element. The arms310are coupled to the rotating valve element302through fasteners (not shown). The plurality of arms310include first arms310aand second arms310binterspersed about the circumference of the closure structure so that the first arms310aare located 180 degrees apart, the second arms310bare located 180 degrees apart and adjacent first and second arms310a,310bare ninety degrees apart. In the illustrated embodiment the first arms310aare shorter that then second arms310band in an opened position, one of the first arms310ais in a top position as shown inFIG. 6Band in the closed position, one of the second arms310bis in a top position as shown inFIG. 6C. The length of the first arms310ais sized so that the feedback control device rotates the valve element302to the closed position when no item is detected and the second arms310bare sized so that the passive control device146interfaces with the second arms310bin the closed position to rotate the closed valve element302to the open position.

FIGS. 6D-6Gprogressively illustrate an embodiment of the feedback control device144including an actuator320operable to move an actuator element322between a retracted position and an extended position as comparatively shown to engage the first arm310acoupled to the valve element302in the opened position. As progressively illustrated inFIGS. 6E-6F, in response to a no-item detection, the controller116provides input to the actuator320to move the actuator element322to the extended position in alignment with the first arm310aat the top of the closure structure. As progressively illustrated inFIGS. 6E-6F, movement of the support platform140(and closure structure) along the path past the feedback control device144as illustrated by arrow324rotates the valve element302via engagement of arm310awith the extended actuator element322to the closed position. Thus contact of the actuator element322with the first arm310acoupled to the valve element302rotates the valve element302from the open position shown inFIGS. 6D-6Eto the closed position shown inFIG. 6F. Thereafter, the actuator element322is retracted before the next head as shown inFIG. 6G. In the illustrative embodiments, the actuator320is a pneumatic cylinder to move the actuator element322between the retracted and extended positions.

FIGS. 6H-6Jschematically illustrate operation of the passive control device146. As schematically shown inFIG. 6H, the passive control device146includes a fixed actuator element326in the path forward of the pick-up location104. In the opened position the first shorted arm310ais at the top and moves past the passive control device146below the fixed actuator element326so that the valve element302remains open. In the closed position shown inFIG. 6I-6J, the second arm310bis located toward the top and is longer than the first arm310aso that it contacts the fixed actuator element326as the closure structure300moves past the passive control device146. Engagement of the second arm310bwith the actuator element326rotates the valve element302to the opened position as the head moves to the pick-up location as shown inFIG. 6J. AlthoughFIGS. 6A-6Jillustrate a particular embodiment, application is not so limited the particular actuator element or interface structure for the valve element302.

FIGS. 7A-7Billustrate another embodiment of an assembly of the present application having a closure element142operable between an opened position and a closed position to control vacuum pressure to the head. As shown, the closure element is a sliding valve element350movable within a closure structure352coupled to the support platform140, between an opened position shown inFIG. 7Aand a closed position shown inFIG. 7B. As shown, the closure structure352includes an inlet coupled to the manifold150through passage158and coupled to the head through the flexible hose166. In the opened position a passage opening354in the sliding valve element350is aligned the inlet operably coupled to the vacuum pressure source and outlet coupled to the head100. The sliding valve element350is moved from the opened position inFIG. 7Ato the closed position inFIG. 7Bin response to a no-item detection.

In particular as shown inFIGS. 7C-7E, the sliding valve element350is moved from the open position to the closed position via an actuator355through an actuator element356of the feedback control device144. The actuator element356is configured to engage an interface structure or knob360on the sliding valve element350to move the valve element between the retracted open position and an extended closed position. As progressively shown inFIGS. 7C-7E, in response to no-item detected, the actuator355moves the actuator element356to engage the interface structure or knob360to push the sliding valve element350to the closed position so that no vacuum pressure is supplied to the head with no item detected. In the particular embodiment shown, the actuator element356is a flapper plate370coupled to a piston of actuator355through a pin372so that retraction of the piston rotates the flapper plate370towards the interface structure or knob360through pin372to close the sliding valve element350in response to no-item detected.

FIGS. 7F-7Gillustrate an embodiment of the passive control device146forward of the pick-up location to open closed heads. As shown, the passive control device146includes a fixed actuator element362which engages the interface structure or knob360on the sliding valve element350to open the closed head. In the opened position the actuator element362is spaced from interface structure360so that the closure structure rotates past the passive control device without action as illustrated inFIG. 7F. Contrastingly, if the valve element350is closed, the fixed actuator element362engages the interface structure to impart force to the valve element350to slide the valve element350to the open position as shown inFIG. 7G.

Embodiment of the present application have application for sorting or handling irregular shaped items such as poultry and meat items. In particular, the nozzle or head of the assembly is designed and sized to provide supply sufficient vacuum pressure to provide sufficient force to pick-up a single item from a supply of overlapping irregular shaped items. Vacuum pressure requirements vary depending upon the size of the nozzle and head and size and weight of the items. The vacuum on-off mechanism or closure elements as described, preserve vacuum pressure to provide sufficient vacuum pressure and limit pressure loss due to opened heads to transport items from a pick-up location to a drop location. In illustrative embodiments, the support platform has multiple heads opened to the vacuum source at one time to carry multiple items from a pick-up location104to a drop-off location106. In the particular application described for handling food or poultry items, the multiple chamber manifold not only provides vacuum pressure but positive pressure to release the items, such as poultry which may tend to stick to the head and cleaning and/or sanitizing solution to limit contamination. For food applications, the head100is formed of a stainless steel or other food grade material.

While illustrated embodiments have been disclosed, application is not limited to the particular embodiments disclosed, nor the particular arrangement of features and components. It will be appreciated by those skilled in the art that changes and modifications can be made without departing from the spirit and scope of the invention and various features of the embodiments disclosed can be combined in alternate arrangements or combinations.