Component feeding with continuous motion escapement

The invention relates to methods and systems for transferring a stream of a components (28, 84, 100, 100′), either as individual components (28, 84, 100′) or as a continuous strip (100) or band from which individual components are cut, from a component feeder (62a) to a component receiver (92, 108), e.g., in a processing machine, with controlled, e.g., continuous, motion escapement of the individual components (28, 84, 100, 100′) from the feeder (62a).

TECHNICAL FIELD

This invention relates to devices and methods for loading parts or components into machines at high rates of speed in a continuous motion.

BACKGROUND

Component feeding in automated assembly machines involves three aspects: (i) singulation, which is the separation of multiple components so they can be manipulated individually, (ii) orientation, which is the manipulation of components into a specific orientation required for the next processing step; and (iii) escapement, which is the controlled separation and transfer of components from the end of a line and insertion into a processing machine, e.g., an assembly machine at a specific spacing between components, as required by the processing machine. Escapement can also include additional aspects of singulation and orientation.

U.S. Pat. No. 3,601,041 describes an apparatus for feeding and orienting parts such as tablets or capsules. Capsules are carried by a hopper set over a rotating disc having slotted radial paths. As the capsules fall from the hopper onto the rotating disc, the are centrifugally thrown toward the outer periphery along the slotted paths and urged into the slots in an end-to-end aligned relation. The capsules are passed between printing members in their oriented position and then discharged into a hopper.

U.S. Pat. No. 3,471,000 describes a mechanism for orienting and feeding items such as fruit and produce to a location for packaging. A conveyor delivers the items to a rotating mechanism. The rotating mechanism includes a plurality of radial arms, which, at a certain point in a cycle of rotation, rise to place the item on a shelf that rotates simultaneously with the radial arms. When the shelf reaches a particular station, the item is urged into a chute or outlet. This cycle is continuous during rotary motion of the mechanism.

As shown inFIG. 1, known escapement mechanisms involve an intermittent feeding, also known as “slice” feeding, of components into processing machines. That is, each component, or batch of components, is stopped or slowed to a momentary standstill so that they can be transferred and then inserted into the processing machine at a predetermined spacing between components. Thus, the time interval during which the components are stopped creates the required spacing.

In general, a transfer disk20, with a number of component holders22, rotates about an axis24in the direction of arrow26. As each component holder22moves into contact with the end of a stream of components28, the holder captures the component, and separates it from the stream. The remaining parts in the stream28advance rapidly to position or location30vacated by the one taken and wait for the next component holder22to advance to position30. This time delay results from the predetermined spacing32between the component holders22and thus between the components28as they exit the transfer disk20at location34. As seen inFIG. 1, the distance along the curve between component holders22on disk20is essentially the same as the distance between the components after they exit the disk at position or location34.

This slice feeding mechanism provides the required spacing between components, but requires that all components stop, one after the other. This process is thus wasteful in terms of energy and time, and significantly limits the overall processing speed. In addition, the jarring of components when they stop can lead to damage of the components and can impair their orientation, which is particularly important when working with asymmetrical and aspherical components that are processed at high speeds.

SUMMARY

The invention is based, in part, on the recognition that if one delivers a component to a capture location at a first distance from a central axis of a surface, e.g., a disk in the shape of a circle or polygon, and at a first radial position, and moves the component to a delivery location at a second radial position using a component holder that actively grips only one component at the capture location and deposits the component at the delivery location in a defined orientation; then one can achieve a smooth transfer of the component from one location to another in a controllable, continuous flow, and with a defined orientation, without the need to stop the components at any point along the transfer path.

In general, in one aspect, the invention features continuous motion escapement systems that include a rotatable disk including a central axis; a capture location at a first distance from the central axis and at a first radial position with respect to the central axis; a delivery location at a second radial position with respect to the central axis; and a plurality of component transfer mechanisms arranged on the disk, wherein each component transfer mechanism includes a component holder configured to actively grip only one component at the capture location, and wherein each component transfer mechanism is configured to move the component holder from the capture location to the delivery location, enable the component holder to deposit the component at the delivery location in a defined orientation, and return the now empty component holder to the capture location within one rotation or less of the disk.

In the new systems, the delivery location can be at a second distance from the central axis different than the first distance; and the distance of the component from the central axis can change as the component transfer mechanism moves the component from the capture location to the delivery location. The second distance can be smaller than, longer than, or the same as the first distance. For example, if the second distance is longer than the first distance, the spacing between the components as they leave the delivery location is increased compared to their spacing as they arrive at the capture location. In certain embodiments, the distance of the component from the central axis changes continuously as the component transfer mechanism moves the component from the capture location to the delivery location.

The systems can also include a drive that causes the disk to rotate about the central axis, and a controller that controls the speed of rotation, wherein a continuous rotation of the disk causes the component transfer mechanisms to deliver a continuous stream of components from the capture location to the delivery location. The systems can also include a component feeder that is arranged to singulate components and feed them to the capture location in an orientation that enables the component holder to grip individual components.

In various embodiments, the component transfer mechanisms can be arranged symmetrically on the disk about the central axis, and each component transfer mechanism can move the component holder radially outwardly from the capture location to the delivery location, where the second distance is larger than the first distance.

In other embodiments, each component transfer mechanism can move the component holder radially inwardly from the capture location to the delivery location, where the second distance is smaller than the first distance.

The component transfer mechanisms can include an arm having a distal end and a proximal end, wherein the component holder is attached to the distal end, and wherein the arm pivots about the proximal end causing the component holder to move from the first distance from the central axis to the second distance from the central axis. The systems with such arms can further include a cam, wherein the arms pivot in response to contact with the cam. For example, each arm can move the component holder radially outwardly from the capture location to the delivery location, wherein the second distance is larger than the first distance, or each arm can move the component holder radially inwardly from the capture location to the delivery location, wherein the first distance is larger than the second distance.

In certain aspects, the component transfer mechanisms can be blocks, wherein the component holders are attached to the blocks, and wherein as the disk rotates the blocks move from the first distance at the capture location to the second distance at the delivery location along a path parallel to a surface of the disk. These systems can further include a cam, wherein the blocks slide radially outwardly or inwardly in response to contact with the cam.

In these systems, as the disk rotates the component holders can move radially from the first distance at the capture location to the second distance at the delivery location along a path parallel to a surface of the disk, or the component holders can move radially from the first distance at the capture location to the second distance at the delivery location along a path at an angle to a surface of the disk. In certain embodiments the disk can be a circular or in the shape of a polygon.

In another aspect, the invention features methods of continuously transferring a stream of components from a capture location to a delivery location by capturing and gripping each component with a component transfer mechanism at a capture location at a first distance from, and at a first radial position of, a central axis; moving the component transfer mechanism gripping the component to a delivery location at a second radial position with respect to the central axis different from the first radial position; and depositing the component in a defined orientation into a component receiver at the delivery location.

In these methods, each component can be gripped individually, the delivery location can be at a second distance from the central axis different than the first distance, and the distance of the component from the central axis can change as the component transfer mechanism moves the component from the capture location to the delivery location. In certain embodiments, the distance of the component from the central axis changes continuously as the component moves from the capture location to the delivery location. In addition, a first spacing between components as they arrive at the capture location can be smaller or larger than (or the same as) a second spacing between components as they leave the delivery location, and the first distance from the central axis can be smaller or larger than (or the same as) the second distance from the central axis.

In various embodiments, the capture location can be positioned on a first plane, the delivery location can be positioned on a second plane, and the second plane can be at a different level then the first plane. For example, the first plane can be higher than the second plane, or the capture location and delivery locations can be on the same plane.

In some embodiments, the capture location is at an end of a component feeder, and the component receiver can include individual component holders into which the components are inserted in a predetermined orientation. The components can be fed to the capture location in a continuous stream and the first spacing between components can be, e.g., 30 mm or less. The components can leave the delivery location at a second spacing of, e.g., 50 mm or more. In some embodiments, the components can be in a first orientation at the capture location and can be released at the component receiver in a second orientation, that is either the same as or different than the first orientation.

The new methods and systems for controllable or continuous motion escapement avoid the loss of energy and efficiency often found in intermittent or “slice feeding” motion escapement systems. In addition, the new methods and systems avoid mechanical jarring of the components, which can prevent damage and loss due to jamming of components in processing systems. The systems also provide positive gripping and precise orientation of individual components as they are transferred from a capture location to a delivery location. The result is a system that provides a controllable, e.g., continuous flow of components from a component feeder to a component receiver at a very high rate of speed with little or no misalignments or loss or damage of components. The systems also provide the means for reorienting components at high speed by incorporating appropriate axes of motion within the component holder. Thus, the components may be rotated or flipped in a controlled manner to any desired orientation during the transfer from capture location to delivery location.

In these methods and systems, the components enter the system at a velocity equal to the product of the desired feed rate multiplied by the incoming component spacing and exit the system at a velocity equal to the feed rate multiplied by the desired component spacing.

DETAILED DESCRIPTION

The invention relates to methods and systems for transferring a stream of a components, either as individual components or as a continuous strip from which individual components are cut, from a component feeder to a component receiver, e.g., in a processing machine, with controlled, continuous motion escapement of the individual components from the feeder. The new methods and systems will work for any size component.

General Methodology

In general, as shown inFIG. 2, the new methods and systems involve a transfer surface, e.g., of a disk40(which can be circular or have some other shape, e.g., an oval, ellipse, or a polygon, such as an octagon, hexagon, pentagon, square, rectangle, or triangle), with a number of component holders42. Disk40rotates about a central axis44in the direction of arrow46. As each component holder42moves into contact with the end of a stream of components28, the holder picks up a component at capture position or location50, without the need for the entire stream of components to come to a stop. Instead, the new systems create the required spacing52between components after they leave the component holder42, e.g., by continuously increasing the distance of a given component holder from central axis44as the holder moves from capture location50to delivery location54as disk40rotates. Thus, by the time the component holder reaches the delivery location, which inFIG. 2is 180° from the capture location50(but can be at any location between about 90 and about 270° or more compared to the capture location), it has reached a distance from the central axis44that provides the required spacing52between components28as they exit the component holder at delivery location54.

The required spacing may be the same as, smaller than, or larger than the spacing between components as they arrive at the capture location. In some embodiments, the spacing does not change at all, and the system is used to simply move components from a capture location to a delivery location in a controlled fashion, e.g., to provide a defined orientation to the component once it is deposited at the delivery location.

The new methods can be embodied in various devices and systems that can move components from a first distance from a central axis at a capture location to a second distance from the central axis at a delivery location. Thus, in general, the new methods include transferring a continuous stream of components that arrive at a capture location with a first spacing between components (e.g., little or no spacing between components) to component receivers with a second spacing between components that is different than the first spacing by capturing and gripping each component individually at a capture location at a first distance from a central axis of, and at a first radial position of a disk, e.g., a circle; moving each component to a delivery location at a second distance from the central axis, e.g., different than the first distance, and at a second radial position of the disk different from the first radial position; wherein the distance of the component from the central axis can change continuously, or essentially continuously, as the component is moved from the capture location to the delivery location; and depositing the component into a component receiver at the delivery location at the second spacing between components.

In certain embodiments of the new methods, the first spacing between components, such as individual plastic or metal parts, is smaller than the second spacing between components, and the first distance from the central axis is smaller than the second distance from the central axis. For example, the spacing may be almost zero mm, or only 1 or 2 mm, where the components arrive at the escapement apparatus in a stacked or almost stacked configuration. The spacing between the components is then increased to at least 10 mm or more, e.g., 20, 50, 75, or 100 mm or more. In the case of component feeding, the spacing between incoming components is essentially the length of the components touching end to end in the feed track. The second spacing would be the distance between component nests in the processing machine. A typical application might have components 10 to 30 mm long and processing nests spaced 25 to 100 mm or more apart.

In other embodiments, the first spacing between components can be larger than the second spacing between components, e.g., where the components arrive with a relatively large spacing, and need to be brought closer together for the next machine in a series or the components need to be removed from a processing machine and transferred into a feed track or onto a conveyor in a controlled, gentle manner. In this scenario, the first distance from the central axis is larger than the second distance from the central axis.

In certain embodiments, the first spacing between components can be the same as the second spacing between components, e.g., where the components arrive with a spacing that is about the same as the spacing needed for the next machine in a series. In this scenario, the first distance from the central axis is the same as the second distance from the central axis, and the system is used to provide a controlled, gentle transition of the components from the capture location to the delivery location. In some of these embodiments, the system is also used to manipulate the components in a way that aligns their orientation with the nest into which they are deposited. For example, the components may need to be rotated about one or more axes, e.g., they may need to be inverted from the orientation in which they arrive at the capture location.

In some embodiments, the capture location can be positioned on a first plane, and the delivery location can be positioned on a second, different plane, e.g., parallel with the first plane. The first plane can be higher or lower than the second plane. Both the capture location and delivery location can also be on the same plane. The change in plane can be accompanied by a change in distance from the central axis, or not.

In general, the new systems include a component transfer mechanism that grips, manipulates, and moves the component from the capture location to the delivery location. The component transfer mechanism typically includes a component holder, e.g., at a distal end of an arm or lever, that can include grasping or gripping jaws, hooks, fingers, one or more chucks, or other devices that can temporarily, but securely, hold individual components. The component holder maintains the component in a fixed orientation with respect to the holder in three-dimensional space, that can, but need not, change as the holder moves from the capture location to the delivery location. Thus, the components can be in a first relative orientation at the capture location and can be released or delivered at a component receiver in a second, different relative orientation. However, in some embodiments, the holder keeps the component in the same relative orientation in space as it moves the component from the capture location to the delivery location.

Continuous Motion Escapement Systems

The new methods can be embodied in various devices and systems. In general, the new continuous motion escapement apparatuses include at least the following elements: a rotatable plate or disk having a central axis; a capture location at a first distance from the central axis and at a first radial position of the disk; a delivery location at a second radial position of the disk, and optionally at a second distance from the central axis different than the first distance; and a plurality of component transfer mechanisms (e.g., 2, 5, 10, 20, 30, or more) arranged on the disk. Each component transfer mechanism includes a component holder configured to actively grip only one component (or a set number of components, e.g., 2, 3, or 4) at a time at the capture location.

The individual components can be supplied as separate components, or they can be supplied as a continuous strip of component material that is cut into separate, individual components as they enter, are in, or just after they exit the capture location.

The component transfer mechanisms are configured to move the component holder from the capture location to the delivery location, enable the component holder to release and deposit or deliver the component at the delivery location, and return the now empty component holder to the capture location within one rotation or less of the disk.

Continuous Feed of Individual Components

One such system is illustrated inFIGS. 3A-3C,4A-4C, and5, which show a continuous motion escapement system60arranged at the end of a component feeder62a, and a plurality of component transfer mechanisms70. The system includes a rotating disk64that has a central axis66and a central shaft68. Each of the component transfer mechanisms70include an arm72, a component holder74(seeFIGS. 4A-4C), which includes a pair of gripping jaws76and78(shown inFIGS. 4A-4C), a base80, and a pivot82. Each pair of gripping jaws holds a component84, e.g., a plastic razor cartridge housing. The component transfer mechanisms70can be arranged symmetrically on the disk about the central axis. Arms72have a distal end, to which is connected the component holder74, and a proximal end, which ends in pivot82.

Disk64rotates around central axis66in the direction of arrow86. Rotation of arms72about pivot82is controlled by gear wheel sections88. As disk64rotates, a stationary cam98(FIGS. 3A-3C,4A, and4B) causes each of the arms72to rotate from an upright capture position (as shown inFIGS. 3A-3Cand4A-4C) to a horizontal delivery position (as shown inFIG. 6A). Cam followers95are affixed to sliding members97within each arm base80. Each sliding member incorporates a rack (linear gear)99that meshes with the circular gear wheel sections88attached to the pivotal arm72. The follower95rides against a central stationary cam98and, as the disk rotates, the cam moves the follower-slider-rack in and out, which causes the gear segment and pivotal arm72to rotate about pivot82.

Because the cam has a smooth contour, the distance of the component holder74(and thus the component) from the central axis66changes continuously as the component transfer mechanism70moves the component84from the capture location50(FIG. 2) to the delivery location54(FIG. 2).

FIG. 4Ashows a more detailed view of an individual component transfer mechanism70, including an arm72, a component holder74with gripping jaws76and78, base80, and pivot82. Arm72is in a vertical capture position, with jaws76and78positioned to accept a component. Mechanism70also includes a plunger73with a roller/cam follower94. This plunger operates to temporarily hold component84in place once it is deposited into a component holder or “nest”90(see,FIGS. 3A and 6B). Component transfer mechanism70also includes a sliding member97with cam follower95, which is pressed against stationary cam98, as described in further detail below.

FIG. 4Bshows a side view of the component transfer mechanism70shown inFIG. 4A. As noted, this mechanism includes a roller/cam follower95fixed to a sliding member97, which incorporates a linear gear99that engages with a circular gear section88attached to arm72at the pivot point82. Coil springs99′ in base80bias the sliding member97radially inwardly, keeping the cam follower95pressed against the stationary cam98on central shaft68.FIG. 4Cshows an exploded view of the component transfer mechanism70shown inFIGS. 4A and 4B.

FIG. 5shows an enlarged view of component holder74, with gripping jaws76and78holding a plastic razor cartridge housing84. The cartridge is still within a curved guide track62b, an extension of component feeder62a. One arm72and one component84are shown for clarity, but numerous arms and a stream of components follow behind the one shown. The stream of components84enter the curved track62bunder the influence of gravity or air pressure or other forces such that they abut end to end with slight pressure. As disk64(see, e.g.,FIG. 3A) turns and the arms and jaws with captured components move around the curved track62b, the stream of components follows and subsequent arms and jaws move outward to capture their adjacent components. The radial position of the arms is set, by the cam, such that the circumferential spacing between jaws equals the end-to-end spacing of the components in the curved track and, as such, there is no circumferential relative motion between the jaws and the components during capture, only the radial relative motion of the jaws to engage the component. The components follow the arms around at the speed of the disk, which is set as required for the processing machine. Once the components are captured, the curved track62bends and the arms72are free to move outward to transfer the component to the delivery position.

As shown inFIG. 6A, arm72has been rotated about 90° around pivot82into a horizontal delivery position (in the direction of arrow89inFIG. 4B) by virtue of the cam follower95riding against cam98. Thus, arm72, and component holder74, move radially outwardly from the capture location to the delivery position at the delivery location. In this position, component holder74places component84into a component “nest”90riding on the rotating disk (as best seen inFIG. 6B). After placement, a positive action “stripper” mechanism is used to hold the component in the nest while the arm moves upward and disengages from the component.

As disk64continues to rotate in the direction of arrow86, a roller/cam follower94passes under a stationary overhead cam96, which forces a plunger73down against component84and holds it in nest90as seen inFIG. 6B. While follower94is under stationary cam96holding the plunger73down and the cartridge in the nest, arm72begins to move upward, allowing spring loaded gripper fingers76and78to slip past and release the component, e.g., a cartridge, leaving it in nest90.FIG. 6Bshows plunger73and roller/cam follower94just about to leave from under stationary cam96.FIG. 6Cpresents the same view asFIG. 6B, but a few degrees of rotation later, and shows that as disk64continues to rotate in the direction of arrow86, overhead stationary cam96ends, which releases plunger73and allows arm72to move up to the vertical position in the direction of arrow87, leaving component84behind in nest90.

In this embodiment, the distance of the component holder to the central axis66increases from the capture location at the curved track62bto the delivery location at the component receiver92. This increase in distance translates into an increase in the spacing distance between components as they leave the delivery location. In addition, the component moves along a path that is at an angle to the surface of disk64.

Note thatFIGS. 6A-6Cshow only one of numerous component transfer mechanisms70.

In other embodiments, each component transfer mechanism can move the component holder radially inwardly from the capture location to the delivery location. In these embodiments, the second distance from the central axis is smaller than the first distance from the central axis.

In other systems, each component transfer mechanism includes a block, wherein the component holder is attached to the block, and wherein as the disk rotates the block moves from the first distance at the capture location to the second distance at the delivery location along a path parallel to a surface of the disk. The block can move parallel to the surface of the disk or at an angle to the surface. In these systems, the blocks are moved by contact with a cam. For example,FIG. 7shows a system for continuous motion escapement for component receivers or “transport pucks.”

As shown inFIG. 7, a disk64arotates in the direction of arrow86a, causing radially sliding blocks114, each with a cam follower116, to rotate as well. The cam followers116push against a stationary cam118, located under disk64a. Pucks92a(only one shown) are moved into a capture location by a high slip conveyor63(shown in dashed lines), queue up at a curved guide119at the entrance to the system, and are grasped by grippers120. Blocks114are retracted at a capture location such that the spacing between grippers120equals the spacing of the pucks on the conveyor. A first block114grasps the lead puck in the queue and, as disk64arotates, the pucks on the conveyor follow and the next block114grasps the next puck. As disk64arotates, blocks114move radially outward to a delivery position and pucks92aare subsequently transferred to a processing machine at the desired spacing (behind disk64ashown inFIG. 7), which is greater than their spacing in the queue. In other embodiments, as pucks92aleave the conveyor and the capture location, their spacing can be decreased compared to their spacing as they arrive at the system, depending on the motion of sliding blocks114based on the profile of stationary cam118.

All of the new motion escapement systems include a standard drive and control system (not shown) that cause disk64,64ato rotate and to control the speed at which it rotates. At process speeds, disk64can rotate at speeds of, e.g., 0 to 60 rpm, or can start, stop, accelerate, and/or decelerate without consequence to the proposed system, which will stay synchronized by virtue of its geometric simplicity. This embodiment incorporates a direct drive servo-system for the disk drive, but the drive system can be any type or form that can provide relatively smooth and stable control.

In addition, the system operates in conjunction with a component feeder62athat is arranged to singulate components and feed them to the capture location in an orientation that enables the component holder to grip individual components.

Continuous Feed of Component Material Strip

The new systems can also be designed to accommodate components that arrive to the continuous motion escapement apparatus as a continuous strip of component material. As shown inFIG. 8, a continuous strip100of component material, e.g., plastic or metal, is supplied to a capture location50. A component holder102grips the strip and moves as disk104rotates in the direction of arrow106. Component receivers108are brought into contact with disk104.

As disk104rotates, the strip of material is drawn into a capture location50tangent to the path of the grippers (76aand78a, as shown inFIGS. 11,12A, and12B), which sequentially lock onto the strip100as disk104rotates. The holders102move the strip in an arc into a cutting zone110where the strip is cut between adjacent grippers by a cutting device, such as a slicing blade or so-called “flying knife” (described below) or a laser112. In some embodiments in which the disk rotates very rapidly, the blade or laser beam may move from side to side in the direction of motion of the strip (and then back “upstream”) to track the moving strip of component material and provide a clean, radial cut. Once the strip100is cut into individual components100′, the component holders102continue on their path to the delivery location54and release and insert the individual strip components100′ into a component receiver108. As they leave the delivery location on their respective component receivers, the individual components100′ are spaced apart with the precise distance required for the next processing step.

FIG. 9shows a continuous strip of component material100that has been cut by the laser into an individual component100′. Laser cutting of the strip of material occurs within cutting zone110as seen inFIG. 8. Alternatively, the cutting can be done by a blade or knife. For example,FIG. 10shows an embodiment including a flying knife cutter130used to slice through the strip of component material100in cutting zone110. Flying knife130includes at least two blades132in blade holders134on a rotating carrier136. As carrier136rotates, blades132pass through the strip of material100. The spacing between blades, the rate of rotation of carrier136, and the speed of the strip of material cause the cuts to be made at a precise spacing to provide a cut strip of component material100that is exactly the proper length. The cuts are made between two component transfer mechanisms70a(which are not shown inFIG. 10) gripping the continuous strip of component material100and the individual component100′, respectively.

FIG. 11shows a component transfer mechanism70a, which is similar to the component transfer mechanism70shown inFIG. 4, but designed to grip a narrow strip of component material, hold the strip while it is cut (e.g., with positive grip on either side of the cut by adjacent component transfer mechanisms), and then continue holding the individual cut component until it is delivered to the delivery location54.

Component transfer mechanism70aincludes an arm72a, a component holder74awith gripping jaws76aand78a, base80a, and pivot82a. Arm72ais in an angled capture position, with jaws76aand78aholding a cut strip component100′.FIGS. 12A and 12Bshow enlarged views of component holder74a, with gripping jaws76aand78aholding a cut strip of plastic100′. Rotation of arms72aabout pivot82ais controlled by gear wheel sections88a. As disk104rotates, a stationary cam on the disk (as shown for cam98on disk64inFIGS. 6A and 6B) causes the arms72ato rotate down to deposit the strip of plastic100′ into a nest on a puck108. The motion of arms72ais similar to that of arms72shown inFIGS. 4A-4Cand6A-6C. Because the cam has a smooth contour, the distance of the component holder74a(and thus the component100′) from the central axis66changes continuously as the component transfer mechanism70amoves the component100′ from the capture location50(FIG. 9) to the delivery location54(FIG. 9). Of course, there are other ways to get the arms to rotate, e.g., individual small servo-motors can be used on the disk, or different cam actuators can be used. For example, the arms can be driven directly by a globoidal 3-dimensional cam, obviating the need for a gear and rack mechanism.

As shown inFIGS. 12A and 12B, each of arms72ahas a roller/cam follower94athat contacts a plunger73athat, in turn, pushes down on component holder74a, causing the gripping jaws76aand78ato release the cut component strip100′ and press this component strip100′ into a component receiver108in much the same way as plunger73pushes a component into a component holder74as shown inFIGS. 6A and 6B.

In this embodiment, the distance of the component holder74ato the central axis66increases from the capture location50at the component strip infeed guide101to the delivery location54at the component receiver108. This increase in distance translates into an increase in the spacing distance between components as they leave the delivery location (from a spacing of zero when the components are part of one continuous strip as they arrive to the capture location). In addition, the individual components, once cut from the strip, move along a path that is at an angle to the surface of disk104.

Applications

The new controlled, continuous motion escapement systems can be configured to operate with a wide variety of types of components. For example, the components can be individual razor cartridge components, such as cartridge housings or hoods, inserts for such housings, and metal blades and/or blade supports or trimmer components. The components can also be continuous strips of material that are cut by the system into individual components, such as lubricating strips made of plastics that contain polymers, or blades cut from long strips of steel.

Other systems can be made to move batteries and their components such as electrodes, housings, and contacts; electric toothbrush brushheads and their components; the various components in munitions, cigarettes, and medical devices; and parts, e.g., in subassemblies, in the auto and aircraft industries. In general, the new methods and systems can be used for the assembly of any components that can be oriented and delivered in a feed track.

Other Embodiments

List of Elements