System and method for accumulating items

Abstract: A system for sequentially establishing batches of predetermined numbers of items is disclosed. The system includes a feeder (10) for continuously dispensing items (12) serially and one at a time. A counter (14) counts items as they are dispensed by the feeder and emits a batch control signal each time a predetermined number of items has been dispensed by the feeder. An item accumulator/separator (15) separates items fed on a continuous basis into batches. The separator includes a diverter (25) for diverting items forming each succeeding batch to a collection location separated from the location of items in the batch immediately preceding each separated batch while maintaining all items along a flow path from the feeder to a collection station. The diverter is operative to establish diversion of items of a succeeding batch in response to each such batch control signal. A collector (16) is positioned at the collection station for sequentially collecting such batches and maintaining them in such separated condition.

Description: This invention relates to item dispensing and accumulation and more particularly to a novel and improved accumulator system which enables continuous automatic dispensing of counted and accumulated item sets. With packaging and other operations vibratory feeders are used to dispense discrete items, such as parts or pills, sequentially. Typically, an automatic counter detects the items as they are sequentially dispensed and emits a signal each time a predetermined number of items have been detected. Output signals from counters are typically used to stop the operation of the vibratory feeder. For example, if parts are being fed directly from a counter into a bag that is to be sealed to form a package, part feed will stop until a bag with a completed set of parts has been removed from a load station and replaced by a new bag to receive a subsequent set of parts. In other applications, the counted items are collected in an accumulator and the feeder will be stopped until the accumulator has been emptied and an accumulator ready signal is transmitted to the feeder. Yet another approach to separating dispensed items into sets of predetermined numbers is the use of a diverter plate to divert items dispensed after an accumulator has collected a set of predetermined size. Typically, subsequently delivered items are diverted into a supplemental accumulator for subsequent return to the feeder and recycling through the counting procedure. Not only is such procedure wasteful, but it has other drawbacks as well. If the items being dispensed are parts of a nature which can become disfigured or indeed damaged, the quality of items being dispensed can be degraded. The diverters have other disadvantages, such as on occasion a part which is intended to be diverted will fall into the accumulator in spite of the presence of the diverter, resulting in an overcount. On other occasions, parts may bounce off the diverter and back through the counter to result in a miscount. Alternately, they may miss the secondary accumulator and fall into the floor or go to some other undesired location. Accordingly, there is a need for a system to allow the continuous operation of an item dispenser which at the same time is capable of segregating all dispensed items into individual sets of predetermined numbers of dispensed items. Both prior Patent Application No. GB 1491475A and U.S. Patent No. US 3129544 disclose an apparatus comprising a batch separator in accordance with the preamble of claim 1. The present invention is defined in the claims, to which reference should now be made. According to the present invention there is provided a batch separator for establishing batches of predetermined numbers of items dispensed serially from a feeder for sequential deposit in batches at a collection station, the separator comprising: an apertured tube defining a through passage, the tube being for positioning around a single item path of travel from the feeder to the station; a diverter mounted in the tube, the diverter being shiftable between a flow position and a collection position obstructing the path, the diverter being connectable to prime mover means for shifting between its positions, the diverter when in the flow position permitting the flow of items from the feeder to the station and when in the collection position interrupting such flow in response to a control signal received each time a predetermined number of items has been received at the inlet of the separator, to separate a batch of items from a previous batch; the separator being characterized by the tube being an open ended tubular housing having a through opening defined in part by a spaced pair of side walls and the diverter having at least a section positioned within the opening; the section having a first position adjacent one of the side walls, a second position adjacent the other of the side walls, a third position extending across the opening from a location near a first end of the one side wall to a location near a second end of the other side wall, and, a fourth position extending across the opening from a location near the first end of the other side wall to a location near the second end of the one side wall; the prime mover means being for shifting the section sequentially from the first position to the third position; from the third position to the second position; from the second position to the fourth position; from the fourth position back to the first position; and, thereafter repeating the sequence. Preferably the first end is a lower end and the second end is an upper end of the opening. Preferably, the tube is a tubular body having spaced pairs of side and end walls delineating a through passage with input and output ends; the diverter is a baffle member movably mounted in the passage and has a lateral dimension slightly less than but substantially equal to the width of the passage between the end walls; the separator includes a baffle support pivotally mounted on the housing at a mounting location above the outlet when the accumulator is in use; the baffle support pivotally supports the baffle at a pivot location below the outlet when the accumulator is in use; the prime mover means includes a first prime mover mechanism operably connected to the housing and the support for selectively shifting the support between a first position wherein the pivot location is near one of the side walls and a second position wherein the pivot location near the other of the side walls; and the prime mover means includes a second prime mover mechanism for selectively causing pivotal movement of the baffle between a first position adjacent the one side wall and a second position across the passage, and between a third position adjacent the other side wall and a fourth position across the passage. The second prime mover mechanism desirably includes a cam operably interposed between the baffle and the support. A pair of baffle support pivotal mountings may be connected to respective end walls. The present invention further provides a system for sequentially establishing batches of predetermined numbers of items including: a feeder for continuously dispensing items serially and one at a time; a counter for counting items as they are dispensed by the feeder and operable to emit a batch control signal each time a predetermined number of items has been dispensed by the feeder; and collection means at the collection station for sequentially collecting batches and maintaining them in such separated condition, the system being characterized by comprising a batch separator as specified above. Desirably, there is provided a collection means condition sensor operable to emit collection means condition signals according to the readiness of the collection means to receive batches of items from the batch separator. Preferably, control means are provided operably connected to the feeder, the counter, the separator and the sensor for emitting batch separation signals to the separator and a feeder stop signal when the system is not in condition properly to process further batches. The control means desirably issues a feeder stop signal when the counter has issued a batch counted signal and the sensor has not emitted a collector ready signal. The present invention additionally provides a method of collecting dispensed items in batches of predetermined numbers at a collection station comprising the steps of: a) serially and continuously dispensing items from a feeder and counting items; b) gravity feeding dispensed items along a path into a batch separator; and c) collecting dispensed items at a first location at the collection station until a first batch of a predetermined number of items is collected, characterized by; d) as a last item of a first batch is being fed, shifting a diverter from the or a discharge position alongside the path to a collection position across the path to divert subsequently dispensed items into a second location within the separator; e) collecting dispensed items in the second location; f) as items of the second batch are being fed, shifting the diverter from its collection position to a discharge position to release the diverted items to the first location and permit the flow of subsequently dispensed items to the first location; g) as the last item of the second batch is being fed shifting the diverter to a further collection position across the path to divert subsequently dispensed items of a further batch into a third location within the separator; and h) as items of a further batch are being fed, shifting the diverter from its collection position to a discharge position to release the diverted items to the first location and permit the flow of subsequently dispensed items to the first location; i) sequentially repeating steps (d), (e), (f), (g) and (h). The first batch is preferably dispensed into a receptacle commencing at least as early as when the diverter is in the or a discharge position. The diverter may be delayed in shifting as the last second batch item is dispensed until a receptacle ready condition is sensed. The method advantageously includes the steps of: a) the diverter is first positioned adjacent a first wall section of the accumulator to allow a first batch of items to pass through the batch separator to the receptacle; b) as the last item of the first batch passes through the batch separator the diverter is shifted to a position across the passage to accumulate a second batch within the accumulator; c) a second receptacle is positioned to receive the second batch and thereafter the diverter is shifted to position it adjacent another wall section and discharge the second batch into the second receptacle; d) as the last item of the second batch passes through the batch separator the diverter is shifted to a further position across the passage to accumulate a third batch within the separator; e) a third receptacle is positioned to receive the third batch and thereafter the diverter is shifted to position it adjacent the first wall section and discharge the third batch into the third receptacle; and f) steps (a), (b), (c), (d) and (e) are thereafter repeated to sequentially accumulate further batches. A system made in accordance with the present invention utilizes a vibratory feeder which dispenses items sequentially and one at a time. A counter is provided which detects each dispensed item and emits a signal each time a predetermined number of dispensed items have passed through the counter. An accumulator/separator is provided which accumulates dispensed items and in response to signals received from the counter, separates the items into individual sets, each of a predetermined number. Items discharged from the accumulator/separator are gravity fed to a further receptacle which may take any one of a number of forms. The further receptacle may, for example, be an accumulator which in turn discharges the items for further processing, a receptacle on a bucket type conveyor, or a bag in which an item set is to be packaged. The accumulator/separator includes a body having a through tubular passage which is oriented vertically to receive gravity fed dispensed and counted items. A diverter plate is positioned within the housing. A spaced pair of diverter supports are pivotally supported, respectively on opposite sides of the housing. The diverter is pivotally supported by the supports below an outlet of the housing with the plate extending upwardly from the pivotal support. The supports are pivotally movable to shift the diverter pivot support between spaced positions each adjacent a different housing end wall. A cam follower projects upwardly from the diverter pivot outwardly of one of the supports. The cam follower engages an associated cam which is movable to coact with the cam follower and cause limited pivotal movement of the diverter about the axis of the pivot. In use the diverter is initially positioned adjacent one end wall and items of a first batch are allowed to pass through the accumulator/separator. As the last item of the first batch passes the counter an output signal from the counter causes an actuator to shift the cam which in turn shifts the diverter to a position diagonally across the housing passage. As a result of the shifting of the diverter, the last item of the first batch is, if engaged by the diverter at all, knocked downwardly into the accumulator/separator and items of a second batch are collected between the diverter and the one wall. Once a further receptacle beneath the accumulator/separator has received the first batch and been conditioned to receive the second batch, the support arms are pivoted to shift the diverter pivot across the housing outlet to a position adjacent the other end wall. This shifting of the diverter pivot releases the accumulated items of the second batch and positions the diverter adjacent the other end wall. As the last item of the second batch is sensed, the cam is returned to its initial position, shifting the diverter this time across the tubular passage with the top of the diverter near the one wall. A third batch is now collected atop the diverter and adjacent the other end wall. Once the collector is conditioned to received the third batch, the diverter pivot is shifted back to its original position allowing the third batch to pass through the housing and positioning the diverter back in its original position. Once the last item of the third batch is detected the diverter is shifted to the same position it assumed to collect the second batch, a fourth batch is collected and the entire process repeats. A receptacle condition sensor is preferably provided. The condition sensor emits a signal to indicate a receptacle which has received a batch has been emptied or replaced by a further receptacle which is prepared to receive the next succeeding batch. When the receptacle condition sensor emits a signal indicating it is prepared to received the next batch, the diverter pivot is shifted across the discharge opening to move the diverter from one of its positions across the passage to a position adjacent one of the end walls, allowing the discharge of the batch being formed. An overfeed prevention control will stop feed from the feeder in that situation where the counter has indicated completion of a batch, but no receptacle ready signal has been received. In that situation, an operator warning is preferably emitted to indicate the system needs operator attention to correct whatever problem has caused the system to fail to operate in its intended continuous feed manner. In setting up the system for operation, the discharge rate of the vibratory feeder is adjusted relative to the rate at which receptacles are positioned to successively receive discharged batches of counted items. Once adjusted, the feeder will operate continuously providing the advantages of minimizing the power required for feeder operation and minimizing the opportunity for feeder caused degradation to the items being dispensed while optimizing the rate of item dispensing and accumulation. The invention described herein provides a novel and improved dispensing system including a novel and improved accumulator/separator enabling continuous feeder operation, and a method of accumulating and separating items into batches of predetermined numbers. Embodiments of the invention will now be described in more detail, by way of example only, and with reference to the accompanying drawings, in which: Figure 1 is a somewhat schematic view of the system of this invention; Figures 2 - 5 are elevational views showing sequentially the diverter in its four operating positions; Figure 6 is a bottom plan view of the accumulator/separator of this invention; and, Figure 7 is a schematic view of the system. Description of the Preferred Embodiment A vibratory feeder is shown somewhat schematically at 10 in Figure 1. The feeder 10 dispenses items 12 which are gravity fed past a counter 14. One suitable feeder and counter system is sold by the present assignee, Automated Packaging Systems, Inc. of Streetsboro, Ohio under the designation Accu-Count DAC-1000. Items dispensed by the feeder pass into and through an accumulator/separator 15 and thence to a receptacle shown schematically at 16. As indicated previously, the receptacle may be a bucket conveyor C, an accumulator A, a bag B at a bagger load station, or other packaging container such as a bottle, Figure 7. The accumulator/separator 15 includes a housing 18 delineating a through vertically oriented passage 20. Items 12 enter the passage 20 through an inlet 22 and exit through an outlet 24 and then fall into the positioned receptacle 16. A diverter 25 is mounted in the passage 20. The diverter or baffle 25 is pivotally supported at 26 by each of a spaced pair of supports 28. The diverter pivot 26 is immediately below the outlet 24. The supports 28 in turn are supported by pivots 30 connected to the housing 18 near the inlet 22. Each support 28 includes an actuator arm 32 extending orthoganally from a depending portion 34. An arm actuator 35 extends between an anchor 36 and the actuator arms 32. The anchor 36 is secured to the housing 18. The upper end of the arm actuator 35 is connected to the arms 32 by a cross arm 38. Actuation of the arm actuator 35 to extend it will shift the supports 28 to the position shown in Figures 2 and 3 while retraction of the arm actuator 35 shifts the supports 28 to the position shown in Figures 4 and 5. A cam 40 is reciprocatively carried by the support which is visible in Figures 2 - 5 and is the left hand support in Figure 6. A pair of cam guides 42 extend from the depending portion 34 of the support and project through cam slots 44. A cam actuator 45 is connected to the cam and to the support 28 for selectively shifting the cam up and down relative to the depending portion 34. The shifting is rectilinear motion controlled by coaction of the cam guides 42 and slots 44. The cam 40 includes a diverter position control slot 46. A cam follower 48 extends into and coacts with the position slot 46. The cam follower 48 is carried by a follower arm 50 which is fixed to the diverter pivotor shaft 26. Actuation of the cam actuator 45 will shift the cam 40 between an upper position shown in Figures 3 and 4 and a lower position shown in Figures 2 and 5. Operation In operation the counter 14 is preset for the number of items to be collected in each sequential batch of items. The speed of the vibratory feeder 10 is then set to dispense items at a rate which will produce batches at the cycle rate of the receptacles 16. Thus, as an example, if a new receptacle 16 is to be positioned at the load station where it is shown in Figure 1, once every five seconds, and five items 12 are to the preselected preset number of items for each batch, the feeder will be adjusted to dispense items at a rate of one per second. Once the counter has been set and the feed rates of receptacle positioning and vibratory feed have been coordinated, items are dispensed. Assume the diverter to be initially in the position of Figure 2 adjacent an end wall 52 which is the right hand end wall as viewed in Figure 2. An empty receptacle 16 will at this juncture be positioned below the accumulator/separator 15. Items will then be dispensed and gravity flowed through the passage 20. As the fifth or last item in our examplory batch is counted, a control 53 in response to a signal from the counter 14 will cause the cam actuator 45 to be energized to shift the cam 40 vertically from its position of Figure 2 to the position of Figure 3. In the Figure 3 position, the diverter 25 extends laterally across the passage 20 to the other or left hand side wall 54 as seen in Figures 2 - 5. Since, as is best seen in Figure 6, the diverter extends from close juxtaposition with a side wall 56 across the passage 20 to close juxtaposition with another side wall 58, following items will be collected above the diverter and between the diverter and the right hand end wall 52. The timing of the movement of the diverter 25 from its Figure 2 to its Figure 3 position is such that if it strikes a dispensed item of the first batch at all, it will divert it downwardly toward the receptacle 16 without danger of it hitting the diverter and bouncing away from its intended feed into the receptacle 16. Items of the second batch will be collected on top of the diverter 25 until the receptacle 16 containing the first batch has been removed and an empty receptacle for the second batch is in position to receive it. Once a receptacle ready signal is emitted by a receptacle sensor 60, the control 53 causes the arm actuator 35 to be energized to foreshorten it and shift the supports 28 from their positions of Figures 2 and 3 to the positions of Figure 4. This results in the diverter being positioned parallel to and adjacent the left hand end wall 54 as shown in Figure 4. Concurrently accumulated items of the second batch will be dropped through the outlet 24 into the second batch receptacle 16. As the last items of the second batch is counted, a count complete signal is emitted by the counter 14. In response to the count complete signal the control 53 causes the cam actuator 45 to again be energized, this time to raise the cam and cause the diverter 25 to shift from the Figure 4 position to the position of Figure 5 where it extends diagonally across the passage. In the Figure 5 position the pivot 26 adjacent the left hand end wall 54 while top of the diverter is adjacent the right hand end wall 52 to divert and collect a third batch. As the third batch is being collected, the receptacle now containing the second batch is removed and a further receptacle is positioned at the load station. A further receptacle ready signal is emitted by the receptacle sensor 60. The receptacle ready signal results in the actuator 35 again being extended and in the process moving the support and diverter from the position of Figure 5 back to the position of Figure 2. As the count complete signal indicating the last item of the third batch has passed the counter 14, the cam actuator 45 is again energized to move the diverter 25 again to the position of Figure 3 and the entire cycle is thereafter repeated sequentially. At any time when the control 53 receives a signal from the counter 15 indicating a given batch is complete but the control has not received a receptacle ready signal from the sensor 60, the feeder 10 is stopped and the accumulator/separator is maintained in its existing position to retain the just completed batch. Once a receptacle ready signal is received one of the arm and cam actuators 35, 45 is actuated to discharge the retained batch. The other of the actuators is then actuated to position the diverter 25 across the passage 18 in a collection position and the feeder is restarted. Although the invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction, operation and the combination and arrangement of parts may be resorted to without departing from the scope of the invention as hereinafter claimed.

Claims: A batch separator (15) for establishing batches of predetermined numbers of items (12) dispensed serially from a feeder for sequential deposit in batches at a collection station, the separator comprising: an apertured tube (18) defining a through passage (20), the tube being for positioning around a single item path of travel from the feeder to the station; a diverter (25) mounted in the tube, the diverter being shiftable between a flow position and a collection position obstructing the path, the diverter being connectable to prime mover means (35,45) for shifting between its positions, the diverter when in the flow position permitting the flow of items from the feeder to the station and when in the collection position interrupting such flow in response to a control signal received each time a predetermined number of items has been received at the inlet of the separator, to separate a batch of items from a previous batch; the separator being characterized by: a) the tube being an open ended tubular housing (18) having a through opening (20) defined in part by a spaced pair of side walls (56,58); b) the diverter (25) having at least a section positioned within the opening; c) the section having: i) a first position adjacent one of the side walls; ii) a second position adjacent the other of the side walls; iii) a third position extending across the opening from a location near a first end (22 or 24) of the one side wall to a location near a second end (22 or 24) of the other side wall; and iv) a fourth position extending across the opening from a location near the first end of the other side wall to a location near the second end of the one side wall; and, d) the prime mover means (35,45) being for shifting the section sequentially: i) from the first position to the third position; ii) from the third position to the second position; iii) from the second position to the fourth position; iv) from the fourth position back to the first position; and, v) thereafter repeating the sequence. A separator according to claim 1 wherein the first end is a lower end (24) and the second end (22) is an upper end of the opening (20). A separator according to any of claims 1 or 2, further characterized by: a) the tube being a tubular body (18) having spaced pairs of side (56,58) and end (52,54) walls delineating a through passage (20) with input and output ends (22,24); b) the diverter being a baffle member (25) movably mounted in the passage and having a lateral dimension slightly less than but substantially equal to the width of the passage between the end walls; c) the separator including a baffle support (28) pivotally mounted on the housing at a mounting location above the outlet when the accumulator is in use; d) the baffle support pivotally supporting the baffle at a pivot location (26) below the outlet when the accumulator is in use; e) the prime mover means including a first prime mover mechanism (35) operably connected to the housing and the support for selectively shifting the support between a first position wherein the pivot location is near one of the side walls and a second position wherein the pivot location near the other of the side walls; and, f) the prime mover means including a second prime mover mechanism (45) for selectively causing pivotal movement of the baffle between a first position adjacent the one side wall and a second position across the passage and between a third position adjacent the other side wall and a fourth position across the passage. A separator according to claim 3, characterized in that the second prime mover mechanism (45) includes a cam (40) operably interposed between the baffle and the support. A separator according to claim 3 or 4, characterized by a pair of baffle support pivotal mountings (30) connected to respective end walls. A system for sequentially establishing batches of predetermined numbers of items including: a feeder (10) for continuously dispensing items (12) serially and one at a time; a counter (14) for counting items as they are dispensed by the feeder and operable to emit a batch control signal each time a predetermined number of items has been dispensed by the feeder; and collection means (16) at the collection station for sequentially collecting batches and maintaining them in such separated condition, the system being characterized by comprising a batch separator according to any preceding claim. A system according to claim 6, characterized by a collection means condition sensor (60) operable to emit collection means condition signals according to the readiness of the collection means to receive batches of items from the batch separator. A system according to claim 6 or 7, characterized by control means (53) operably connected to the feeder (10), the counter (14), the separator (15) and the sensor (60) for emitting batch separation signals to the separator and a feeder stop signal when the system is not in condition properly to process further batches. A system according to claim 8, characterized in that the control means (53) issues a feeder stop signal when the counter (14) has issued a batch counted signal and the sensor (60) has not emitted a collector ready signal. A method of collecting dispensed items (12) in batches of predetermined numbers at a collection station comprising: a) serially and continuously dispensing items from a feeder and counting items; b) gravity feeding dispensed items along a path into a batch separator (15); and c) collecting dispensed items at a first location at the collection station until a first batch of a predetermined number of items is collected, characterized by; d) as a last item of a first batch is being fed, shifting a diverter (25) from the or a discharge position alongside the path to a collection position across the path to divert subsequently dispensed items into a second location within the separator; e) collecting dispensed items in the second location; f) as items of the second batch are being fed, shifting the diverter from its collection position to a discharge position to release the diverted items to the first location and permit the flow of subsequently dispensed items to the first location; g) as the last item of the second batch is being fed shifting the diverter to a further collection position across the path to divert subsequently dispensed items of a further batch into a third location within the separator; and h) as items of a further batch are being fed, shifting the diverter from its collection position to a discharge position to release the diverted items to the first location and permit the flow of subsequently dispensed items to the first location; i) sequentially repeating steps (d), (e), (f), (g) and (h). A method according to claim 10, characterized in that the first batch is dispensed into a receptacle commencing at least as early as when the diverter (25) is in the or a discharge position. A method according to claim 10 or 11, characterized in that the diverter (25) is delayed in shifting as the last second batch item is dispensed until a receptacle ready condition is sensed. A method according to any of claims 10 to 12 wherein: a) the diverter (25) is first positioned adjacent a first wall section of the accumulator (15) to allow a first batch of items to pass through the batch separator to the receptacle; b) as the last item of the first batch passes through the batch separator the diverter is shifted to a position across the passage to accumulate a second batch within the accumulator; c) a second receptacle is positioned to receive the second batch and thereafter the diverter is shifted to position it adjacent another wall section and discharge the second batch into the second receptacle; d) as the last item of the second batch passes through the batch separator the diverter is shifted to a further position across the passage to accumulate a third batch within the separator; e) a third receptacle is positioned to receive the third batch and thereafter the diverter is shifted to position it adjacent the first wall section and discharge the third batch into the third receptacle; and f) steps (a), (b), (c), (d) and (e) are thereafter repeated to sequentially accumulate further batches.

Inventors: WEHRMANN RICK STEVEN, WEHRMANN, RICK STEVEN
Applicants: AUTOMATED PACKAGING SYST INC, AUTOMATED PACKAGING SYSTEMS, INC.
Application year: 1996
Main classification: B65B57
IPC codes: B65B5, B65B57