Abstract:
A rotary feeder for transferring articles includes a support frame, a rotatably driven bowl assembly mounted on the support frame and including a bowl mounted for rotation about a bowl axis, and a rotatably driven shaft mounted on the support frame for rotation about a shaft axis. A coupling is rotatably driven by the shaft and has a first end coupled to the shaft and a second end, the second end being pivotable with respect to the first end to define a tilt axis oriented at an angle with respect to the bowl axis. An adjustable guide assembly is mounted on the support frame and adapted to secure the coupling second end along a selected tilt axis. A disc is coupled to the coupling second end and rotates about the tilt axis, the disc including a lower portion and an upper portion, the upper portion defining an article transfer point.

Description:
FIELD OF THE DISCLOSURE  
       [0001]     The present disclosure generally relates to article handling equipment and, more particularly, to rotary feeders for transferring articles from a reservoir to a support surface positioned adjacent thereto.  
       BACKGROUND OF THE DISCLOSURE  
       [0002]     During various types of processes, such as manufacturing or assembling articles, it is often necessary to orient and/or singulate the articles to facilitate automated feed into associated processing equipment. In particular, rotary feeders are known which use centrifugal force to create a series or stream of singulated articles. Typically, a bulk volume of articles are placed in the rotary feeder, which then acts to singulate and/or orientate the articles as they are supplied to associated equipment or the like, with the articles arranged into a sequential stream where all of the articles are typically arranged in a single orientation. This type of technology is typically employed in automated processes, where relatively higher throughput is required. Conventional rotary feeders are disclosed in U.S. Pat. Nos. 6,578,699; 5,145,051; and 4,429,808.  
         [0003]     A typical rotary feeder has two primary components: a bowl assembly and a feed disc assembly. The bowl assembly includes a bowl defining a reservoir for holding a plurality of articles and an out-turned flange onto which each article is to be transferred. The bowl is typically rotatable about a substantially vertical bowl axis. The feed disc assembly includes a feed disc disposed inside the bowl at an inclined angle to define a lower portion positioned near a bottom of the bowl and an upper portion positioned near the out-turned flange. The feed disk is rotated so that it engages individual articles disposed inside the bowl and transports them, via centrifugal force, up the inclined angle to out-turned flange. The bowl assembly may also be rotated to advance articles deposited onto the out-turned flange to a discharge point, where the articles are further processed by other machinery.  
         [0004]     While the previously known rotary feeders are generally suitable for creating a series of singulated articles, it is overly difficult or impossible to adjust the disc for use with articles of different geometries or sizes. Some rotary feeders have a feed disc that is fixed at a single incline angle, and therefore is suitable only for certain types of articles or operations. Other rotary feeders are known which allow adjustment of the feed disc incline angle, but allow such adjustment only by moving the entire shaft to which the feed disc is coupled, such as U.S. Pat. Nos. 3,960,293 and 3,702,663. Adjustment of the entire feed disc shaft is not only overly difficult, but also complicates coupling of the shaft to a drive for rotating the shaft.  
         [0005]     In addition, conventional rotary feeders are overly difficult to assembly for custom article sizes and to maintain sufficient tolerances between components. In known feeders, the bowl is typically formed with the desired out-turned flange and then is subsequently mounted on a support frame. The flange must be sized not only to properly support the particular articles being processed, but must also cooperate with surrounding structures such as a guide fence and discharge point positioned about a perimeter of the bowl, and therefore close tolerances between these parts must be maintained. With conventional rotary feeders, the bowl is typically a custom fabricated item and therefore can be overly expensive. In addition, formation of the out-turned flange prior to assembly may result in unintended and possibly unacceptable gaps between the bowl and surrounding structures.  
       SUMMARY OF THE DISCLOSURE  
       [0006]     In view of the foregoing, a rotary feeder for transferring articles includes a support frame, a rotatably driven bowl assembly mounted on the support frame and including a bowl mounted for rotation about a bowl axis, and a rotatably driven shaft mounted on the support frame for rotation about a shaft axis. A coupling is rotatably driven by the shaft and has a first end coupled to the shaft and a second end, the second end being pivotable with respect to the first end to define a tilt axis oriented at an angle with respect to the bowl axis. An adjustable guide assembly is mounted on the support frame and adapted to secure the coupling second end along a selected tilt axis. A disc is coupled to the coupling second end and rotates about the tilt axis, the disc including a lower portion and an upper portion, the upper portion defining an article transfer point.  
         [0007]     In an alternative embodiment, a rotary feeder includes a support frame, a rotatably driven lower hub mounted on the support frame, and a bowl coupled to the lower hub assembly for rotation about a bowl axis, the bowl including a side wall and a flange. A rotatably driven shaft is mounted on the support frame for rotation about a shaft axis, the shaft axis being substantially coincident with the bowl axis. A coupling is rotatably driven by the shaft, the coupling having a first end coupled to the shaft and a second end, the second end being pivotable with respect to the first end to define a tilt axis oriented at an angle with respect to the bowl axis. A riser is mounted on the support frame, and an adjustable guide assembly is coupled to the riser and adapted to secure the coupling second end at a selected tilt axis. A disc is coupled to the coupling second end and rotates about the tilt axis, the disc including a lower portion and an upper portion, the upper portion defining an article transfer point for transferring articles from the disc to the bowl flange.  
         [0008]     In accordance with additional aspects of the present disclosure, a method of assembling a rotary feeder comprises providing a support frame, forming a bowl having a side wall and an out-turned flange, the out-turned flange having a standard width, mounting the bowl on the support frame, and trimming the out-turned flange to a custom width while the bowl is mounted on the support frame. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]     For a more complete understanding of the disclosed subject matter, reference should be made to the embodiments illustrated in greater detail on the accompanying drawings, wherein:  
         [0010]      FIG. 1  is a perspective view of a rotary feeder in accordance with the present disclosure;  
         [0011]      FIG. 2  is a side elevation view of the rotary figure of  FIG. 1 ;  
         [0012]      FIG. 3  is a side elevation view, in cross-section of the rotary feeder of  FIG. 1  with the bowl removed for clarity;  
         [0013]      FIG. 4  is an enlarged side elevation view, in cross-section, of a detail of the rotary feeder illustrated in  FIG. 1 ; and  
         [0014]      FIG. 5  is a perspective view of a bowl used in the rotary feeder of  FIG. 1 . 
     
    
       [0015]     It should be understood that the drawings are not necessarily to scale and that the disclosed embodiments are sometimes illustrated diagrammatically and in partial views. In certain instances, details which are not necessary for an understanding of the disclosed methods and apparatuses, or which render other details difficult to perceive, may have been omitted. It should be understood, of course, that this disclosure is not limited to the particular embodiments illustrated herein.  
       DETAILED DESCRIPTION  
       [0016]     A rotary feeder is disclosed herein having a disc rotatable about a disc axis that is disposed at an angle with respect to an axis of a drive shaft coupled to the feed disc. In addition, the incline angle of the feed disc is adjustable to accommodate different article geometries and sizes, or to perform certain types of transfer procedures. For example, the feed disc may be oriented with its upper portion disposed below the bowl out-turned flange so that the articles flip as they are transferred from the feed disc to the flange. Alternatively, the feed disc may be positioned with its upper portion above the bowl so that the articles are dropped onto the flange. While particular rotary feeder structure and processes are described herein, it will be appreciated that this disclosure is not limited thereto as the disclosed features may be incorporated into any type of rotary feeder that may benefit from the advantages described herein.  
         [0017]     An exemplary embodiment of a rotary feeder  20  is illustrated in  FIGS. 1-5 . This type of article handling equipment is particularly suited for handling bulk volumes of individual articles, wherein it is desired to singulate (i.e., form a single, sequential stream of articles) and/or orient (i.e., arrange each of the articles in the same, single orientation) such as for delivery during automated processing to associated equipment and the like. As an example, plastic closures for containers are typically singulated and oriented (e.g., all top-side up or all top-side down) for delivery to associated bottling equipment.  
         [0018]     Referring to  FIGS. 1-3 , the rotary feeder  20  includes a support frame  22  on which the various components of the feeder are mounted. In the illustrated embodiment, the support frame  22  is formed as a generally rectangular plate having four feet  24  extending downwardly therefrom to contact the floor or other support surface. First and second motors  26 ,  28  are mounted on the support frame  22 . A platform  30  is positioned above the support frame  22  and is coupled to the support frame by columns  32 .  
         [0019]     The rotary feeder  20  includes a bowl assembly  34  that is operably coupled to the first motor  26 . As best shown in  FIG. 3 , the bowl assembly  34  includes a lower hub  36  operably coupled to the first motor  26  by a pulley  38  and belt  40 . A bearing  42  has a stationary outer race attached an upper surface of the platform  30  and a rotatable inner race coupled to a bottom end of the lower hub  36 , thereby allowing the lower hub  36  to rotate with respect to the support frame  22 . A second bearing  44  is also attached to a top end of the lower hub  36 . A support plate  46  is attached to and rotates with the lower hub  36 . A bowl  48 , in turn, is coupled to the support plate  46 . The bowl  48  includes a sidewall  50  and an out-turned flange  52 . The sidewall  50  has an inner surface  54  that preferably has a semi-spherical shape. The out-turned flange  52  has an upper surface  56  that is preferably flat and substantially horizontally oriented. When assembled, the bowl  48  and support plate  46  define a reservoir for receiving individual articles, as will be better understood below. The bowl  48  rotates about a bowl axis  53 , which may be substantially vertically oriented.  
         [0020]     The bowl  48  is preferably formed of a polymer material to reduce the weight of the bowl and minimize noise during operation. In a currently preferred embodiment, the bowl  48  is cast from a hybrid, two-part synthetic urethane. In this embodiment, a two-piece mold may be used that forms a cavity there between. The two-part urethane is poured into the cavity and hardens over time. The mold is then separated and the bowl  48  is removed. By using a polymer material, the weight of the bowl  48  is reduced, thereby lowering the amount of power needed to rotate the bowl. In addition, noise generated by articles impacting the inner surface of the bowl is lower than that seen with typical metal bowls. The use of a resilient material, such as the urethane noted above, also cushions the impact of articles on the bowl, thereby reducing the chance of damage to the articles during processing.  
         [0021]     A shaft  62  is also coupled to the support frame  22  as best shown in  FIG. 3 . The shaft  62  is mounted on and rotatable with respect to the platform  30 . Specifically, a lower bearing  64  is positioned between a lower end of the shaft  62  and the platform  30 , while an upper bearing  66  is disposed between an upper end of the shaft  62  and a riser  68 . The shaft  62  is operably coupled to the second motor  28  by a pulley  70  and belt  72 . In the illustrated embodiment, the shaft  62  has an axis  63  that is generally vertically oriented. The shaft axis  63  may be coincident with the bowl axis  53 , as illustrated.  
         [0022]     A disc assembly  74  is coupled to the shaft  62 , as best illustrated in  FIG. 4 . The disc assembly  74  includes a disc  76 , enclosure  78 , top plate  80 , spacer  81 , and cap  82 . The enclosure  78  includes an access opening  79  that may be closed off by a cover  83 . The disc assembly  74  is connected to the shaft  62  by a pivotable coupling  84 . In the illustrated embodiment, the coupling  84  is a universal joint having a first end  86  attached to the shaft  62 , a second end  88  attached to the disc assembly  74 , and a ball joint  90 . The second end  88  is pivotable with respect to the first end  86  to be oriented along a tilt axis  92 . The tilt axis  92  is oriented at an angle, and therefore is non-parallel, to the bowl axis  53 . The disc  76  is oriented at an incline that is substantially perpendicular to the tilt axis  92 . As such, the disc  76  has a lower portion positioned near a bottom of the bowl  48  and an upper portion positioned near the flange  52 . The upper portion includes a transfer point where articles are passed from the disc  76  to the bowl flange  52 .  
         [0023]     The rotary feeder  20  also includes an adjustable guide assembly  100  for securing the disc assembly  74  and coupling second end  88  at a desired tilt axis  92 . As best shown in  FIG. 4 , the adjustable guide assembly  100  includes a bracket  102  mounted to the support frame  22  via the riser  68  and platform  30 . An adjustable pin, such as threaded rod  104 , passes through an aperture in the bracket. First and second nuts  106 ,  108  may be threaded onto the threaded rod  104  above and below the bracket  102  to secure the threaded rod  104  at the desired elevation. To accommodate changes in the orientation of the threaded rod  104 , the bracket aperture may be oversized and semi-spherical washers  110 ,  112  may be disposed between the associated nut  106 ,  108  and the bracket  102 .  
         [0024]     The adjustable guide assembly  100  further includes a hub  114  disposed between the shaft  62  and the disc assembly  74 . The hub includes a cavity  116  sized to receive the shaft  62  and coupling first end  86  and is sufficiently large to allow the hub  114  to pivot with respect to the shaft  62 . A threaded aperture  118  is formed in a lower phase of the hub  114  and is sized to receive the threaded rod  104 . A collar  120  is formed at an upper end of the hub  114  and includes a cylindrical outer surface  122 . The top plate.  80  and spacer  81  define a cylindrical inner surface spaced from the collar cylindrical outer surface  122 . A bearing  126  is disposed between the outer and inner surfaces  122 ,  124  to allow the disc assembly  74  to rotate with respect to the hub  114 . In the illustrated embodiment, the bearing  126  is retained in place by upper washers  128  fastened to the collar  120  and lower washers  130  fastened to the top plate  80 .  
         [0025]     The incline angle of the disc  76  may be adjusted by changing the elevation of the threaded rod  104 . Adjusting the elevation of the threaded rod  104 , which engages the threaded aperture  118  formed in the hub  114 , causes the hub  114  to change the angle at which it is tilted. A change in the orientation of the hub  114  causes the disc assembly  74  to similarly change, and this change in orientation is accommodated by the pivotable coupling second end  88 . Accordingly, the relative position of the disc transfer point defined by the disc upper portion with respect to the bowl flange  52  may be adjusted as desired simply by changing the elevation of the threaded rod  104 . A desired orientation may be secured by tightening the nuts  106 ,  108  to hold the threaded rod  104  in place. This can be done without adjusting the orientation of the shaft  62 .  
         [0026]     In operation, the first and second motors  26 ,  28  rotate the bowl  48  and disc  76 , respectively. The disc  76  is rotated at a speed such that at the transfer point, the static friction between the articles and the disc  76  is overcome by the centrifugal force acting on the articles, thereby causing the articles to move outward onto the flange  52 . The bowl  48  is operated at a speed, typically greater than the disc speed, so that the parts are deposited on the flange  52  with desired spacing. As noted above, it may be desirable to raise or lower the disc upper portion so that the transfer point is above or below the flange  52 . The adjustable guide assembly  100  allows the disc to be held at different incline angles without requiring a change in the orientation in the shaft  62 .  
         [0027]     The present disclosure also contemplates a method of assembling rotary feeders that is less expensive and more precise. Specifically, it is noted that the width of the out-turned flange  52  is dependent on the size or orientation of the articles to be processed. Rather than fabricating the bowl  48  with the desired flange width, the bowl  48  may be formed with a standard, oversized flange width Ws that is later cut down to a custom width Wc ( FIG. 5 ). As a result, multiple identical bowls  48  having oversized flanges may be formed, and each may then be modified to a custom flange width as needed. It is preferable to cut the flange to the desired flange width after the bowl has already been attached to the lower hub and support plate. By waiting until after the bowl is assembled in place, the flange may be cut to a precise, custom size that takes into account any tolerance or other issues that may form undesirable gaps between the flange and surrounding structure.  
         [0028]     While the foregoing was written with reference to specific examples and embodiments, it is to be understood that the scope of the disclosure is not limited thereby. Instead, the detailed description is provided to satisfy best mode and enablement requirements while providing support for any and all claims which may issue here from.