Abstract:
A counting and portioning system which counts discrete articles that conform to predetermined specifications into lots having a predetermined number of articles or a target volume. The system includes at least one portioning bin positioned to receive articles from a conveyor. The at least one bin has at least first and second outlet gates for emptying articles into separate respective first and second locations. A scanner detects and maintains a count of articles that are received in the at least one portioning bin and fall within the predetermined specification. The detector unit generates an out-of-specification signal when an article or group of articles received in the at least one portioning bin falls outside the predetermined specification. A control unit causes the first outlet gate to open when the count or volume of articles is equal to the predetermined number and causes the second outlet gate to open in response to receipt of an out-of-specification signal. The profile/volume signature for every part scanned and delivered from the infeed to the scanner is stored.

Description:
BACKGROUND AND SUMMARY OF THE INVENTION  
         [0001]    This invention relates to an apparatus and method for detecting and discriminating articles that are within a predetermined range of a specification into lots. More particularly, this invention relates to an apparatus and method for detecting and discriminating articles as aforesaid that have been separated and singulated while being conveyed to the apparatus of the present invention. The specification could be volume, individual or total, of articles; size or other physical characteristic of the articles; count of articles; or combinations of these properties.  
           [0002]    Devices for counting or aggregating articles are known. For example, U.S. Pat. Nos. 5,313,508 and 5,454,016, which are incorporated herein by reference in their entireties, disclose methods and apparatus for counting irregularly shaped articles. A pair of alternately energized light sources is provided at a sensing plane through which articles to be counted pass. Each of the light sources emits a light beam that is at an angle to the other light beam, such as an angle of about 90°.  
           [0003]    U.S. Pat. No. 5,804,772, which is incorporated herein by reference in its entirety, discloses an apparatus and method for aggregating a desired number of articles without individually counting out each article to achieve the desired number. A stream of the articles is discharged into a weigh hopper until substantially a predetermined weight of articles is in the hopper. The number of articles in the hopper is determined from the total weight of the hopper and the weight of a single article.  
           [0004]    U.S. Pat. No. 6,360,870, which is incorporated herein by reference in its entirety, discloses an apparatus which comprises a plurality of outlets radiating outwardly from the periphery of a feeder bowl. The number of outlets can be as few as two with no upper limit except as dictated by physical constraints. It is possible that as many as about 100 could be used depending on bowl size and/or diameter, and track size. Specifically, the device has multiple tracks spiraling or radially exiting out from a center cone or other structure. The tracks all have tooling designed to shed bulk loose product down to single file feed, exiting product in controlled flow from the bowl around the entire periphery at the end of each track. The bowl passes the excess overflow via an integral catch pan that provides a path for the bulk excess product to exit the bowl feeder from underneath the multiple tracks for a return run through the multi-track feeder. At each exit, an optical parts detector, laser, light beam, load cell, or similar type device, with a product diverter gate, and an accumulator with discharge gates, is positioned to count, weigh, apportion by volume, discriminate by some other characteristic of the articles, or some combination of these properties, the loose product into the desired batch size or volume. These detectors may combine their counts for large batch sizes, or each be individually programmed to count each total batch or any combination of these optical batches and weighed batches satisfying their requested batch size or volume.  
           [0005]    In another aspect of the invention of the aforementioned U.S. Pat. No. 6,360,870, a bowl configuration is provided for bulk product distribution that can deliver product uniformly and/or oriented in a controlled fashion out its entire periphery overflowing out of itself evenly and smoothly around a 360 degree circle. This bowl is designed to receive bulk product from bucket conveyors, bin vibratory elevators, and/or other similar delivery means. This device by nature of its design shape will collect the product in the bottom center of a cone, bowl or other similar shaped device. The bowl has spiral vanes, tracks, diverters, or other similar devices affixed to its interior surfaces that will guide and encourage the product to climb out of and spread itself evenly and uniformly out of the periphery of the device.  
           [0006]    Because previously known devices do not detect and package a lot of articles having a predetermined count and a predetermined size and reject lots having articles falling outside the predetermined size range, in my copending application Ser. No. 09/970,658, filed Oct. 5, 2001, which is incorporated herein by reference in its entirety, I disclose a counter unit for counting discrete articles within a predetermined size range into lots having a predetermined number of articles. The counter unit includes (1) a first conveyor that delivers a flow of articles separated at intervals, and (2) at least one bin positioned to receive articles from the conveyor. The at least one bin may have first and second outlet gates for emptying the articles into first and second separate locations. A detector unit counts the articles that are received from the conveyor into the at least one bin and which fall within the predetermined size range.  
           [0007]    A control unit causes the first outlet gate to open when the count of articles is equal to the predetermined number of articles. However, when an article falls outside the predetermined size range, the detector generates an out-of-size signal. The control unit, upon receipt of the out-of-size signal from the detector unit, causes the second outlet gate to open, thereby rejecting the articles. The counter unit may also be used to for counting articles having a predetermined color into lots having a predetermined number of articles. When an article does not have the predetermined color, the detector generates an out-of-color signal. The control unit, upon receipt of the out-of-color signal from the detector unit, causes the second outlet gate to open, thereby rejecting the articles.  
           [0008]    The counter unit of the aforementioned application Ser. No. 09/970,658 is quick and efficient. There is a need, however, for an improvement on that counter unit which is more suitable for use with certain applications. In particular, although as non-limiting examples, in packaging of pharmaceutical dosage forms such as pills, capsules, or the like; or of foods such as soups or other mixtures of various ingredients, apportioning the articles by gross volume is more efficient.  
           [0009]    It is, therefore, an object of the present invention to overcome the deficiencies of prior art devices and methods and to provide an apparatus and method for apportioning articles that accurately counts a predetermined number of discrete articles, regardless of size and/or shape, and/or dispenses articles that are within predetermined specifications such as total size or volume.  
           [0010]    It is another object of the present invention to provide an article detecting and counting or volume totaling apparatus that is relatively simple and inexpensive to manufacture and to maintain and that is both accurate and reliable.  
           [0011]    It is still another object of the present invention to provide a method of counting and portioning articles accurately and efficiently  
           [0012]    Consistent with the foregoing objects, the present invention provides an article detecting and counting apparatus which comprises a detector unit which detects and maintains a count of articles that are received in the apparatus or which fall within a predetermined range of a predetermined specification such as volume, which detector generates an out-of-specification signal when an article or group of articles received in the apparatus falls outside the predetermined range; a chamber positioned to receive articles from a flow of articles delivered to the apparatus; a diverter gate which holds and releases batches of articles for further processing, the diverter gate being disposed in the chamber; at least first and second outlet gates for emptying articles from apparatus into respective first and second locations which are separated from each other; and a control unit which causes the first outlet gate to open when the count or volume of articles is equal to the predetermined number and/or the articles fall within the predetermined range of the predetermined volume, for example, and causes the second outlet gate to open in response to receipt of an out-of-specification signal from the scanner.  
           [0013]    Other objects, advantages and novel features of the present invention will become apparent from the following detailed description of the invention when considered in conjunction with the accompanying drawings. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0014]    [0014]FIG. 1 is a perspective view from the top and front of a bowl feeder schematically showing the placement of the counting and portioning system of the present invention;  
         [0015]    [0015]FIG. 2 is an elevational view, schematically shown for illustrative clarity, of one embodiment of the counting and portioning system of the present invention;  
         [0016]    [0016]FIG. 3 is an elevational view of the embodiment of FIG. 1 showing the diverter gate in a holding position;  
         [0017]    [0017]FIG. 4 is an elevational view of the embodiment of FIG. 1 showing the diverter gate allowing a first batch to proceed to the next position;  
         [0018]    [0018]FIG. 5 is an elevational view of the embodiment of FIG. 1 showing the first batch being held while the diverter gate is in a holding position for a second batch;  
         [0019]    [0019]FIG. 6 is an elevational view of the embodiment of FIG. 1 showing the first batch being dispensed while the diverter gate is in a holding position for a second batch;  
         [0020]    [0020]FIG. 7 is an elevational view of the embodiment of FIG. 1 showing the diverter gate opening to allow a second batch to pass to the next position and showing the reject gate in an open position;  
         [0021]    [0021]FIG. 8 is an elevational view of the embodiment of FIG. 1 showing a second batch being rejected while the diverter gate is in a holding position for another batch;  
         [0022]    [0022]FIG. 9 is an elevational view of the embodiment of FIG. 1 showing all gates closed to begin a new cycle;  
         [0023]    [0023]FIG. 10 is an elevational view, schematically shown for illustrative clarity, of another embodiment of the counting and portioning system of the present invention;  
         [0024]    [0024]FIG. 11 is an elevational view of the embodiment of FIG. 10 showing the diverter gate in a holding position;  
         [0025]    [0025]FIG. 12 is an elevational view of the embodiment of FIG. 10 showing the diverter gate allowing a first batch to proceed to a dispensing position;  
         [0026]    [0026]FIG. 13 is an elevational view of the embodiment of FIG. 10 showing the first batch being held for dispensing while the diverter gate is in a holding position for a second batch which will include an out-of-specification article;  
         [0027]    [0027]FIG. 14 is an elevational view of the embodiment of FIG. 13 showing the first batch being dispensed while the diverter gate is in a holding position for a second batch;  
         [0028]    [0028]FIG. 15 is an elevational view of the embodiment of FIG. 10 showing the diverter gate opening to allow a rejected batch to pass to the next position and showing the reject gate in an open position;  
         [0029]    [0029]FIG. 16 is an elevational view of the embodiment of FIG. 10 showing a batch being rejected, while another batch is being held for dispensing and while the diverter gate is in a holding position for still another batch;  
         [0030]    [0030]FIG. 17 is an elevational view of the embodiment of FIG. 10 showing all gates closed to begin a new cycle;  
         [0031]    [0031]FIG. 18 is a flow chart diagram of a method for detecting and counting articles that are within a predetermined range of a desired property into lots according to the present invention;  
         [0032]    [0032]FIG. 19 is a flow chart diagram of a sub-routine of the diagram of FIG. 18  
         [0033]    [0033]FIG. 20 is a flow chart diagram of another subroutine of the diagram of FIG. 18; and  
         [0034]    [0034]FIG. 21 is a schematic diagram of a counting and portioning system according to the present invention.  
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0035]    Referring first to FIG. 1, there is shown a bowl feeder generally designated by the numeral  10  according to the aforementioned U.S. Pat. No. 6,360,870. The bowl feeder  10  has a central receiving section  12  which receives bulk product to be distributed to the counting and portioning system. The product could be pieces of food such as carrots, potatoes, pasta, or any other type of food which can be handled in bulk and separated into discrete units to have volume determined, to be counted, measured, weighed, or subjected to measurement of any other physical characteristic such as color, shape, or the like, or combinations such as volume determinations combined with count; pharmaceutical products such as tablets, capsules, or any other dosage form which can be subjected to handling; electronic components such as chips, resistors, capacitors, transistors, or the like; or any other type of product to be separated from bulk quantities into individual or multiple package units.  
         [0036]    The bowl feeder  10  shown is a vibratory feeder. Due to the vibration, the bulk product is moved along one or more tracks  14  spiraling or radiating out from the center of the apparatus. This movement separates and singulates (causes the product to assume a single file) the product. Only one track  14  is shown in FIG. 1 but it is understood that there may be as many as 100, or more, channels, the number being dictated only by practical considerations such as the size of the installation. A device for counting, sorting, combining, weighing, separating, or the like is affixed to the end of a track as is shown schematically at  16 .  
         [0037]    One embodiment of the counting and portioning system of the present invention is shown in FIG. 2, generally designated by the numeral  20 . Parts  22  which have been singulated by the device  10  enter the system at the inlet end  24  to be optically scanned by scanner  26 . Scanner  26  is any suitable detecting device such as that of the aforementioned U.S. Pat. No. 5,313,508. Diverter gate  28  is in a first position to accumulate a batch of a predetermined number or volume of parts  22 . Accept gate  30  and reject gate  32  are both in the closed positions. In FIG. 3, the parts  22  have all passed through scanner  26 , are within the predetermined specifications, and are accumulating. In FIG. 4, the batch count or volume is completed, that is, the predetermined number or volume of in-specification parts  22  has accumulated. The diverter gate  28  swings to its second position allowing the first batch to drop down into the holding area at the outlet end  34  of device  20 . Accept gate  30  and reject gate  32  are still closed. As shown in FIG. 5, while the first batch is being held at  34 , a new batch is entering at inlet end  24 , with diverter gate  28  holding the new batch. The new batch shown will include an item  36  which is out of specification. It is to be understood that out-of-specification article  36  is shown schematically and could, in fact, be a cluster of items which, collectively, do not meet the prescribed specification such as volume.  
         [0038]    Typically, the plurality of devices  20  are disposed above a conveyor system (not shown) which moves containers into which the parts  22  will be dispensed. When a container is aligned under device  20 , accept gate  30  is opened while reject gate  32  remains closed. This releases an accepted batch to drop into a container, as shown in FIG. 6. Now, as shown in FIG. 7, as the first batch is being dispensed into a container, diverter gate  28  swings between the out-of-specification part  36  and the next entering in-specification part  22 , accept gate  30  closes and reject gate  32  opens only when the accept gate  30  is closed. The partial batch containing out-of-specification part  36  is rejected as shown in FIG. 8 while a new batch begins to accumulate. A container, bin, trough, or the like (not shown) is disposed beneath the reject gate to catch the rejected batch. In FIG. 9, the diverter gate  28 , accept gate  30 , and reject gate  32  are in the positions allowing counting and accumulation of another batch while the rejected batch drops away.  
         [0039]    A second embodiment of the instant invention, generally designated by the numeral  40 , is shown in FIG. 10. Parts  22  which have been singulated by the device  10  enter the system at the inlet end  42  to be optically scanned by scanner  26 . Diverter gate  28  is in a first position to accumulate a batch of a predetermined number or volume of parts  22 . Accept gate  30  and reject gate  32  are both in the closed positions. In this embodiment, the reject gate  32  is at the side of device  40  rather than at the bottom as in device  20  of the first embodiment.  
         [0040]    In FIG. 11, the parts  22  have all passed through scanner  26 , are within the predetermined specifications, and are accumulating. In FIG. 12, the batch count is completed, that is, the predetermined number or volume of parts  22  have accumulated. The diverter gate  28  swings to its second position allowing the first batch to drop down into the holding area at the outlet end  44  of device  40 . Accept gate  30  and reject gate  32  are still closed. As shown in FIG. 13, while the first batch is being held at  44 , a new batch is entering at inlet end  42 , with diverter gate  28  holding the new batch. The new batch shown will include a part  36  which is out of specification.  
         [0041]    When a container is aligned under device  40 , accept gate  30  is opened while reject gate  32  remains closed. This releases an accepted batch to drop into a container, as shown in FIG. 14. Now, as shown in FIG. 15, the first batch has been dispensed into a container, diverter gate  28  swings between the out-of-specification part  36  and the next entering in-specification part  22 , accept gate  30  is closed and reject gate  32  opens only when the accept gate  30  is closed. The partial batch containing out-of-specification part  36  is rejected as shown in FIG. 16 while a new batch begins to accumulate. As in the first embodiment, a container, bin, trough, or the like (not shown) is disposed beneath the reject gate to catch the rejected batch. In FIG. 17, the diverter gate  28 , accept gate  30 , and reject gate  32  are in the positions allowing counting and accumulation of another batch while the rejected batch drops away.  
         [0042]    According to the method of the present invention, a flow of articles separated by discrete intervals is provided to at least one portioning device  20 ,  40  positioned to receive the articles. Using the scanner  26 , a count of articles that are received in the at least one portioning device and/or fall within a predetermined range of a predetermined specification such as volume, size, color, weight, or the like is calculated. The predetermined specification could be, for example, volume of an individual article or total volume of an aggregate group of articles. The at least one device is emptied into a first location when the count maintained by the detector is equal to the predetermined number. When articles in the flow that fall outside the predetermined range of size, weight, volume, or the like, however, an out-of-specification signal is generated. The at least one device is emptied into a second location in response to the generation of an out-of-specification signal.  
         [0043]    As already discussed, the first location may be, for example, a package for receiving one lot of articles having the predetermined specifications. The package may be situated on a second conveyor that moves packages sequentially into the first location. The second location may be, for example, a container for receiving and storing groups of articles that include articles that fall outside the predetermined specifications such as total volume.  
         [0044]    [0044]FIG. 18 is a flow diagram for operating a method according to the present invention. The main loop is started at  100 . Then, in step  101 , it is determined whether there is a demand (i.e., whether there is a first location capable of accepting the counted articles, such as a package in which a preset number or volume of articles is to be filled). If there is a demand, the counter unit determines whether any lots are ready for packaging, that is, whether there is a stored batch, at  102 . If there is a stored batch, the accept gate is opened and that stored batch is dumped at  103 .  
         [0045]    Even if there is no demand at  101 , or if there is no stored batch at  102 , an incoming stream of product is scanned at  104 .  
         [0046]    The scan part routine is shown in the flow diagram of FIG. 19. The part enters the optics at  105 . Different characteristics are scanned denoted as “scan X”  106  and “scan Y”  107 . The routine queries whether the part is in the optics at  108 . If yes, the scan is stored. If no, the size of the part is calculated at  109 . If the part size meets specifications, the batch count or volume is tallied and calculated at  110 . At this point, the part scan is finished unless a part is off-size or the batch number is wrong, in which case the batch is marked as bad.  
         [0047]    After scanning, the method determines whether the product feed needs adjustment at  111  (FIG. 18). The adjust product feed routine is shown in the flow diagram of FIG. 20. If the flow of articles is too fast for the diverter or deflector gate to separate them, as determined in step  112 , the product feed is decreased, thereby slowing the flow of articles to the scanner.  
         [0048]    Returning to FIG. 18, after product feed is adjusted, if necessary, part data is stored in temporary storage at  113 . If the batch is finished, the batch accumulator is not full, and the batch is good, the part data is stored in permanent storage at  114  and the batch is stored in an accumulator at  115 . The profile of every item passing through the system is stored for future reference.  
         [0049]    The method of the present invention includes counting and/or detecting a predetermined physical characteristic of the articles by detector  26  which sends the count and in-specification or out-of-specification signal to control unit  50 . Control unit  50  sets the diverter gate  28  in the proper position and opens the appropriate accept gate  30  or reject gate  32 . Responsive to the incoming feed rate, control unit  50  also re-sets feed rate. Information about the batches of articles is stored in data storage  52 .  
         [0050]    Although particular embodiments of the present invention have been illustrated and described, it will be apparent to those skilled in the art that various changes and modifications can be made without departing from the spirit of the present invention. It is therefore intended to encompass within the appended claims all such changes and modifications that fall within scope of the present invention.