Abstract:
The automated bin filling system provides an efficient means of placing a relatively fragile bulk product into a container (such as a bulk storage bin) without substantially damaging the product. Specifically, the bin filling system moves bulk products (preferably fruits or vegetables) from a feed conveyor into a product accumulation section where the product is arranged to be uniformly loaded into a mobile tray. Once the mobile tray is filled, the tray is lowered into the bin and gently deposited. The empty tray is then elevated and retracted to its initial position and the loading cycle is repeated. This process continues until the bin is filled.

Description:
FIELD OF THE INVENTION 
     The present invention relates to an automated mechanical bin filling system. Specifically, the invention relates to a means of moving a bulk product (preferably fruits or vegetables) from a feed conveyor to a mobile storage bin so that the product is not bruised or otherwise adversely affected. 
     BACKGROUND OF THE INVENTION 
     Millions of pounds of agricultural products are harvested, packed, and shipped, yearly. Conventional packing devices are designed to move bulk products quickly and efficiently, many times at the cost of bruising and destroying significant quantities of the product. In addition to the products that are destroyed, those that are merely damaged (but not immediately destroyed) are vulnerable to insects, disease, and accelerated decay. These damaged products are mixed with previously undamaged products so that the damaged goods are difficult to remove and may spread rot and disease to otherwise healthy products that are stored in a common storage area. 
     Previous attempts to limit damage to agricultural products during the packing process have been expensive, complex, and in some cases counterproductive. One means of minimizing product damage is through the use of “water handling” devices. These devices use water to cushion and protect a product from the impacts associated with the harvesting and packing process as the product is moved from one container to the next. 
     However, these devices require a series of tanks, pumps, and filters that must be cleaned and maintained during the harvesting and packaging process. This equipment takes up additional space, is cumbersome for workers, and generally increases product handling costs and slows the overall packing process. Further, wet handling has the potential to facilitate the spread of post-harvest diseases. 
     The need exists for a product handling method that efficiently transfers bulk products from a conveyor-type feeder to a storage container without significantly damaging the products. The current invention comprises a compact, efficient, reliable means of transferring products from a conveyor-type feeder to a storage means while imparting little or no damage to the products. 
     SUMMARY OF THE INVENTION 
     This disclosure is directed to a system and a method of filling a storage receptacle. In the preferred embodiment, the storage receptacle is a bulk products bin that is moveable with a conventional forklift. 
     The system includes an accumulation section with a plurality of helical and non-helical brushes. A feed conveyor directs products into the accumulation section. The volumetric flow of products and the rotation of the accumulation section brushes push the products through the accumulation section and into a transfer container positioned at an output end of the accumulation section. At least one optical proximity sensor monitors an area adjacent to the accumulation section for the presence of voids. A transfer container extension means moves the transfer container horizontally, and an elevator apparatus moves the transfer container vertically. 
     A product loading cycle is initiated when a product is gathered in the accumulation section and urged into the transfer container. When the optical proximity sensor detects that there are no voids adjacent the accumulation section, the transfer container extension means incrementally extends the transfer container away from the accumulation section until the transfer container is filled with products. The elevator apparatus then moves the transfer container into the bin and deposits the products. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of the current invention prior to the start of the loading process. The transfer tray is shown in the elevated and retracted position. 
         FIG. 2  is a top view of the accumulation section. The transfer tray is shown in the elevated and retracted position at the initiation of the loading cycle. 
         FIG. 3  is a perspective view of the system with the transfer tray partially loaded. The transfer tray is shown in the elevated and partially extended position. 
         FIG. 4  is a perspective view of the system with transfer tray fully loaded. The transfer tray is shown in the elevated and fully extended position. 
         FIG. 5  is a perspective view of the system with the transfer tray fully loaded and in position to deposit a product in the bin. The tray is shown in lowered and fully extended position. 
         FIG. 6  is a profile view of the transfer tray with the tray floor panels in the closed (horizontal) position. The transfer tray is shown in the lowered and fully extended position (See  FIG. 5 ). 
         FIG. 7  is a profile view of the transfer tray with the transfer tray floor panels in the open (partially vertical) position so that the fruit is deposited in bin. The transfer tray is shown in the lowered and fully extended position. 
         FIG. 8  is a profile view of the transfer tray with the transfer tray floor panels in the open (vertical) position. The transfer tray is shown in the fully extended partially elevated position. 
     
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     The present invention comprises a mechanical system  30  for filling a storage receptacle  32 . In the preferred embodiment, the storage receptacle is a rectangular bin that is movable by a conventional forklift. The system  30  is particularly useful in moving bulk products (like fruits and vegetables) that do not have a uniform size or shape. Although the system  30  may be used to move any type of product vulnerable to bruising or breakage, for the sake of simplicity, this disclosure uses fruit as an exemplary product. 
     As generally shown in  FIG. 1 , the system  30  comprises mechanical, electrical and hydraulic components associated with three primary functional groups: a product accumulation section  40 , a transfer container assembly  60 , and an elevator and support apparatus  80 . In the preferred embodiment, the transfer container assembly  60  comprises a mechanical means to support and move a rectangular tray component  62 . 
     As shown in  FIGS. 1 and 2 , in operation, fruit is initially fed into the accumulation section  40  in the direction of the arrow  41  via a feed conveyor belt  42 . The fruit is gathered and distributed uniformly across the accumulation section  40  and fed into the tray  62 . As successive rows of the transfer tray  62  are filled, the tray advances horizontally away from the accumulation section  40  until the entire tray  62  is filled.  FIG. 3  shows the transfer tray  62  partially extended, and  FIG. 4  shows the tray  62  fully extended. As shown in  FIG. 5 , after the tray  62  is filled, the tray  62  is lowered into the storage bin  32 .  FIGS. 6-8  show details of the tray  62  and tray floor panels  78  as the tray is moved from the elevated “load” position shown in  FIG. 4  to the “unload” position shown in  FIG. 5 . Operation of the system  30  is described in greater detail infra. 
     As best shown in  FIG. 2 , fruit enters the accumulation section  40  from the feed conveyor  42  and is advanced in the direction of the arrow  41  to the first of a plurality of generally cylindrical roller brushes  44 . In the preferred embodiment, the tops of the roller brushes  44  rotate in the direction that the fruit is advanced, however the rotation of the brushes  44  alone is not sufficient to propel the fruit forward. The fruit is gently pushed forward by both the rotation of brushes  44  as well as the volumetric flow of new articles of fruit leaving the conveyor belt  42  and entering the accumulation section  40 . This design ensures that the fruit is generally “gathered” in the initial stages of the accumulation section  40  and moves through the accumulation section  40  as a cluster, thereby minimizing the force of the fruit&#39;s collisions in the accumulation section  40 . 
     As shown in  FIG. 2 , if the feed conveyor  42  is narrower than the width of the roller brushes  44 , outwardly angled side panels  46  maintain the fruit within the accumulation section  40  while allowing the stream of fruit to expand to the full width of the roller brushes  44 . After the fruit passes over the cylindrical roller brushes  44  it is directed to a plurality of helical roller brushes  48 . These brushes  48  are similar to the cylindrical roller brushes  44  however they have helical outer contours so that (starting at the center of the brush  48 ) half of the helical portion of the brush  48  has a clockwise orientation, and the other half has a counter clockwise orientation. 
     As best shown in  FIG. 2 , the helical shape of the brushes  48  moves the fruit outwardly away from the center of the accumulation section  40 , thereby ensuring that the fruit is fully distributed across the width of the section  40 . The fruit then moves down a transfer incline  50  and into the transfer tray  62 . 
     Although the  FIG. 2  exemplary embodiment shows five cylindrical brushes  44  and  2  helical brushes  48 , in alternative embodiments there may be a lesser or greater number of either type of brush  44 ,  48 . Further, although the preferred embodiment shows the brushes  44 ,  48  as having an essentially uninterrupted cylindrical or helical contour, in alternative embodiments the brushes  44 ,  48  may have any contour or texture known in the art and may be comprised of smooth, grooved, or otherwise textured rollers either with or without traditional bristles. Although these alternative embodiments are not obvious, they should be considered to be disclosed and within the scope of the current invention. 
     As shown in  FIGS. 1 and 2 , at the beginning of the tray-loading cycle, a distal end  64  of the tray  62  is positioned adjacent a delivery end  52  of the transfer incline  50  so that the remainder of the tray  62  is positioned below the accumulation section  40 . An array of optical product proximity sensors  66  is directed toward the delivery end  52  of the transfer incline  50 . In alternative embodiments, the sensors  66  may utilize any technology known in the art consistent with the functions described herein. 
     As the fruit feeds into the tray  62 , the product proximity sensors  66  sense the presence or absence of fruit adjacent to the delivery end  52  of the transfer incline  50 . Specifically, the product proximity sensors  66  monitor a selected area adjacent to the delivery end  52  of the transfer incline  50  for voids. For the purposes of this disclosure, a “void” is defined as an absence of fruit in a selected area that would otherwise be filled with fruit. 
     When the product proximity sensors  66  indicate that there are no voids and all of the space adjacent to the delivery end  52  of the transfer incline  50  is filled with fruit, the proximity sensors  66  communicate the information to an electronic control mechanism attached to a horizontal linear actuator  68 . The horizontal linear actuator  68  then incrementally slides the tray  62  horizontally away from the transfer incline  50  until at least one of the proximity sensors  66  detects a void (i.e. an absence of fruit) adjacent to the transfer incline  50 . As fruit continues to move through the accumulation section  40  and down the transfer incline  50 , the previously detected void(s) is filled by incoming fruit. 
     When the product proximity sensors  66  detect that there are (once again) no voids adjacent to the delivery end  52  of the transfer incline  50 , the horizontal linear actuator  68  (once again) incrementally advances the tray  62  until another void is detected. When the void is detected the advance of the tray  62  is halted until the void is filled by incoming fruit, at which time the tray  62  advances again.  FIG. 3  shows the tray  62  in the partially extended position. 
     As best shown in  FIG. 4 , the incremental extension and loading process continues until the tray is  62  fully extended and the transfer incline  50  is adjacent to a proximal edge  70  of the tray  62 . Once the tray  62  is in the fully extended position, a limit switch on the tray extension linear actuator  68  is engaged. In the preferred embodiment, the limit switch deactivates the feed conveyor  42  and stops the rotation of the roller brushes  46 ,  48  so that the flow of fruit is halted. The transfer incline  50  is then rotated upwardly to a level position to prevent any additional fruit from flowing off the incline  50  and into the tray  62 . 
     In alternative embodiments, the transfer incline  50  may continue to rotate upwardly (past level) so that the transfer incline  50  is angled back toward the fruit accumulation section  40  thereby further ensuring that no additional fruit rolls off the transfer incline  50 . Alternatively a panel (not shown) on the edge of the transfer incline  50  may pivot upwardly to form a barrier/wall that prevents additional fruit from leaving the transfer incline  50 . 
     As best shown in  FIG. 5 , the tray  62  is then shifted to a centered position above the bin  32 . As the tray  62  is shifted, a spring loaded panel (attached to the frame) deploys to prevent fruit from rolling off the proximal end  70  of the tray  62 . The tray  62  is then lowered into the bin  32  by the elevator and support apparatus  80 . In the preferred embodiment, the elevator and support apparatus  80  is comprised of a rack  82  and pinion  84  drive system. Specifically, four rack components  82  are positioned adjacent the corners of the tray  62  and four corresponding pinion or cog components  84  are mated to the teeth of the racks  82 . The rack  82  and pinion  84  drive system ensures a smooth and level transition of the tray  62  from the elevated position shown in  FIG. 4 , to the lowered position shown in  FIG. 5 . 
       FIG. 6  is a more detailed view of the tray  62  in the lowered position shown in  FIG. 5 . The floor of the tray  62  is comprised of multiple hinged panels  78  that support the fruit in the tray  62  when the panels  78  are in a (horizontal) closed position. Support cables  76  extend from opposite ends of each of the floor panels  78 . A vertical linear actuator mechanism  75  (see  FIGS. 3-5 ) controls the tension on the cables  76 . Vertical proximity sensors  74  communicate with a control mechanism that governs the vertical movement of the tray  62 . In the preferred embodiment, the vertical proximity sensors  74  are ultrasonic proximity sensors. 
     As shown in  FIG. 7 , once the downward travel of the tray  62  has stopped, the vertical linear actuator mechanism  75  releases the tension on the cables  76 , thereby causing the floor panels  78  to pivot downwardly so that the panels  78  rest on the top of the fruit in the bin  32  (or on the bin floor if the bin  32  is empty). The elevator apparatus  80  then begins to raise the tray  62  so that the panels  78  continue to pivot downwardly toward a vertical position. As the tray  62  is raised, the fruit that was previously in the tray  62  gently spills into the bin  32 . 
     As shown in  FIG. 8 , as the tray  62  continues to move upwardly, the fruit remains in the bin  32 . When the empty tray  62  reaches the elevated position shown in  FIG. 4  (sans fruit), upward movement of the tray stops. The vertical linear actuator mechanism  75  then retracts the cables  76  and thereby brings the hinged floor panels  78  back to their (closed) horizontal position. The empty tray  62  is then horizontally retracted toward the accumulation section  40  until it reaches the original starting position shown in  FIGS. 1 and 2 . A subsequent loading cycle is then initiated and the process is repeated until the tray  62  is refilled and the next load of fruit is deposited in the bin  32 . 
     In the preferred embodiment, elements of the system  30  such as the horizontal linear actuator  68 , the pinion  84 ; and the vertical linear actuator  75 , mechanism are hydraulically powered. However, in alternative embodiments, these components  68 ,  75 ,  84  may also be solely or partially electrically or pneumatically powered, or powered by any means consistent with the function of the invention. Further, the tray  62  may be raised, lowered, and/or extended by any means known in the art consistent with the functions described herein. 
     For the foregoing reasons, it is clear that the invention provides an innovative system for moving and handling fragile bulk products. The invention may be modified in multiple ways and applied in various technological applications. For example, although the invention is capable of handling fruits and vegetables, it may also be used for non-food items such as breakable containers of any variety. 
     The current invention may be modified and customized as required by a specific operation or application, and the individual components may be modified and defined, as required, to achieve the desired result. For example, although the receptacle  32  in the exemplary embodiment is a bin designed to be moved by a forklift, the receptacle  32  may also include larger containers such as truck trailers, rail cars, and the like, or smaller containers such as cardboard boxes, wooden crates, and the like. 
     Although the materials of construction are not described, they may include a variety of compositions consistent with the function of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.