Patent Description:
The present invention relates generally to automated product handling machinery, to automated machinery that organizes and feeds cylindrical products from a bulk supply to a product take away conveyance and more particularly, to an automated machine for organizing and feeding cylindrical products with the features of the preamble of claim <NUM>.

Automated machinery can be employed to handle cylindrical-shaped items such that the product is separated and flows in a consistent orientation into further stages of handling or packaging machinery. <CIT> discloses an automated machine for organizing and feeding cylindrical products with the features of the preamble of claim <NUM>. <CIT> discloses an article handling machine.

Prior solutions employed vision inspection coupled with mechanical means or pneumatic means to remove individual products from a conveyor that were not in the desired orientation. However, this is inefficient because the output of product from the machine is reduced by approximately <NUM>% due to the necessity of removing all improperly-aligned product from the conveyor line that must then be re-routed to an earlier stage of the machinery. Thus, output speeds of the automated machinery are limited.

A further drawback of conventional automated handling machinery for cylindrical-shaped items is that re-orientation of the product from one plane to another can produce jams and misalignments if the unit output speed of the product is set too fast. This is exacerbated by product that deviates from specified tolerances. Therefore, the operating speeds of the conventional machinery is quite limited and jams can occur more often than desired.

Therefore, there remains a need to improve the methods and apparatus for organizing and feeding cylindrical products from a bulk supply to a product take away conveyance.

Further developments are given in the dependent claims.

The disclosure addresses the problems discussed above by providing an automated machine for organizing and feeding cylindrical products. Bulk products are loaded in into the hopper and proceed to a singulation device, proceed across a conveyor and into a pair of rollers to align product orientations before engaging pockets in a miter wheel assembly to transfer the products to a vertical accumulation chamber, where the products are discharged to a take away device. Additional aspects and details are described in the Detailed Description and illustrated in the various figures.

An automated machine for organizing and feeding cylindrical products includes a conveyor to space apart the cylindrical products. A pair of elongated rollers is disposed downstream from the conveyor to orient the cylindrical products in the same direction. A miter wheel disposed downstream of the pair of elongated rollers transfers the cylindrical products from the pair of rollers to a vertical accumulation chamber while changing the orientation of the cylindrical products from a vertical alignment to a horizontal alignment. The cylindrical products are discharged from the vertical accumulation chamber to a take away conveyance. Operation of the components of the automated machine can be controlled by a computer. Optical sensors can be employed to monitor flow of the cylindrical products through the automated machine during operation.

The disclosure includes an automated machine for organizing and feeding cylindrical products according to claim <NUM>. A pair of elongated rollers are disposed downstream from a conveyor, wherein the pair of rollers define a gap dimension laterally between the pair of rollers, wherein the gap dimension laterally between the pair of rollers is such that a small diameter end of the cylindrical products can pass through the gap but an opposing larger end of the cylindrical products cannot pass through the gap, thereby allowing each individual cylindrical product to freely swing as it travels along the rollers so that the small end is facing downward as the product proceeds forward longitudinally along the pair of rollers. A miter wheel is disposed downstream of the pair of elongated rollers in order to change the orientation of the cylindrical products from a vertical alignment to a horizontal alignment.

A vertical accumulation chamber is provided to receive a plurality of the cylindrical products that exit the meter wheel. The accumulation chamber includes an outlet.

The cylindrical products can be bullet ammunition in one example,.

Speed of the conveyor is variable to impart spacing between individual cylindrical products as the cylindrical products are introduced to the conveyor.

A constriction can be disposed between the conveyor and the pair of elongated rollers. The constriction can be sized and shaped such that cylindrical products falling within a predetermined dimensional range pass through the constriction and are accelerated ahead by an air jet provided to the constriction while cylindrical products that are larger than the predetermined dimensional range are stopped by the constriction.

A chute can be disposed downstream from the constriction that transitions the cylindrical products passing through the constriction to the pair of rollers.

The pair of rollers can be inclined vertically downward from the conveyor along a longitudinal axis of the pair of rollers. The pair of rollers define a gap dimensior laterally between the pair of rollers such that a small diameter end of the cylindrical products can pass through the gap but an opposing larger end of the cylindrical products cannot pass through the gap, thereby allowing each individual cylindrical product to freely swing as it travels along the rollers so that the small end is facing downward as the product proceeds forward longitudinally along the pair of rollers. Each roller in the pair of rollers can rotate in a direction opposite to one another to impart an upward force on the cylindrical products.

A plurality of optical sensors can be disposed throughout the automated machine to monitor flow of the cylindrical products through the automated machine, wherein the plurality of optical sensors are coupled to a computing device that automatically adjusts one or more operating parameters of the automated machine.

The miter wheel can define a plurality of individual pockets in a perimeter surface of the miter wheel. The miter wheel also can be oriented transverse to both the pair of rollers and the vertical accumulation chamber. The miter wheel can comprise a section of a truncated cone with a cone angle such that the cylindrical products are transitioned by a half turn of the miter wheel from a vertical orientation as the cylindrical products exit the pair of rollers to a horizontal orientation as the cylindrical products are discharged into the vertical accumulation chamber.

The miter wheel can be coupled to a drive flange of a motor via a magnetic holding clamp. A magnetic attraction force between the drive flange and the magnetic holding clamp can be applied or removed by a control knob disposed atop the magnetic holding clamp. The magnetic attraction force between the magnetic holding clamp and the drive flange can be such that there is no slippage of the miter wheel in normal running conditions, but slippage will occur in the event of a jam condition encountered by the miter wheel.

The product path defined through the vertical accumulation chamber can be zig-zag and along a vertical axis. A plurality of level monitoring optical sensors can be provided to the vertical accumulation chamber to monitor a level of cylindrical product present in the vertical accumulation chamber. The plurality of level monitoring optical sensors can be coupled to a computing device that automatically adjusts one or more operating parameters of the automated machine.

A take away conveyance can be disposed adjacent to an outlet of the vertical accumulation chamber. The take away conveyance can define a plurality of scallops to cradle the cylindrical product in side-by-side arrangement as the cylindrical product exits the vertical accumulation chamber.

The disclosure also includes a method of operating an automated machine to organize and feed cylindrical products. A speed of a conveyor can be varied to impart spacing between individual cylindrical products as the cylindrical products are introduced to the conveyor. The cylindrical products can be passed longitudinally across a gap defined between a pair of rollers such that a small diameter end of the cylindrical products can pass through the gap but an opposing larger end of the cylindrical products cannot pass through the gap, thereby allowing each individual cylindrical product to freely swing as it travels along the gap. A miter wheel can be rotated to transfer cylindrical products from the pair of rollers to a vertical accumulation chamber while changing the orientation of the cylindrical products from a vertical alignment to a horizontal alignment.

A drive flange of a motor can be coupled to the miter wheel via a magnetic holding clamp. The magnetic attraction force between the magnetic holding clamp and the drive can be such that there is no slippage of the miter wheel in normal running conditions, but slippage will occur in the event of a jam condition encountered by the miter wheel. A rotating control knob can be disposed atop the magnetic holding clamp to decouple the drive flange from the miter wheel.

The cylindrical products can be passed through a restriction prior to the cylindrical products reaching the pair of rollers. The constriction can be sized and shaped such that the cylindrical products falling within a predetermined dimensional range pass through the constriction and are accelerated ahead by an air jet provided to the constriction while cylindrical products that are larger than the predetermined dimensional range are stopped by the constriction.

The cylindrical products can be passed from the vertical accumulation chamber to a take away conveyance disposed adjacent to an outlet of the vertical accumulation chamber. The take away conveyance can define a plurality of scallops to cradle the cylindrical product in side-by-side arrangement as the cylindrical product exits the vertical accumulation chamber.

The above summary is not intended to limit the scope of the invention, or describe each embodiment, aspect, implementation, feature or advantage of the invention. The detailed technology and preferred embodiments for the subject invention are described in the following paragraphs accompanying the appended drawings for people skilled in this field to well appreciate the features of the claimed invention. It is understood that the features mentioned hereinbefore and those to be commented on hereinafter may be used not only in the specified combinations, but also in other combinations or in isolation, without departing from the scope of the claims.

While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular example embodiments described. On the contrary, the invention is to cover all modifications, equivalents, and alternatives falling within the scope of the invention as defined by the appended claims.

In the following descriptions, the present invention will be explained with reference to various exemplary embodiments. Nevertheless, these embodiments are not intended to limit the present invention to any specific example, environment, application, or particular implementation described herein. Therefore, descriptions of these example embodiments are only provided for purpose of illustration rather than to limit the present invention. It is understood that the various features and aspects discussed herein may be used in any combination, or in isolation, without departing from the scope of the claims.

An automated machine <NUM> for organizing and feeding cylindrical products will now be described with reference to <FIG>. The machine description will correspond to the method or process by which the cylindrical objects pass through the machine as they proceed from bulk supply to the take away conveyance.

The cylindrical products (P) illustrated in the figures are bullet-type ammunition. However, other generally-cylindrical shaped products can also be handled by the disclosed machine because various shapes and sizes of components can be varied in order to adapt the machine to the alternate products.

The products P to be processed are first loaded in bulk into the hopper <NUM>. The hopper is shown in many of the figures and particularly in <FIG>.

The products are then metered into a singulation device connected to the hopper. The product outputs from the singulation device along a conveyor <NUM> (e.g., <FIG>) such that the average output rate meets the operator's set output speed requirement. However, the instantaneous output rate varies above and below the set output rate.

The products P next side transfer from the singulation device onto the conveyor <NUM> which is operated with a conveyor surface speed slightly faster than that of the output of the singulation device. This relatively faster conveyor speed results in a gap being between each product. The products P being moved along the conveyor <NUM> are all arranged in a single file orientation as can be seen in <FIG>, with some products oriented such that their large end is leading and some products oriented oppositely such that their small end is leading.

The products complete their journey along the conveyor <NUM> and enter a constriction <NUM> at the discharge of the transfer conveyor <NUM>. Properly sized products pass thru this constriction and are accelerated ahead by air jets within the constriction. Products that are too large or that are misshapen to pass through the construction are stopped by the constriction and are automatically removed from the line by the machine.

The products P successfully passing through the restriction <NUM> next transfer to a chute <NUM> which includes air jets from the bottom of the chute which act as air bearings for the cute to provide free flow of product.

The products P then transfer from the chute <NUM> to gap defined between a pair of elongated rollers <NUM>. These rollers spin in opposing directions at identical speeds. The rollers are mounted such that their longitudinal axis extends at a downward angle to define a sloped path such as can be appreciated from <FIG>. The gap dimension between the rollers <NUM> is finely adjusted so that the small diameter end of the product P can pass between the rollers but the large diameter end cannot.

The aforementioned spacing between consecutive products proceeding through the roller section <NUM> is useful to allow each individual product to freely swing as it travels along the rollers so that the small end of the product is facing downward as the product proceeds forward in the gap between the rollers. The combination of the upward rotation of the rollers and the downward inclination (slope) of the rollers propels the product toward a discharge end <NUM> of the roller section <NUM>.

The now consistently-oriented products traveling across the rollers surge against one another at the discharge end <NUM>. The rollers are of a sufficient length to allow the upstream end of the product queue to move upstream and downstream in response to a varying discharge rate of the singulation device. This provides a buffer between the variable input rate and the constant discharge rate of the roller assembly <NUM>.

Flow of product P into and out of the various stages of the machine <NUM> is monitored by a plurality of optical sensors <NUM>. These sensors are coupled to computer controls that automatically adjust machine operating parameters, such as conveyor speed for example, to ensure maximized consistent flow of product through the machine <NUM>.

The products P next transfer from the rollers <NUM> into individual pockets <NUM> formed in the perimeter of a miter wheel assembly <NUM>. The miter wheel <NUM> rotates at a fixed speed to carry product from the roller assembly <NUM> to an accumulation device. The form of the wheel <NUM> is a truncated cone as can be seen best in <FIG> and <FIG>. The cone angle is such that the surface of the pockets is oriented parallel to the product axis at the transition from the roller assembly <NUM> and oriented horizontal at the discharge position <NUM>° in rotation opposite the intake point. The product P is carried through the miter wheel <NUM> assembly at a constant rate.

The miter wheel <NUM> is coupled to the drive flange of a motor <NUM> via magnetic holding clamps <NUM>. The magnetic attraction force between the drive flange and the magnetic holding clamps <NUM> is applied or removed by rotating the control knobs <NUM> atop the clamps <NUM>. The magnetic attractive force between the friction surfaces on the miter wheel <NUM> and on the drive flange results in sufficient torque being transferred to rotate the miter wheel <NUM> in normal running conditions, but slippage will occur in the event of a jam condition. Thus the magnetic holding clamps <NUM> provide both a convenient miter wheel mounting means as well as overload/jam protection.

The products P next transfer from the miter wheel assembly <NUM> to the input of a vertical accumulation chamber <NUM> (e.g., <FIG> and <FIG>). The product path <NUM> through the vertical accumulation chamber is zig-zag and along the vertical axis and laid out so that product's axis cannot rotate beyond approximately <NUM>° from horizontal, thus providing smooth product flow and maintaining consistent product orientation. The product path through the vertical accumulation chamber <NUM> is of a length that allows the upstream end of the product queue to move upstream and downstream in response to varying rate of the take away device <NUM>.

Flow of product into and out of the vertical accumulation chamber <NUM> is also controlled by level monitoring optical sensors <NUM> coupled to the machine's computer control system.

Product is transferred from the vertical accumulation chamber to a scalloped take away conveyance <NUM> (e.g., <FIG> and <FIG>) and which moves regularly in a move and dwell fashion under the output of the accumulation chamber <NUM>. Product is removed from the accumulation chamber <NUM> when the take away conveyance <NUM> is in motion. The take away conveyance <NUM> can define a series of side-by-side channels <NUM> to prevent the product P from changing orientations and to keep a consistent spacing.

The device and method described herein advantageously control product movement in each of the elements of the device. The device is tolerant of product to product variation and does not dependent on tightly toleranced features. The machine features establish and maintain correct product orientation and minimize the likelihood of jams. The machine and method are thus able to be run at far higher product output speeds (e.g. <NUM>-<NUM> products per minute) than conventional systems.

Claim 1:
An automated machine for organizing and feeding cylindrical products, comprising:
a hopper (<NUM>) with a singulation device disposed downstream of the hopper (<NUM>);
a conveyor (<NUM>) disposed downstream of the hopper (<NUM>) and the singulation device;
a pair of elongated rollers (<NUM>) disposed downstream from the conveyor (<NUM>),
wherein the pair of rollers (<NUM>) define a gap dimension laterally between the pair of rollers, wherein the gap dimension laterally between the pair of rollers (<NUM>) is such that a small diameter end of the cylindrical products (P) can pass through the gap but an opposing larger end of the cylindrical products (P) cannot pass through the gap, thereby allowing each individual cylindrical product (P) to freely swing as it travels along the rollers (<NUM>) so that the small end is facing downward as the product (P) proceeds forward longitudinally along the pair of rollers (<NUM>);
characterized in that:
a miter wheel (<NUM>) is disposed downstream of the pair of elongated rollers (<NUM>) in order to change the orientation of the cylindrical products from a vertical alignment to a horizontal alignment; and
a vertical accumulation chamber (<NUM>) is positioned to receive a plurality of the cylindrical products that exit the miter wheel (<NUM>), wherein the vertical accumulation chamber (<NUM>) includes an outlet.