Patent Description:
Feed systems for bulk objects such as fasteners are common in fixed automation processes. However, such systems are often hard-tooled only for a specific type of fastener and are inflexible.

Flexible feeding systems are relatively new to the market with the aim of providing enhanced flexibility in properly orienting and picking objects such as fasteners. Typically such systems include an external hopper for bulk storage of the objects, a vibration table that receives a quantity of the bulk objects from the hopper and uses vibration to orient and/or singulate the objects, and a vision-guided system including a robot that locates and picks the objects from the table one at a time.

<CIT> discloses a method and apparatus for aligning and conveying small articles such as rivets, bolts, screws and the like. A table is mounted on a frame for reciprocable movement in a generally horizontal direction, said table having a plurality of longitudinally extending grooves therein adapted to receive at least a part of the articles being aligned and conveyed in the desired position. A roller is rotatably mounted above said table with the axis of rotation extending at right angles across said grooves with the surface of said roller being spaced from the grooved surface of said table a distance such that only articles properly positioned in said grooves can pass beneath said roller. While the table is rotated with the peripheral surface of the roller adjacent the grooved surface of the table moving in a direction opposite to the desired conveying direction to impel articles not in the grooves backwards on the table.

At least one problem with conventional flexible feeding systems of the type described above is that misoriented and oriented objects are often commingled together on the vibration table, which can obstruct the robot from picking up only the oriented objects. In addition, such conventional systems require complicated external vision-guided systems and algorithms for locating and picking only the objects that are properly oriented amid the other misoriented objects.

An aspect of the present invention provides a flexible feeding system that segregates oriented objects from misoriented objects, and singulates the oriented objects for improving the picking of the objects.

The present invention provides a flexible feeding system comprising: a multi-directional vibratory platform; a tray operatively coupled to the vibratory platform, the tray comprising: a bulk region configured to contain a plurality of objects in bulk form; an orienting region having one or more orienting slots configured to orient one or more of the objects within each of the one or more slots; and a divider that separates the orienting region from a singulating region of the tray; wherein the one or more orienting slots extend across the divider from the orienting region into the singulating region of the tray; wherein the divider includes one or more openings that correspond with the one or more orienting slots, the one or more openings being configured to permit the objects which are oriented and singulated in series in the one or more orienting slots to pass across the divider into the singulating region, and the divider being configured to restrict the objects which are misoriented in the orienting region from passing across the divider into the singulating region; wherein the tray further includes a pick region downstream of the singulating region; wherein the one or more orienting slots extend through the singulating region to the pick region; and wherein the pick region includes one or more one-way stops that correspond with each of the one or more orienting slots, the one or more one-way stops being configured to permit the objects which are oriented in the one or more orienting slots to pass across the respective one-way stops in a downstream direction, and to restrict said objects from passing back across the one-way stop in an opposite upstream direction.

Preferred embodiments are stated in the dependent claims.

Preferably, the one or more orienting slots are configured to receive a lower portion of each of the objects when oriented, such that an upper portion of each of the objects which are oriented protrudes above the one or more orienting slots; and wherein each of the one or more openings of the divider are configured to permit the upper portions of the objects which are oriented in the one or more orienting slots to pass across the divider.

Preferably, the one or more orienting slots are formed as recesses in a support surface of the tray, the one or more orienting slots being configured to receive the lower portion of each of the objects which are oriented, and the support surface being configured to support the upper portion of each of the objects which are oriented.

According to an embodiment of any paragraph(s) of this summary, a width of each of the one or more openings is wider than a width of each the corresponding one or more orienting slots.

Preferably, the divider is fixed in position relative to the orienting region.

Preferably, any paragraph(s) of this summary, the bulk region is recessed in the tray at a lower elevation than the orienting region.

Preferably, the tray further includes a feed region connecting the bulk region to the orienting region, the feed region being upwardly inclined from the bulk region to the orienting region.

Preferably, the orienting region includes a ledge between the one or more orienting slots and the bulk region, such the objects which are misoriented can move toward the bulk region and pass over the ledge to fall into the bulk region.

Preferably, the pick region includes one or more recessed areas that correspond with each of the one or more orienting slots, the one or more recessed areas being at an elevation below an elevation of the singulating region, and wherein the one or more recessed areas form respective one or more ledges that define the one or more one-way stops; and wherein each of the one or more recessed areas has an axial length along each of the one or more slots that is sufficient to contain only a single one of the objects in each of the one or more slots.

Preferably, the tray is removable from the vibratory platform; and wherein the tray has a fastener configured to be received in a receiver of the vibratory platform to secure the tray to the vibratory platform; or the tray has a receiver configured to receive a fastener of the vibratory platform to secure the tray to the vibratory platform.

Preferably, the multi-directional vibratory platform is operatively coupled to a controller that is configured to drive one or more actuators of the vibratory platform that causes movement of the objects from the bulk region downstream to the orienting region and across the divider into the singulating region.

The present invention also provides a tray for being operatively coupled to a vibratory platform of a flexible feeding system, the tray comprising: an orienting region configured to receive a plurality of unoriented objects, the orienting region having one or more orienting slots configured to orient one or more of the unoriented objects within each of the one or more slots; a divider that separates the orienting region from a singulating region of the tray; wherein the one or more orienting slots extend beyond the divider from the orienting region into the singulating region of the tray; wherein the divider includes one or more openings that correspond with the one or more orienting slots, the one or more openings being configured to permit the objects which are oriented in the one or more slots to pass across the divider into the singulating region, and the divider being configured to restrict the objects which are unoriented in the orienting region from passing across the divider into the singulating region; wherein the tray further includes a pick region downstream of the singulating region; wherein the one or more orienting slots extend through the singulating region to the pick region; and wherein the pick region includes one or more one-way stops that correspond with each of the one or more orienting slots, the one or more one-way stops being configured to permit the objects which are oriented in the one or more orienting slots to pass across the respective one-way stops in a downstream direction, and to restrict said objects from passing back across the one-way stop in an opposite upstream direction.

Preferably, the one or more orienting slots are configured to orient and singulate the objects in series within each of the one or more orienting slots, and are configured to guide the objects which are oriented and singulated in series along each of the one or more orienting slots across the divider into the singulating region.

The tray further includes a pick region downstream of the singulating region, and the one or more orienting slots extend through the singulating region to the pick region; and preferably the pick region includes one or more recessed areas that correspond with each of the one or more orienting slots, each of the one or more recessed areas forming opposing abutments along each of the one or more orienting slots, the respective opposing abutments being configured to contain only a single one of the objects in each of the one or more orienting slots.

The present invention also provides a method for singulating objects from bulk includes: disposing a plurality of objects in a bulk region of a tray that is operatively coupled to a vibratory platform; driving one or more actuators of the vibratory platform to move the objects on the tray, the driving the one or more actuators including the steps of: driving the one or more actuators in a direction that causes the objects to move from the bulk region of the tray to an orienting region of the tray having one or more orienting slots, such that one or more of the objects orient in the one or more orienting slots; driving the one or more actuators in a direction that causes the objects to move toward a divider that separates the orienting region from a singulating region of the tray, wherein the divider permits the objects which are oriented in the one or more orienting slots to pass across the divider into the singulating region, and wherein the divider restricts the objects which are misoriented in the orienting region from passing across the divider into the singulating region; and driving the one or more actuators in a direction that causes the objects to move toward a pick region of the tray; wherein the one or more orienting slots extend through the singulating region to the pick region, the pick region including one or more one-way stops that correspond with each of the one or more orienting slots, the one or more one-way stops being configured to permit the objects which are oriented in the one or more orienting slots to pass across the respective one-way stops in a downstream direction, and to restrict said objects from passing back across the one-way stop in an opposite upstream direction; and the method further comprising: moving the objects beyond the one or more one-way stops to confine respective ones of the objects in each of the one or more orienting slots at predetermined locations in the pick region.

Preferably, after the objects enter the orienting region, the method further including a step of: moving the objects in a direction opposite the direction toward the divider, such that the objects which are not in the slots are caused to move over a ledge and fall into the bulk region.

Preferably, the method further includes a step of: using a robot to pick the objects when they have reached the pick region.

Preferably, the method further includes a step of: using a sensor to count the number of the objects in at least one region of the tray, and feeding additional objects onto the tray when the number of the objects on the tray is below a predetermined number.

The following description and the annexed drawings set forth certain illustrative embodiments of the invention. Other objects, advantages and novel features according to aspects of the invention will become apparent from the following detailed description when considered in conjunction with the drawings.

The principles and aspects of the present invention have particular application to flexible feeding systems such as for use with fasteners in an assembly process, and thus will be described below chiefly in this context. It is understood, however, that principles and aspects according to the present invention may be applicable to other flexible feeding systems for other types of objects, such as where it is desirable to improve singulation of bulk objects by segregating oriented objects from misoriented objects.

Referring initially to <FIG> and <FIG>, an exemplary flexible feeding system <NUM> is shown including a multi-directional vibratory device <NUM> and an exemplary tray <NUM> operatively coupled in vibratory communication with the vibratory device <NUM>. As shown, the tray <NUM> generally includes a bulk region <NUM> configured to contain a plurality of objects in bulk form, an orienting region <NUM> having one or more orienting slots <NUM> configured to orient one or more of the objects within each of the one or more slots, and a divider <NUM> that separates the orienting region <NUM> from a singulating region <NUM> of the tray <NUM>. As described in further detail below, the one or more orienting slots <NUM> extend across the divider <NUM> from the orienting region <NUM> into the singulating region <NUM> of the tray, and the divider <NUM> is configured to permit objects that are oriented in the slots <NUM> to pass to the singulating region <NUM> while restricting objects that are misoriented from passing thereacross. In this manner, the divider <NUM> segregates objects that are oriented from objects that are misoriented, thereby facilitating singulation of the objects and improving presentation of the objects for being picked from the tray <NUM>.

In preferred embodiments, the flexible feeding system <NUM> may be utilized in a manufacturing process, such as in an assembly process that utilizes the objects in an assembly. For example, the objects may be fasteners, such as screws, bolts, or the like, in which it is desirable to locate and pick the objects quickly and precisely for increasing efficiency in the manufacturing process. The exemplary flexible feeding system <NUM> thus provides a manufacturing solution at the point of assembly that can be provided quickly and inexpensively. In addition, the tray <NUM> may be removable or reconfigurable to accommodate production changes, such as when there is a need to different types of fasteners, for example. To facilitate quick changeover of the tray, the tray <NUM> may include a receiver <NUM>, such as a catch or other suitable receiver, that is configured to receive a corresponding fastener <NUM>, such as a latch or other suitable fastener, of the vibratory platform <NUM>. Alternatively, the tray <NUM> may include the fastener and the vibratory platform <NUM> may include the receiver.

As shown, the tray <NUM> includes upright sidewalls <NUM> that contain the objects to inside of the tray. Also as shown, the different parts of the exemplary tray <NUM> may be fixed in position relative to each other with no moving parts. Instead, the system <NUM> may use vibration caused by the vibratory device <NUM> to move the objects across the different fixed regions of the tray <NUM>, as will be described in further detail below.

In preferred embodiments, the vibratory device <NUM> includes a vibratory platform <NUM> having a plurality of vibration generators (e.g., vibrators or actuators) (not shown) that provide two, three, four, five or six degree of freedom functionality. For example, the vibration generators may be capable of vibrating the tray <NUM> in one of three directions (x, y, z), and/or also may be capable of vibrating the tray <NUM> in directions corresponding to any combination of the three directions x, y and z. Each of the vibrating actuators may include a stationary element mounted on a frame (not shown), in which a vibrating element of the actuator is movably mounted relative to the stationary element and connected to a vibrating support. Preferably, the vibration generator is of the piezoelectric, electromagnetic, pneumatic or hydraulic type. In addition, the system may include a power source <NUM> and a controller <NUM> (shown schematically in <FIG>) which is configured to control the vibration generators with a frequency, amplitude and/or desired direction. An example of such a vibratory device is described in further detail in <CIT>, which is incorporated herein by reference in its entirety.

Referring to <FIG>, the bulk region <NUM> of the tray is configured to contain the objects in bulk form (e.g., in a relatively large quantity with no particular orientation, as shown with exemplary reference to the objects "S," for example). In such embodiments, providing the bulk region <NUM> within the walls <NUM> of the tray <NUM> may reduce or eliminate the need for an external hopper for feeding objects S to the tray. Instead, a bulk quantity of such objects S for use with a desired number of assembly units all may be contained within a single tray <NUM>, for example. It is understood, however, that in some embodiments an external hopper may be utilized with the tray <NUM> for feeding objects S to the bulk region <NUM> and/or directly feeding the orienting region <NUM>, as may be desirable for particular applications.

As shown in the illustrated embodiment, the bulk region <NUM> may be recessed below one or more of the other regions of the tray <NUM>, and may be at the lowest elevation of the tray <NUM>. Such recessing of the bulk region <NUM> may enable the objects S to be gravity fed back into the bulk region <NUM>, such as when the vibrational movement from the vibratory device <NUM> is terminated. Alternatively or additionally, such recessing of the bulk region <NUM> may facilitate clearing away of misoriented objects from the orienting region <NUM>, as will be discussed in further detail below. In addition, the recessing of the bulk region <NUM> may help to restrict easy travel of the objects to the orienting region <NUM> absent specific vibration instructions, which may help to prevent the objects from crowding into the orienting region <NUM>. Preferably, the bulk region <NUM> may be devoid of recesses, protrusions or other surface effects that could otherwise impede the flow of the objects from the bulk region <NUM>. It is understood, however, that in some embodiments the bulk region <NUM> may be on the same plane as the other regions, and/or the one or more actuator(s) (e.g., vibrators) of the vibratory platform <NUM> may drive the objects S back toward the bulk region <NUM>.

Referring particularly to <FIG>, the tray <NUM> may further include a feed region <NUM> that is interposed between the bulk region <NUM> and the orienting region <NUM> to facilitate movement of the objects therebetween. As shown, the feed region <NUM> may be configured as a channel that is separated from the bulk region <NUM>, and is configured to allow the objects S to traverse in a downstream direction from the bulk region <NUM> to the orienting region <NUM>. In preferred embodiments, the feed region <NUM> may be relatively narrow compared to the bulk region <NUM> to thereby serve as a fixed restriction portion of the tray that may help to meter and/or regulate the flow of objects toward the orienting region <NUM>. The feed region <NUM> also may include at least one separation wall <NUM> that extends upright to separate the feed region <NUM> from the bulk region <NUM> to prevent the objects from easily falling back into the bulk region.

As shown in the cross-sectional view of <FIG>, the feed region <NUM> may include one or more inclined surfaces <NUM>, <NUM> that are inclined upwardly from the recessed bulk region <NUM> to the elevated orienting region <NUM>. In addition, one or more level landings <NUM> may be provided between inclined surfaces <NUM> and <NUM>, such as where the feed region <NUM> changes direction. As shown in <FIG>, for example, the vibrational motion provided by the vibratory platform <NUM> is configured to impart sufficient motion to the objects S such that they can traverse up the inclined surface(s) <NUM>, <NUM> to the orienting region <NUM>. Such vibrational motion may be modified in the controller <NUM>, for example, depending on the weight, shape and other factors of the objects. The inclined surface(s) <NUM>, <NUM> also facilitate gravity feeding of the objects back toward the bulk region <NUM>, such as when the vibrational motion is terminated.

Referring to <FIG>, the objects S are shown exiting the feed region <NUM> and entering into the orienting region <NUM> of the tray. In the illustrated embodiment, the orienting region <NUM> extends in a transverse direction to the direction of the adjacent feed region <NUM>. As such, the vibration profile provided by the vibratory platform <NUM> and/or the controller <NUM> may change the vibration direction to direct the objects S across the one or more orienting slots <NUM> in the orienting region <NUM> (e.g., direct the objects S in the -X direction in the illustrated embodiment).

As the objects S are passed over the orienting slots <NUM>, the objects may fall into the slots <NUM> in a particular desired orientation, thereby orienting one or more of the objects within each of the one or more slots <NUM>. It is understood that the particular orientation of the objects S in the orienting slots <NUM> may be based on the shape of the object S and the configuration of the slot <NUM>. For example, in exemplary embodiments the width WS of each slot <NUM> (shown in <FIG>, for example) is sufficient to allow only a single object to be oriented at each axial position of the slot, such that multiple ones of the objects are oriented and singulated in series in the slot <NUM> (as shown with oriented objects "SO" in <FIG>, for example).

Referring particularly to the cross-sectional view in <FIG>, the orienting region <NUM> includes a support surface <NUM> with the one or more slots <NUM> being recessed into the support surface <NUM>. In this manner, the one or more slots <NUM> are configured to receive a lower portion L of the oriented object SO, and the support surface <NUM> is configured to support the upper portion U of the oriented object SO. In the illustrated embodiment, for example, the objects S are elongated fasteners having a wider head portion (e.g., upper portion U) and a narrower shank portion (e.g., lower portion L), and the width WS of the orienting slot <NUM> allows the fastener to be oriented in a desired direction with the head side up (as shown). The support surface <NUM> supports the upper portion U of the oriented object SO, and the narrower slot <NUM> guides the oriented object SO downstream through the divider <NUM> (discussed further below). It is understood that the particular configuration of the slots <NUM> and the types of objects S shown in the illustrated embodiment are exemplary, and other slot configurations and/or fasteners may be utilized with the exemplary tray <NUM> as would be understood by those having ordinary skill in the art.

Referring again to <FIG>, it is noted that as the objects S are entering into the orienting region <NUM> from the feed region <NUM>, the orienting region <NUM> may contain both oriented objects SO (in the slots <NUM>) and misoriented objects SM (not in the slots <NUM>). In some cases, because the oriented SO and misoriented SM objects are comingled together in the orienting region <NUM>, the misoriented objects SM may create a crowded mass that blocks or obstructs the objects from being oriented in the slots <NUM> and/or from passing through the divider <NUM>, thus creating a so-called log jam. As such, it may be desirable to clear at least some of the misoriented objects SM away from the orienting region <NUM> after a period of time.

To facilitate such clearing away of at least some of the misoriented objects SM, the orienting region <NUM> may include a ledge portion <NUM> between the orienting slots <NUM> and the bulk region <NUM>, which allows the misoriented objects SM that are not contained in the slots <NUM> to fall back into the recessed bulk region <NUM> for refeeding. For example, as shown in <FIG>, the vibration direction is reversed (e.g., in the -Y direction in the illustration) after a predetermined period of time to cause the misoriented objects SM to pass over the ledge portion <NUM> and fall back into the bulk region <NUM>. As shown, the reversal of the oriented objects SO in the slots <NUM> will reach the upstream end of the slot <NUM> and will be contained in the slot, while the misoriented objects SM fall off of the ledge portion <NUM>. Alternatively or additionally, the vibration profile may direct the misoriented objects back through the feed region <NUM>.

As noted above and shown in <FIG>, because the orienting region <NUM> may contain both misoriented objects SM and oriented objects SO, the divider <NUM> is configured to segregate the oriented objects SO from the misoriented objects SM by allowing the oriented objects SO in the slots <NUM> to pass across the divider <NUM> into the singulating region <NUM>, while confining the misoriented objects SM (not in the slots) to the orienting region <NUM>. In exemplary embodiments, the divider <NUM> is formed as a wall or plate that is fixed in position, and which may be unitary with or attached to the tray <NUM>. It is understood that the particular configuration of the divider <NUM> shown in the illustrated embodiment is exemplary, and other suitable dividers may be utilized as would be understood by those having ordinary skill in the art.

As shown in the illustrated embodiment with particular reference to <FIG> and <FIG>, the divider <NUM> includes one or more openings <NUM> that correspond with the one or more orienting slots <NUM>. The openings <NUM> are configured to permit the objects which are oriented and singulated in series in the slots <NUM> to pass across the divider <NUM> into the singulating region <NUM>. On the other hand, the portions of the divider <NUM> surrounding the openings <NUM> restrict the objects that are misoriented from passing into the singulating region <NUM>. In this manner, the oriented and singulated objects SO are segregated on one side of the divider <NUM> from the misoriented objects SM on the opposite side of the divider.

As discussed above and shown in <FIG>, the orienting slots <NUM> may be configured to receive the lower portion L of each of the oriented objects SO such that the upper portion U the objects protrudes above the support surface <NUM> having the slots <NUM>. As such, the openings <NUM> of the divider <NUM> are configured to permit the respective upper portions U of the oriented objects SO to pass across the divider <NUM> while the lower portions L passes along the respective slots <NUM> extending under the divider <NUM>. In this manner, the cross-sectional shape of the passage defined by the divider opening <NUM> and slot <NUM> generally corresponds with the cross-sectional shape of the object, although slightly enlarged to allow the object to pass therethrough. As shown in the illustrated embodiment, for example, the objects SO may be elongated with a head portion (e.g., upper portion U) and a shank portion e.g., lower portion L), such as a bolt, screw, or the like. As such, the openings <NUM> of the divider <NUM> may be configured with a width WO that is wider than the width WS of the slot <NUM> to correspond with the cross-sectional shape of the object so that the head portion (e.g., upper portion U) passes through the divider opening <NUM> while the shank portion (e.g., lower portion L) passes within the slot <NUM> below the opening <NUM>. The height of the opening <NUM> above the upper support surface <NUM> also is higher than the height that the upper portion U (e.g., head) of the object protrudes above the support surface <NUM>. In exemplary embodiments, the openings <NUM> of the divider <NUM> are completely enclosed by the other portions of the divider <NUM> and the upper support surface <NUM> of the tray to further mitigate the possibility of misoriented objects from passing across the divider <NUM>.

Referring particularly to <FIG>, the orienting slots <NUM> of the orienting region <NUM> extend downstream beyond the divider <NUM> into the singulating region <NUM> of the tray. In this manner, the oriented objects SO (e.g., heads up) and singulated in series (e.g., in line) may advance downstream of the divider <NUM> along the respective slots <NUM> toward a pick region <NUM> of the tray. In exemplary embodiments, one or more of the slots <NUM> may have a downstream segment <NUM> that is angled relative to an upstream segment of the slot <NUM>. Such angling of the slots <NUM> may reduce movement of the oriented objects SO in the -Y direction, such as when the vibration direction is reversed to cause the misoriented objects SM to pass over the ledge portion <NUM> and fall back into the bulk region <NUM>. For example, with the angled slots <NUM> the vibration direction may be actuated in the -X and -Y directions resulting in minimal displacement of the oriented objects SO in the slots <NUM> during return of the misoriented objects SM to the bulk region <NUM>. Such angling also may help to minimize the singulated objects in the pick region <NUM> from being displaced. It is understood that although the tray <NUM> is shown with both straight and angled slots <NUM>, some or all of the slots <NUM> may be angled, or some or all of the slots <NUM> may be straight.

In the illustrated embodiment, the pick region <NUM> is located at a downstream end portion of the slots <NUM>, and is configured to facilitate picking of the objects SO at predetermined locations along the slots. To facilitate such positioning of the oriented and singulated objects SO at the predetermined locations along the slots <NUM>, the pick region <NUM> includes one or more one-way stops <NUM> at the respective end portions of each slot <NUM>. The one-way stops <NUM> are configured to allow the oriented objects SO to pass across the stop <NUM> in one direction (e.g., the +Y direction in the illustration), but to restrict the objects SO from moving back across the stop in the opposite direction (e.g., the -Y direction in the illustration).

Referring to <FIG>, for example, the one-way stops <NUM> may be formed by a recessed portion <NUM> that extends transversely across the slots <NUM> in the pick region <NUM> of the tray. In such a configuration, the recessed portion <NUM> of the pick region <NUM> may have a support surface <NUM> at an elevation below the support surface <NUM> of the singulating region <NUM> and/or orienting region <NUM>, thereby forming a ledge <NUM> that allows the objects to fall into the recessed portion <NUM>. The ledge <NUM> serves as an upstream abutment that restricts the objects from movement in the reverse direction (e.g., to the higher elevation upstream of the ledge <NUM>).

In preferred embodiments, the pick region <NUM> may be a relatively narrow portion in the axial direction along the slots <NUM>, and each slot <NUM> may have opposing abutments (e.g., the ledge <NUM> and the end <NUM> of the slot) that confine only a single object SS to the predetermined location along each slot <NUM>. Such a configuration provides for improved presentation, singulation and orientation of the object SS in each slot <NUM> for picking by the operator or an automated device (e.g., robot), for example. In addition, as shown in <FIG>, to further facilitate a clean pick of the singulated object SS, the other oriented objects SO next in line in each slot <NUM> may be moved upstream away from the respectively contained and singulated object(s) SS in the pick region <NUM> of each slot <NUM> (e.g., in the -Y direction in the illustration) to increase the clearance of the singulated object SS to be picked by the picking tool <NUM>.

Referring to the flowchart in <FIG>, method <NUM> of operating the exemplary flexible feeding system <NUM> is shown. At step <NUM>, the process may begin by providing the exemplary tray <NUM> on the vibratory platform <NUM>, such as with the objects S in bulk form (as illustrated in <FIG>, for example).

At steps <NUM>-<NUM>, the one or more actuator(s) (e.g., vibrators) of the vibratory platform <NUM> drive the objects S in particular directions along the tray <NUM>. It is understood that the controller <NUM> of the flexible feeding system <NUM> may be configured to implement one or more of these steps of the process <NUM> with specifically programmed instructions for driving the actuator(s), as would be understood by those having ordinary skill in the art.

At step <NUM>, the system <NUM> drives the actuator(s) in a direction that causes the objects to move from a bulk region of the tray toward an orienting region of the tray. As shown in <FIG>, for example, the actuator(s) cause movement of the objects to the right in the illustration (in the +X direction), and upwards in the illustration (in the +Y direction), such that the objects S move up the inclined feed region <NUM> of the tray.

At step <NUM>, the system <NUM> drives the actuator(s) in a direction that causes the objects S to move across the orienting slots <NUM>. As shown in <FIG>, for example, the actuator(s) cause movement of the objects S to the left in the illustration (in the -X direction) and/or with some movement toward the divider <NUM> (in the +Y direction). As discussed above, such movement causes some of the objects SO to orient in the orienting slots <NUM>.

Optionally at step <NUM>, the system <NUM> drives the actuator(s) in a direction that causes the objects to move away from the divider, such as to clear obstructions. As shown in <FIG>, for example, the actuator(s) cause movement of the objects downward in the illustration (in the -Y direction). As discussed above, such a step may involve causing the misoriented objects SM to be fed back into the bulk region <NUM>, such as by falling off of the ledge <NUM> between the orienting slots <NUM> and bulk region <NUM>.

At step <NUM>, the system <NUM> drives the actuator(s) in a direction that causes the objects to move toward the divider <NUM>, such as to segregate oriented objects SO from misoriented objects SM, and to advance the oriented objects SO downstream toward the pick region <NUM>. As shown in <FIG>, for example, the actuator(s) cause such movement upwards in the illustration (in the +Y direction).

At step <NUM>, the system <NUM> continues to drive the actuator(s) in the direction that causes the oriented objects SO to move downstream within the slots <NUM> to the pick region <NUM> (e.g., upwards, or in the +Y direction, as shown in <FIG>). The actuator(s) may be driven to continue such movement for a predetermined period of time.

Optionally at step <NUM>, the system <NUM> drives the actuator(s) in a direction away from the pick region <NUM>, such as to clear the oriented objects SO next in line away from the singulated object SS to be picked. As shown in <FIG>, for example, the actuator(s) cause such movement downwards in the illustration (in the -Y direction).

At step <NUM>, one of the objects singulated and oriented in the pick region is picked, such as by an operator or robot with a tool (as shown in <FIG>, for example). The picking tool <NUM> may be a vacuum-enabled suction tool, a pneumatically-actuated gripper tool, a magnetic tool, or any other suitable tool for picking the object. In exemplary embodiments, the system <NUM> does not require vision guidance to locate and pick the objects because the objects are located at predetermined locations in the pick region <NUM>, as discussed above. However, in some embodiments, a vision-guided system may be utilized to facilitate locating and picking the objects.

Optionally, prior to step <NUM>, for automated systems, the system could use a sensor (laser, camera, inductive, etc.) to detect the presence of an object at the pick region <NUM> of a given slot <NUM> to instruct a robot to pick. Alternatively, the robot could blindly go to the location for picking the object via predetermined instructions, and the sensor could be on the pick tooling (vacuum switch, gripper stroke sensor, etc.) to verify that a part was picked. If no object is present to be picked, the robot could then move on to the next slot <NUM>. If all slots <NUM> are empty, the system <NUM> could instruct an action, such as advancing the objects in the slots <NUM>, or run a full recirculation of the objects from the bulk region <NUM> to the pick region <NUM>.

As shown, after step <NUM>, the process may then repeat to continue to feed the objects from the bulk region <NUM> to the pick region <NUM> for picking the objects from the tray <NUM>. Alternatively, before looping to step <NUM> from step <NUM>, the method may loop within step <NUM> without driving objects on the tray such that the objects in each slot <NUM> are picked in the pick region <NUM>. Optionally, after all singulated objects SS are picked in the pick region <NUM> of the slots, the method could loop to step <NUM> to advance the already oriented objects SO in the slots <NUM> to the pick region <NUM> until no singulated objects remain, and then loop back to step <NUM>.

Preferably, the system <NUM> may further include a sensor (such as a vision or weight sensor) that is configured to count the number of objects on the tray, and then provide instructions to feed additional objects into the bulk region <NUM> when the number of objects is below a predetermined number. It is understood that in some embodiments, such as the vision-guided system for counting objects, the bulk objects may be contained in an external hopper that feeds the orienting region <NUM> directly with the objects. In such an embodiment, the inclined feed region <NUM> and/or the bulk region <NUM> may be eliminated, or may be considered coextensive with the orienting region <NUM> having the orienting slots <NUM>. Moreover, in such an embodiment, the controller <NUM> may be programmed with the same or different instructions (e.g., steps <NUM>-<NUM>) to drive the actuator(s) to cause the objects to move across the divider <NUM> toward the pick region <NUM> of the tray. For example, the system may include sensors that monitors the locations of the objects on the tray and carries out one or more of the foregoing steps <NUM>-<NUM> in any sequence based upon a determination of the location of the objects on the tray.

For example, an exemplary method of operating a flexible feeding system that directly feeds objects to the orienting region <NUM> of the tray may include one or more of the steps of driving the actuator(s) to cause the objects in the orienting region to move across the orienting slots <NUM> to orient the objects. Then the system may drive the actuator(s) to cause the objects to advance across the divider <NUM> to the singulating region <NUM> in the manner described above, optionally with intermittent reversals of the driving direction to clear obstructions from the divider <NUM>. Then the objects may be advanced to the pick region <NUM>, such as across the one-way stop <NUM>, and then reversed to move the other oriented objects next in line away from the singulated object SS, thereby allowing an obstruction-free pick.

A flexible feeding system including a tray that is configured to orient, segregate and singulate objects has been described herein. The system and/or tray improves the presentation of the objects to operators or automated systems, while also providing flexibility to change between different types of objects, thereby improving efficiency in manufacturing.

More particularly, in preferred embodiments the flexible feeding system utilizes a programmable multi-axis vibratory platform operatively coupled to the unique tray, which includes one or more features that enhance the ability to orient and singulate the objects from bulk, advance the oriented objects to predetermined pick positions that are separated from misoriented objects for improved presentation to an operator or robot, and/or provide the ability for quick-changeover of the tray such as for use with different types of objects.

The system has bulk object storage on the tray, or can be integrated with more conventional flex feeding features including a hopper and/or vision system to aid in the ability to isolate the objects into the predetermined pick positions.

In exemplary embodiments, the tray includes a divider that allows only properly oriented parts to pass into a region designated for singulated parts, thereby separating oriented parts from misoriented parts to improve picking from the tray.

In preferred embodiments, the tray includes a recessed pick region toward the downstream end of each orienting slot, which is configured to capture the oriented object in the recessed area. The recessed pick region combined with a programmed vibration profile may accurately position the objects, such as by advancing them to the recess for picking, then reversing the singulated objects that are next in line to clear them away from the object(s) ready for picking. Such features may enable a clean pick from a predetermined location, thus reducing or eliminating the need for vision-guided robotics. The pick region also may be compatible with mechanical grippers or vacuum pick tooling. The system may be configured with a vibration profile that advances the objects toward the pick region, then reverses the direction to back other objects away from the object in the pick region, thereby adding additional clearance for pick.

The tray also may be removable from the vibratory platform for enabling quick-changeover of specific types of objects that are desired to be picked. Such a feature may allow the tray to be quickly changed, including the bulk region containing the specific objects, thereby reducing the possibility of mixed hardware. Such trays may have no moving parts, and thus may be supplied at low cost with little to no recurring engineering for new types of objects. In addition, such trays may be conducive to additive manufacturing techniques.

It is to be understood that terms such as "top," "bottom," "upper," "lower," "left," "right," "front," "rear," "forward," "rearward," and the like as used herein may refer to an arbitrary frame of reference, rather than to the ordinary gravitational frame of reference.

As used herein an "operable connection," or a connection by which entities are "operably connected," is one in which the entities are connected in such a way that the entities may perform as intended. An operable connection may be a direct connection or an indirect connection in which an intermediate entity or entities cooperate or otherwise are part of the connection or are in between the operably connected entities. An "operable connection," or a connection by which entities are "operably connected," also may be one in which signals, physical communications, or logical communications may be sent or received. Typically, an operable connection includes a physical interface, an electrical interface, or a data interface, but it is to be noted that an operable connection may include differing combinations of these or other types of connections sufficient to allow operable control. For example, two entities can be operably connected by being able to communicate signals to each other directly or through one or more intermediate entities like a processor, operating system, a logic, software, or other entity. Logical or physical communication channels can be used to create an operable connection.

It is understood that embodiments of the subject matter described in this specification can be implemented in combination with digital electronic circuitry, controllers, processors, computer software, firmware, and/or hardware. For example, embodiments may be implemented in a flexible feeding system that uses one or more modules of computer program instructions encoded on a non-transitory computer-readable medium for execution by, or to control the operation of, data processing apparatus.

In the flow diagram(s), blocks may denote "processing blocks" that may be implemented with logic. The processing blocks may represent a method step or an apparatus element for performing the method step. A flow diagram does not depict syntax for any particular programming language, methodology, or style (e.g., procedural, object-oriented). Rather, a flow diagram illustrates functional information one skilled in the art may employ to develop logic to perform the illustrated processing. It will be appreciated that in some examples, program elements like temporary variables, routine loops, and so on, are not shown. It will be further appreciated that electronic and software applications may involve dynamic and flexible processes so that the illustrated blocks can be performed in other sequences that are different from those shown or that blocks may be combined or separated into multiple components.

"Logic," as used herein, includes but is not limited to hardware, firmware, software or combinations of each to perform a function(s) or an action(s), or to cause a function or action from another logic, method, or system. F or example, based on a desired application or needs, logic may include a software controlled microprocessor, discrete logic like an application specific integrated circuit (ASIC), a programmed logic device, a memory device containing instructions, or the like. Logic may include one or more gates, combinations of gates, or other circuit components. Logic may also be fully embodied as software. Where multiple logical logics are described, it may be possible to incorporate the multiple logical logics into one physical logic. Similarly, where a single logical logic is described, it may be possible to distribute that single logical logic between multiple physical logics.

Algorithmic descriptions and representations used herein are the means used by those skilled in the art to convey the substance of their work to others. An algorithm or method is here, and generally, conceived to be a sequence of operations that produce a result. The operations may include physical manipulations of physical quantities. Usually, though not necessarily, the physical quantities take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated in a logic and the like. It should be borne in mind, however, that these and similar terms are to be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities.

Unless specifically stated otherwise, it is appreciated that throughout the description, terms like processing, computing, calculating, determining, displaying, or the like, refer to actions and processes of a computer system, logic, processor, or similar electronic device that manipulates and transforms data represented as physical (electronic) quantities. It will be appreciated that the processes may be implemented using various programming approaches like machine language, procedural, object oriented or artificial intelligence techniques. In one example, methodologies are implemented as processor executable instructions or operations provided on a computer-readable medium. Thus, in one example, a computer-readable medium may store processor executable instructions operable to perform a method. The computer-readable medium may be a hard-drive, a machine-readable storage device, a memory device, or a combination of one or more of them.

The controller may include all apparatus, devices, and machines for processing data, including by way of example a programmable processor, a computer, or multiple processors or computers. The controller may include, in addition to hardware, code that creates an execution environment for the computer program in question. The computer program (also referred to as software or code), may be deployed in any form, including as a stand-alone program or as a module, component, subroutine, or other unit suitable for use in a computing environment. The computer program may be deployed to be executed on one computer or on multiple computers that are located at one site or distributed across multiple sites and interconnected by a communication network. The processor may include all apparatus, devices, and machines suitable for the execution of a computer program, which may include, by way of example, both general and special purpose microprocessors, and any one or more processors of any kind of digital computer. Generally, the processor will receive instructions and data from a read-only memory or a random access memory or both. The computer may include, or be operatively coupled to receive data from or transfer data to, or both, one or more mass storage devices for storing data. Devices suitable for storing computer program instructions and data include all forms of non-volatile memory, media and memory devices, including by way of example semiconductor memory devices.

To provide for interaction with a user, embodiments may be implemented using a computer having a display device and an input device. Embodiments may include a computing system that includes a back-end component (e.g., as a data server), or that includes a middleware component (e.g., an application server), or that includes a front-end component (e.g., a client computer having a graphical user interface through which a user can interact with an implementation of the subject matter described is this specification), or any combination of one or more such back-end, middleware, or front-end components. The components of the system can be interconnected by any form or medium of digital data communication.

Claim 1:
A flexible feeding system (<NUM>) comprising:
a multi-directional vibratory platform (<NUM>);
a tray (<NUM>) operatively coupled to the vibratory platform, the tray comprising:
a bulk region (<NUM>) configured to contain a plurality of objects (S) in bulk form;
an orienting region (<NUM>) having one or more orienting slots (<NUM>) configured to orient one or more of the objects within each of the one or more slots; and
a divider (<NUM>) that separates the orienting region from a singulating region (<NUM>) of the tray;
wherein the one or more orienting slots extend across the divider from the orienting region into the singulating region of the tray;
wherein the divider includes one or more openings (<NUM>) that correspond with the one or more orienting slots, the one or more openings being configured to permit the objects (SO) which are oriented and singulated in series in the one or more orienting slots to pass across the divider into the singulating region, and the divider being configured to restrict the objects (SM) which are misoriented in the orienting region from passing across the divider into the singulating region;
wherein the tray further includes a pick region (<NUM>) downstream of the singulating region;
wherein the one or more orienting slots extend through the singulating region to the pick region; and
wherein the pick region includes one or more one-way stops (<NUM>) that correspond with each of the one or more orienting slots, the one or more one-way stops being configured to permit the objects which are oriented in the one or more orienting slots to pass across the respective one-way stops in a downstream direction, and to restrict said objects from passing back across the one-way stop in an opposite upstream direction.