Note: Descriptions are shown in the official language in which they were submitted.
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SINGULATING AND ORIENTING OBJECTS FOR FEEDING
The invention is a system for singulating, sorting and orienting objects
and placing selected objects into an ordered array. The invention is primarily
directed toward singufating and orienting objects for automated assembly. In
an
exemplary application, the object can be a fastener such as a screw fed into
an
automated screwdriver. Other types of objects may be used.
BACKGROUND OF THE INVENTION
Automated fastener machines are widely used in manufacturing to
assemble products. Several methods are used in prior art to singulate and
orient
lo fasteners prior to transferring them to a device that places the
fasteners in the parts
to be assembled. Bowl feeders operate by vibrating a spiral ramp. The
vibration
supplies energy to a disordered collection of fasteners in a central reservoir
causing
the fasteners to reorient. The vibration frequency, typicafiy from 60 Hz to
400 Hz, is
tuned for resonance with the fastener to be singulated. Fasteners with a
favorable
orientation (long axis substantially aligned with the local ramp axis) are
propelled
along the spiral ramp and those with an unfavorable orientation fall into the
central
reservoir. In another variant, groups of fasteners are fed to a vibrating ramp
with a
step feeder. In another variant, fasteners are fed onto an intermittently
vibrating
plate with orienting features. After a period of vibration, the orientation of
fasteners
s detected by machine vision and those fasteners with a favorabie orientation
are
extracted with an automated picker. These devices produce significant acoustic
noise that must be muffled. The prior art methods described above are capable
of
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supplying only a few parts per second. A primary object of the invention is to
increase the number of parts per second that can be supplied to an automated
fastening device to increase the manufacturing rate. Another objective of the
invention is to reduce the size of the singulation apparatus. Another
objective of the
invention is to reduce the cost of the singulation apparatus. Another
objective of the
invention is to reduce the noise of the singulation apparatus,
SUMMARY OF THE INVENTION
The invention is a system for singulating, sorting and orienting objects
and placing selected objects into an ordered array In the context of the
invention
ID the term object refers to any item that requires orientation relative to
a substrate or
another object. Objects termed "antioaraller to another object means that the
"antiparallel object is oriented at 180 degrees relative to the reference
object. The
term ordered array has the meaning that there is a constant average
displacemont
between the centers of mass of objects in the array. The orientation of an
object
can be specified by a set of orientation vectors related to at least one
spatially
varying property of the object. For convenience, the center of mass of the
object is
taken as the origin for orientation vectors in the following discussion.
Different
properties may have different sets of related orientation vectors. While
orientation is
often specified by the shape of the object, it may also be specified by an
internal
property of the object unrelated to shape such as a change in material
properties or
the route of an electrical circuit. The term orientation herein generally
refers to a set
of one or more selected orientation vectors. The selected set may contain
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orientation vectors related to different object properties. For
example, one
orientation vector may specify the direction of a surface normal and another
orientation vector may specify the direction from the center of mass to an
electrical
contact. The term orientation axis is used interchangeably with the term
orientation
:3 vector
herein. In an important set of embodiments, the orientation vector
corresponds to a longitudinal axis of the object. The term longitudinal axis
is used
throughout for illustrative purposes and is not to he interpreted as limiting
the
invention to orientation of a longitudinal axis only. Within the spirit and
intent of the
invention, the term longitudinal axis has the same meaning as selected
orientation
lc axis. An
object can, for example be a molded plastic base that is to be bonded with
circuit on a silicon substrate. An object can be a fastener such as a screw or
rivet
that is used to join two or more parts of a manufactured item together. An
object can
be a tulip bulb that requires orientation prior to placement in a sod
substrate_
According to a first aspect of the invention there is provided a method
15 for feeding objects in a stream from a massed supply of the objects where
each
object has an orientation axis and is shaped so that the object has first and
second
different orientations of the orientation axis, the method comprising:
supplying the massed supply of the objects;
transferring the objects from the supply into a singulation duct;
20 forming
the objects into a stream of the objects which are singulated
each from the next by passing the objects along the singulation duct and
rotating the
singulation duct about a rotation axis such that centrifugal forces generated
by the
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rotation act to drive the objects along the singulation duct and to cause
pressure on
the objects against a wall of the singulation duct to slide along the wall;
and orienting the objects in the stream by engaging the objects in the
stream and rotating at least some of the objects so that all the objects at a
location in
the stream after the orientation have the orientations thereof aligned.
The orientation axis is typically longitudinal of the body concerned but
this is not necessarily so as objects of other shapes can be oriented by the
methods
herein.
Preferably the method includes rotating the longitudinal axis of at least
lo some of the objects about a transverse axis so that all the objects at a
location in the
stream after the orientation have the longitudinal axes and the orientations
thereof
aligned.
That is the orientation requires more than simply aligning the objects
along their orientation axis which occurs during movement along the duct but
in
addition another component is provided which acts on the objects so aligned to
rotate the orientation axis. In this way the objects such as screws or other
fasteners
can be arranged with the head leading or the head trailing or the axis of the
screw
transverse to the direction of movement in the stream.
In accordance with another important aspect of the invention there is
provided an object buffering device and a transfer member for transferring the
singulated oriented objects from the object buffering device to the operating
tool.
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In accordance with another aspect of the invention an action to the
oriented objects is provided so that the action takes place on each object in
the
same orientation.
Where the definitions herein refer to a path or duct. it will be
5
appreciated that the rotating body may include a only one singulation duct or
may
carry a plurality of ducts all operating on the same objects to increase
productivity or
operating on different types of objects such as different size of fasteners.
In accordance with another aspect of the invention there is provided a
sensor for detecting the orientation of the objects in the stream, wherein the
objects
are directed along first and second paths depending on the detection of the
first and
second orientations and wherein the first path is arranged to change the
orientation
of the objects therein relative to the second path so that the objects are
combined
into a common stream from the first and second paths in the same orientation.
In one example, the first path is arranged to feed the objects into the
common stream in a first direction and the second path is arranged to feed the
objects into the common stream in a second direction opposite to the first
direction.
This acts to reverse the orientation of the objects in the second path
relative to the
first path to ensure that all objects in the common stream have the same
orientation.
In another example the second path includes a component for
reversing the orientation of the objects therein. This can be a twist for
reversing the
orientation of the objects therein. This can be a movable component operable
to
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carry the objects into a reversed orientation for reversing the orientation of
the
objects therein.
In one arrangement, the orienting of the objects is carried out while the
objects are in the singulation duct.
That is the orienting can be effected by an abutment structure which
engages the objects while in the singulatior duct and acts to rotate object or
the
orientation axis of the object about the transverse axis,
In one example, the orienting acts to rotate the objects so that the
longitudinal axis of all is transverse to a direction of movement along the
singulation
io duct.
This is particularly effective for fasteners where the fasteners are then
supplied
in a magazine or buffer moving toward the tool such as a screw driver with the
axis
of the screw's transverse to the direction of movement.
In one example the objects have a head and a shank and the
longitudinal axis is longitudinal of the shank. However, the arrangements
described
herein can be used with other shapes and constructions of objects which
require
particular orientations. Preferably the screws or fasteners are arranged such
that the
heads and the shanks are aligned at right angles to the direction of movement.
However, the orientation may be used to present the fasteners with the tip at
one
end and at the head at the other along the movement direction.
20 For
example, the orientation can be effected in a duct by providing a
slot in the singulation duct into which the shank falls while the head remains
running
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along in the singulation duct. In this way the slot acts to orient the object
with the
longitudinal axis transverse to the singulation duct.
In another arrangement, the orienting is located beyond an end of the
singulation duct so that the duct acts only to singulate and the orientation
is carried
out while the objects remain in the singulated stream but downstream of the
duct.
In one example the objects are oriented by capture as they are
released from the singulation duct into an orienting member.
In another example, there is provided a sensor for detecting the
orientation of the objects in the stream and the objects are operated upon to
change
the orientation thereof depending on the detected orientation.
This can be done in another example where the objects are directed
along first and second paths depending on the detection of the first and
second
orientations. In this arrangement, preferably the first path is arranged to
change the
orientation of the objects therein relative to the second path so that the
objects are
combined into a common stream from the first and second paths in the same
orientation.
In one particular end use of the singulation and orientation system
described above, the objects are transferred from the singulation duct to a
buffer
container in which the objects are halted to form a feed supply of the
objects. This is
particularly required where the objects are fed to an operating tool as a
supply
thereof. In one example of a device which operates in this manner, the buffer
container rotates with the singulation duct and is subsequently halted to
download
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the objects. That is the buffer collects the objects while the buffer and
singulation
duct are commonly rotating and then the buffer is halted in a downloading
operation.
in this example preferably there is provided at least two buffer containers
where a
first is loaded from the singulation duct while the second is halted.
Where the objects are fed to a tool for using the objects one after
another, in one example the objects are fed directly from the buffer container
to the
tool. However, in another arrangement, the objects are not fed directly but
instead
are inserted into an elongated storage member or magazine which forms a feed
to
the tool. This can be for example a strip of material such as paper on which
the
objects are carried in a row or a tube of material such as plastic in which
the objects
are carried end-to-end in a row.
In addition to orientation, in another example there is provided a
sensor for detecting characteristics of the objects in the stream where some
of the
objects can be discarded or displaced depending on the characteristics
detected.
For example, the system can be used to assess the quality or viability of the
objects
such as screws and to discard from use those which are not suitable. Howover,
many other uses of the sensing or measuring system can be used in many othor
ways,
Where the objects such as screws have a tendency to become inter-
tangled, there is preferably provided a supply duct for transferring the
objects from
the massed supply to the singulation duct where the supply duct is agitated to
ensure the objects enter the singulation duct.
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In another construction, the objects are fed from the singuiation duct to
a supply duct which rotates with the singulation duct and carries the objects
when
singulated and oriented to an exit mouth lying on the axis of rotation of the
singulation duct. In this way the objects emerge from the mouth in a stream
with the
same orientation. This is particularly effective for feeding the singulated,
oriented
moving objects along the axis into the axis of an insertion tool
In some cases. the measurement device which detects one or more
parameters of the objects may only detect the presence of the objects. In
other
cases, the presence and one or more characteristics of the detected object may
also
be obtained.
In accordance with an important optional feature of the invention which
can be used independently with any of the above or following features, there
is
provided an object measuring device for detecting at least one parameter of
the
singulated objects.
In accordance with an important optional feature of the invention which
can be used independently with any of the above or following features, there
is
provided a control system for recording measurements of the objects relative
to time.
In accordance with an important optional feature of the invention which
can be used independently with any of the above or following features, there
Is
provided a control system for recording measurements of the objects relative
to
location in the object buffering device.
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In accordance with an important optional feature of the invention which
can be used independently with any of the above or following features, there
is
provided a diverting device for diverting selected objects away from the
object
buffering device in response to the detecting of at least one parameter of the
singulated objects.
In accordance with an important optional feature of the invention which
can be used independently with any of the above or following features, the
singulation rate is higher than a minimum required rate so that a replacement
object
is available in instances where a first tested object does not meet a
condition to
ic continue to the transfer device and is discarded.
In accordance with an important optional feature of the invention which
can be used independently with any of the above or following features, the
storage
container includes at least first arid second separate containers containing
respective objects with first and second quality parameters and a control
device is
if, used which selects the container.
In accordance with an important optional feature of the invention which
can be used independently with any of the above or following features, a
transfer
device which carries the objects from the exit of the duct to the end use
location
which comprises a belt with receptacles for the objects.
2i] In accordance with an important optional feature of the
invention which
can be used independently with any of the above or following features, the
transfer
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device is arranged such that the angular velocity of an object exiting the
transfer
device is approximately zero.
In accordance with an important optional feature of the invention which
can be used independently with any of the above or following features, the
transfer
device comprises a funnel and a slot that is operable with an actuator to move
between a catch position and a release position. In this arrangement, fn some
cases
there may be provided sensors to detect the presence and/or velocity of the
objects.
Another important feature may provide a sensor which detects whether and when
the object actually reaches the object buffering device to ensure accuracy of
the
to object
feeding action and to halt operation in the event of a blockage or other
inconsistent operation.
In accordance with an important feature of the invention which can be
used independently with any of the above or following features, a packaging
means
is supplied to enclose objects singulated and oriented.
1 5 n
accordance with an important optional feature of the invention which
can be used independently with any of the above or fallowing features, the
object
feeding system includes a system for supplying a surface coat to each or some
of
the objects such as a lubftant oil or an adhesive.
In accordance with an important optional feature of the invention which
20 can be
used independently with any of the above or following features, there is
provided a rotary body mounted for rotation around an axis with the rotary
body
defining at least one duct extending from an inner end adjacent the axis
outwardly to
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an outer end spaced at a greater radial distance outwardly from the axis than
the
inner end, wherein the massed objects are fed at the inner end of said at
least one
duct, the inner end being arranged in an array adjacent the axis so that the
supply
conduit acts to deposit the objects at the inner end of said at least one duct
for entry
of the objects into the inner low velocity end and for separation of the
stream of
objects in the conduit into separate ones of said at least one duct, said at
least one
duct being shaped and arranged so that the objects are accelerated as they
pass
from the inner end to the outer end so as to cause the objects separated into
said at
least one duct to be aligned one after another in a row in the duct as they
move
lo toward the outer end.
In accordance with another important feature of the invention which
can be used independently with any of the above or following features, there
is
provided an agitation means to agitate objects fed from the supply conduit so
as to
cause said objects to flow without binding. Agitation means can he in the
supply
conduit, on the rotating body, or both. The agitation means can, for example
be a
vibrator. The agitation means can be for example an array of paddles made to
rotate relative to the supply conduit or rotary body. The agitation means can
be
protrusions on the inner wall of the supply conduit.
In accordance with another important feature of the invention which
can be used independently with any of the above or following features, there
is
provided a plurality of supply conduits that convey different types of objects
to the
rotating body wherein each supply conduit feeds a set of one or more ducts
distinct
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from the set of one or more ducts supplied by any other supply conduit. The
inner
ends of each set of ducts are preferably displaced axially relative to any
other set of
ducts. The apparatus can be used, for example to supply different types of
objects
to a further process in the ratio needed by adjusting the number of ducts
dedicated
to each type and the rate of passage in the supply conduit for each type of
object.
In accordance with another important feature of the invention which
can be used independently with any of the above or following features. there
is
provided a computing means that receives information about at least one
parameter
of a rotating body and associated supply conduits, ducts, detectors,
diverters, and
ao object buffers.
In accordance with another important feature of the invention which
can be used independently with any of the above or following features, the
computing means produces a summary report to an operator based on the
information received.
In accordance with another important feature of the invention which
can be used independently with any of the above or following features, the
computing means is capable of changing at least one operating parameter based
at
least in part on information received.
In accordance with another important feature of the invention which
can be used independently with any of the above or following features, the
computing means receives information from a plurality of rotating body
apparatus
and changes at least one operating parameter based on the information received
to
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effect a change such that the collective action of plurality of rotating body
apparatus
produce an output of objects lo meet an operator specified parameter.
One objective of the current invention is to increase the rate at which
objects can be presented to an assembly apparatus so that a finished part can
be
manufactured faster. A further objective of the invention is to provide
information
about quality characteristics of each object together with information about
the time
that it is transferred to an object buffer and its position within the object
buffer.
In the most preferred embodiment, the singulation means is as
described in published PCT application WO 2018/018155 by the present applicant
published 1"I February 2018, the arrangement of which can be used herein.
The singulation system thus consists of a rotating body with one or
more ducts running from a central region where bulk objects are introduced
from the
bulk object reservoir to an outer region where singulated objects are
released. The
objects are accelerated by inertial forces dependent on the angular speed of
the
13 rotating body and the shape of the ducts. The singulation rate achieved
by a single
duct in this apparatus is significantly higher than the singulation rate
achieved by the
bowl feeder in prior art allowing objects to be transferred to an object
buffer at a
significantly higher rate. An automated assembly station based on the present
embodiment can assemble finished parts faster because the singulation step is
not
rate limiting. A singulation system of this type requires only a rotary motor
which can
be conveniently driven by electricity or by hydraulic power.
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Is
The singulation system described in published PCT application WO
20181018155 emits objects at intervals determined in part by the distribution
of
center to center distances in the bulk objects. The average period and
variance in
the period depend on the size and shape distribution of the objects as well as
surface texture, which modulates friction with duct walls. Each object orients
in a
duct so as to minimize potential energy. For all but spherical objects, the
long axis
of the object will preferentially align with the axis of the duct. The
specification
includes measurement of object properties either within a duct or after
release as
well as a means to redirect objects based on measured properties. The object
to buffer in the present invention functions to allow emission of objects
from the object
buffer at a constant rate. The maximum rate of emission from the object buffer
is the
average rate of arrival of objects into the object buffer.
In other embodiments, the object is collected by a funnel and
deposited in a slot that is operable with an actuator to move between a catch
Is position and a release position. The width of the slot is selected such
that the slot
can receive an object for a length of time corresponding to the variance in
release
times. Atter an object is caught, the actuator accelerates toward the release
position
and inertial forces drive the object against the trailing edge of the slot.
The trailing
edge is shaped to orient the object. For example, the trailing edge may itself
have a
20 slot wide enough to accept a screw body, but narrow enough to exclude the
screw
head,
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In many cases the method includes carrying out an operation on the
singulated objects while they remain singulated. That operation can include
merely
looking at or counting the singulated objects. However, the singulation is
particularly
effective for processing the singulated objects such as by coating with a
lubricant or
adhesive. In other cases, the operation can include carrying out analysis or
assessment of the objects.
In some embodiments the object measurement means is an imaging
system that provides information about the size, shape and reflectance of the
object
at one or more wavelengths.
In some embodiments the object measurement means is acoustic and
provides information about variation in density within the object. The
measurement
could, for example detect a crack. The system could reject cracked objects to
prevent possible failure in a finished assembly.
In some embodiments, a plurality of measurement means is used. In
I 5 some embodiments, information about the object together with
information about its
location in the object buffer is stored.
In a preferred embodiment, the object feeding system has a diversion
means operable to divert objects to different locations depending upon at
least one
measured quality parameter of each object. If a quality parameter meets an
29 operator-determined threshold, the object continues to the object
buffer, otherwise
the object is diverted to a container. For example, if the object is a screw,
a screw
determined to be good continues to the object buffer and a screw determined to
he
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defective is diverted to a reject bin. in this embodiment, it is desirable to
operate the
singulation means at a rate slightly higher than the rate the object buffer is
emptied
by an assembly tool so that a replacement object is available shortly
thereafter if an
object is diverted to the reject bin. In some embodiments, surplus objects
that are
otherwise suitable for use are diverted to a storage bin and re-introduced to
the
singulation means at a later time. This could occur, for example, if the
object buffer
is full.
In some embodiments, the object buffer is a packaging container that
is replaced with another packaging container when a pre-determined number of
io .. objects have been placed in the container. In some cases, the packaging
container
receives only one object in a specified orientation. For example, the
packaging
container could be a tape strip with a series of compartments to hold
electronic parts
in a definite orientation.
In some embodiments. the object feeding system is associated with a
plurality of bulk object reservoirs, each containing a different type of
objects. The
computation means selects which one object reservoir is connected with and
feeds
the singulation means at any time.
While the system can be effective for a single duct to generate a high-
speed stream of singulated objects, in many cases there is provided a
plurality of
ducts arranged in an array around the center feed conduit. This arrangement
can
both increase the rate of object singulation and as described below allow
multiple
object types to be singulated simultaneously. Each object type has a
corresponding
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feed conduit that delivers objects to an axial platform in communication with
one or
more ducts dedicated to that object type. The axial platforms for each object
type
are staggered along the rotation axis of the singulation system. For example,
one
duct could singulate #4-40 screws while another duct could singulate 46-32
screws.
The apparatus defined above can be used for detecting at (oast one
measurable parameter of a stream of objects comprising:
carrying objects in a stream of objects in a supply conduit;
rotang a rotary body around an axis;
the rotary body defining at least one duct extending from an inner end
ao adjacent
the axis outwardly to an outer end spaced at a greater radial distance
outwardly from the axis than the inner end
the inner end being arranged adjacent to the axis so that the supply
conduit acts to deposit the objects at the inner end of said at least one duct
for entry
of the objects into the inner end;
said at least one duct being shaped and arranged so that the objects
are accelerated as they pass from the inner end to the outer end so as to
cause the
objects separated into the duct to be aligned one after another in a row in
the duct
as they move toward the outer eriel
and for each of said at least one duct, measuring said at least one
parameter of the objects.
In some cases, the apparatus is provided for sorting the objects so
that, for each of the ducts, the objects are directed into one of a plurality
of paths as
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determined by the measurement of the parameter. The measured parameter can be
the orientation of each object. Objects of each orientation are directed into
a
different path. For example, a stream of screws will align parallel and
antiparallel to
a duct axis. Screws aligned parallel are directed to a different path than
screws
5 aligned antiparallel. In a preferred embodiment, the different paths are
arranged to
bring objects to a common alignment and subsequently merge into a single path.
However, the measurement of the parameter or parameters, which is obtained
more
effectively in view of the increased degree of singulatien of the objects
using the
arrangement herein, can be used for other purposes.
10 The arrangement defined above therefore can provide an advantage
that the increased velocity obtained by rotation of the body together with the
increased acceleration of the objects on the body better separates each object
from
the next for detection of the parameter. In addition, the increased velocity
of the
objects can be used to increase the throughput of the system as the detection
or
measurement of the parameter can be carried out more quickly.
In one arrangement the measurement of the parameters is carried out
while the objects are in the duct. This has the advantage that the location of
the
objects is more clear and defined since it is controlled by the rotation of
the body and
the position of the duct. In view of the more accurate location of the object,
the
2o measurement of the parameter can in many cases be carried out more
effectively.
In this case preferably the measurement of the parameter is carried out
by a measurement device carried on the rotary body. In this way the
measurement
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"10
device is located at a specific position relative to the duct and relative
therefore to
the objects. This can simplify the operation of the measurement device since
it can
be focused more accurately on a specific location. In this case each duct may
include one or more separate measurement devices dedicated to the measurement
of the objects flowing through that duct. That is each object when moving
along a
duct can pass a number of sensors or measurement devices, which may be aligned
in a row, where each detects a different parameter of the object to enable a
better
assessment of the object to be made. However, in some cases a single sensor
can
provide all of the required information.
ic
Preferably, at least a portion of the duct proximate to the measurement
devices is comprised of a transparent material. The provision of a portion of
the duct
as transparent allows the measurement to be carried out through the
transparent
section while the duct remains of a constant shape to continue to control
movement
of the object.
In one arrangement, the walls of the ducts or the ducts themselves are
segmented with one or more gaps between segments. One or more measurement
devices are located proximate to the gaps to measure different parameters of
the
object with a view unobstructed by the walls of the ducts. Where the duct
itself is
divided into separated segments, each segment is preferably arranged along the
path of the duct substantially parallel to the average velocity vector of the
objects at
the location of said segment to minimize perturbation of object flow along the
duct.
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The object can thus be operated upon using any of the techniques described
herein
while it is in the gap.
In another arrangement, the separation of the objects can be carried
out using electrostatic forces where the objects are charged differentially
according
to selected parameters and then passed through an electric field so that the
differential charging causes the objects to divert to different paths.
Typically. an
arrangement is provided which generates an equal charge on each object so that
objects of different mass are separated by passing those objects through an
electric
field which acts differentially on the objects based on their different masses
since
o each object has a different or unique charge per unit mass. This method
could be
used for example to direct objects containing an unwanted void to a reject
bin.
Preferably the ducts are curved so that the outer end is angularly
retarded relative to the inner end. This shape typically follows closely the
path of the
object as it is accelerated under centrifugal force and Conchs force so that
the object
can travel along the path without excessive friction against the sides of the
duct.
Preferably the ducts are arranged immediately side by side at the inner
ends adjacent the axis so that the reed conduit deposits the objects in the
manner
which separates the objects directly into the inner ends of the ducts, with
the ducts
increasing in spacing toward the outer ends as the ducts move toward areas of
increased diameter on the rotary body.
Preferably the axis of the rotary body is vertical so that the disk lies in a
horizontal plane. However other orientations can he used.
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Preferably a side wall of each duct against which the objects run is
inclined in a direction along the axis so that acceleration forces on the
objects act to
move the objects into a common radial plane for release from the rotary body.
That
is the acceleration forces tend to move the objects axially of the rotary body
toward a
common axial position. In this way, even if the objects enter the ducts at
positions
spaced along the axis, the shape of the duct brings them all to the same axial
location.
In one preferred arrangement, each duct is shaped such that the
acceleration causes the object to move against a wall of the duct where the
wall is
lo V-shaped to confine the object to a base of the V-shape. The wall can
include a
surface which includes rifling for engaging and rotating the object in the
duct. In
addition, the wall can include one or more openings at a location such that
components smaller than the objects are separated from the objects by release
through openings, Each duct can include an associated second duct parallel to
the
duct into which the separated smaller components enter. This can be used in a
system where there is a stack of such ducts so that the objects are separated
by
size from the first. In a related preferred arrangement, the openings in duct
walls
permit passage of only part of an object so as to cause the object to align
relative to
the duct wall For example. a duct wall may contain a slot enabling the body of
a
screw to pass through but not the head. If the slot is deep enough, the screw
axis
becomes aligned perpendicular to the duct wall.
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In one example each separating device comprises a separating head
having a front edge arranged such that the objects to be separated move to rd
the
front edge in a stream and an actuator for moving the front edge between a
first
position on one side of the stream arranged to direct the object to a second
side of
the stream, and a second position on a second side of the stream, arranged to
direct
the object to said one side of the stream.
In this example preferably the separating head is arranged in a radial
plane of the rotating body and the first arid second sides are arranged on
respective
sides of the radial plane.
In this example preferably the separating head includes inclined guide
surfaces on the first and second sides of the front edge so that the
separating head
is generally wedge shaped. In other embodiments, the separating head may have
three or more generally triangular faces with base sides forming of each
triangle a
polygon with wherein the normal to the polygon is (for the neutral position)
180
degrees from the direction of incident objects. The separating head need not
come
to a sharp point: that is the sides may be trapezoidal. In this arrangement
the base
of the separating head is a polygon and the point of the separating head is
similar to
the base polygon differing only in scale. For example, the separating head may
be
generally tetrahedral in shape for directing objects into three distinct
paths, For
example the separating head may be generally pyramidal in shape for directing
objects into four distinct paths.
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Preferably the actuator is moved by piezo electric members. However
other drive forces can be used for example an electromagnetic voice coil.
Preferably the actuator is mounted in a tube which extends radially
outward of the separating head and lies in a radial plane of the separating
head,
The present invention is not limited to the typo or size of object concerned
and may be operated with different particles or objects to be separated. The
arrangement of the invention may be used for objects ranging in size from
microns
to meters. In the micron size range, the objects may be for example flakes
such as
quantum dots where the optical properties depend on the object dimensions and
lo
orientation. The object may be for example a crystal and the arrangement
herein is
used to orient a crystal face relative to an internal crystallographic plane_
The crystal
may for example be birefringent and the orienting operation of the present
invention
is used to align an optical axis for assembly in an optical system. The
crystal may
for example be silicon and the orienting operation of the present invention is
used to
Is present
a particular crystallographic axis for further processing operations such as
laser ablation, ion machining or etching. The object may for example be a MEMS
device or a part of a MEMS device such as a micro mirror or a micro lens. The
objects may be passive electronic components such as a resistors or capacitors
that
are singulated and oriented by the present invention for packaging or for
placement
20 on a
carrier such as a printed circuit board. The objects may be active electronic
components such as transistors, LED's, or integrated circuit chips that are
singulated
arid oriented by the present invention for packaging or placement on a
carrier. The
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objects may be fasteners such as buttons, clasps, screws, bolts, nails,
rivets, nuts or
washers. The objects may be electronic connectors that are singulated and
oriented
for installation on for example a panol assembly. The objects may be
manufactured
parts or sub-assemblies of manufactured goods that are singulated and oriented
by
the present invention for packaging or further assembly. The manufactured
parts
may have irregular shapes, The objects may be plants or parts thereof such as
tulip
bulbs, pine trees or vines that must be singulaled and oriented (root side
down) prior
to planting. The objects may be bales of material that are singulated and
oriented to
for example orient fibers in a composite material. The objects may be packages
of
lo .. food products or packages of manufactured goods that are singulated and
oriented
by the present invention during packaging. The objects may be envelopes,
boxes,
packages, or shipping containers that are singulated and oriented by the
present
invention in a postal system or a courier system to track and direct each
object to a
destination. Similarly the invention may be used in distribution and inventory
control
systems. The objects may be for example luggage in transport system such as an
airport, rail station, bus depot, or port. The types of objects and
applications
referenced herein are illustrative and do not limit the scope of the invontion
to the
types of objects and applications described herein.
While the duct as described in some examples herein is typically a
channel with upstanding sides formed in a disk, the duct can also be circular,
oval,
triangular or quadrilateral etc. or can he a partial tube that is generally C-
shaped, V-
shaped or L-shaped. The duct can also be defined by a minimal two- or three-
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dimensional surface, or surfaces defined by the points of contact imparting
force on
the objects. The duct can also be an enclosed tube of many different cross-
sectional shapes such as circular, oval, triangular or quadrilateral.
The duct may consist of a plurality of pathways wherein each pathway
conveys objects with a different set of orientations and there is provided a
means to
move objects from a first pathway to a second pathway dependent on object
orientation. In some embodiments at least one of the pathways within a duct is
shaped and arranged to change the orientation of an object entering the
pathway.
In some embodiments at least one of the pathways within a duct is shaped and
R) arranged to change the orientation of an object within the pathway. In some
embodiments at least one of the pathways within a duct is shaped and arranged
to
change the orientation of an object exiting the pathway. In some embodiments
at
least one of the pathways contains a means to eject objects to a discard bin
based
at least in part on a measured parameter. In some embodiments at least one of
the
ii pathways contains a means to eject objects to a discard bin based on
a dynamical
property of the object. In some embodiments at least one of the pathways
contains
a means to direct objects to a recirculation bin based at least in part on a
measured
parameter. In some embodiments at least one of the pathways contains a means
to
direct objects to a recirculation bin based on a dynamical property of the
object. In a
2to preferred embodiment, the pathways within a duct are shaped and
arranged to
cause objects entering the duct with different orientations to exit the duct
with the
same orientation.
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In the present invention, the inertial forces on the object reckoned in a
rotating frame of reference are resisted in at least one direction by normal
forces
provided by the pathway surface and the object is accelerated in response to
the
remaining net inertial force. The inertial forces generated within the
rotating frame of
reference depends on the angular velocity and may be much larger than the
force of
gravity used in prior art systems. Larger forces enable the arrangement of the
present invention to singulate and orient objects at a higher rate. The
optimal
rotation rate depends on the magnitude of surface forces. Generally micron
sized
objects experience strong surface forces resisting motion and high rotation
rates
ii such as
100,000 RPM, for example are appropriate_ For meter sized objects,
surface forces relative to mass are small and rotation rates such as 100 RPM,
for
example may provide adequate throughput. Higher rotation rates may he used to
increase throughput. Lower rates of rotation may be used to limit impact
forces on
delicate objects.
The means to move an object from one pathway to another pathway
may be dynamic or static. In the static case, the shape of the pathway exerts
different normal forces on objects oriented differently for at least one point
along the
pathway and the different forces cause objects oriented differently to follow
different
paths. For example, objects in a radial duct section of the present invention
are
accelerated outward by the centrifugal force and tangentially into a duct wall
by the
Coriolis force. The duct wall may be stepped tangentially such that an object
in a
first orientation fits within a first step and an object in a second
orientation extends
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beyond a first step. The object in a first orientation experiences no net
force in the
tangential direction and no net torque about a radial axis. The object in the
second
orientation experiences a net torque about a radial axis and possibly a net
tangential
force (depending on where the object center of mass is positioned relative to
the
step). The net torque and/or net tangential force on the object in the second
orientation cause the said object to follow a different pathway from an object
in a first
orientation. In another example, the duct wall includes a tangential wedge
shaped
protrusion positioned such that objects in a first orientation are not engaged
by the
protrusion and a part of objects in a second orientation engage the protrusion
and
experience a torque and changes the path of said object in second orientation.
The
displacement vector of objects in a duct may include a component parallel to
the
rotation axis by inclining a portion of the duct wall with respect to the axis
of rotation.
In another example the duct wall may be shaped to perrnit an object in a first
orientation to have displacement parallel to the rotation axis and to prevent
an object
in a second orientation to have displacement parallel to the rotation axis.
The
process may be repeated to sort objects with a plurality of different
orientations each
to paths with different displacements parallel to the rotation axis. In
some
embodiments, objects are fed into a different buffer for each object
orientation.
Objects in a first orientation along a pathway may be rotated to a second
orientation
by placing a protrusion along the pathway such that the protrusion engages so
as to
produce a torque on the object. In a preferred embodiment, objects in each
orientation are rotated to a common orientation prior to placement in a
buffer.
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The mechanics of dynamic embodiments are similar to the mechanics
of the static embodiments discussed above except that a sensor system measures
orientation of each object and sends signals to one or more actuators to
change the
shape of the pathway for each object. For example, a protrusion may be
extended
from a duct wall when the sensor detects a first object orientation and said
protrusion acts as a pivot point causing objects incident on the pivot to
rotate 90
degrees about an axis perpendicular to the duct wall. The protrusion is
retracted for
objects detected to be in a second orientation and no rotation occurs.
In some embodiments, an operation is carried out on singulated and
to oriented objects during the singulation and orientation process. The
operation can
be inspection by a sensor means at any tocation along the object pathway. In
some
embodiments the inspection is done at a plurality of locations along an object
path
and the path Is shaped to present different surfaces of an object to
inspection by one
or more sensors at each location. For example, an object pathway may be
15 configured to present each of six sides of a rectangular box to a camera
in
succession. In some embodiments information from sensors is used to track the
location of each object. In some embodiments, sensor information about each
object is stored and analyzed. In some embodiments, objects are directed to a
different path based at least in part on at least one object parameter
measured by a
20 sensor. The operation can be labeling or marking, for example with a
laser or with a
dye. The labeling or marking operation may, for example place a product code
or a
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lot code or a dale code or information about a measured parameter of the
object.
The operation can be coating, for example with a preservative, lubricant or
adhesive.
BRIEF DESCRIPTION OF THE DRAWINGS
One embodiment of the invention will now be described in conjunction
with the accompanying drawings in which:
Figures 1A and 1B show a schematic illustration of a preferred
embodiment the present invention where Figure 1A is a top view and Figure 1B
is a
side view.
Figure 2 is an isometric view of a sorting apparatus showing an
arrangement for object singulation according to the present invention.
Figure 3 is a vertical cross-sectional view through the apparatus of
figure 2.
Figures 4A, 4B and 4C show vertical cross-sectional views through the
is separating device of the apparatus of figures 2 and 3.
Figure 5 is a schematic illustration of an alternative singulation and
orientation arrangement according to the present invention.
Figure 6A, 6B and 6C show schematic illustrations of another
arrangement according to the present invention for orienting objects.
Figure 7 is a further schematic illustration of an apparatus for directing
the flow of singulated and oriented objects where the objects are delivered in
an
axial direction of an axis of rotation of the singulation system.
Figures 8A and 8B show a schematic illustration of an arrangement
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according to the present invention to singulate and orient objects of
different types.
Figures 9A, 9B and 9C show three positions of a further schematic
illustration of an arrangement according to the present invention to singulate
and
orient objects of different types.
Figures 10A and 108 show a schematic illustration of a further
apparatus to singulate and orient objects of different types.
Figures 11A and 11B show a schematic illustration of a further
apparatus to singulate and orient objects of different types.
Figure 12 is a schematic illustration of one path 86 of the arrangement
lo of Figure 6A which acts to change the orientation of the objects.
Figure 13 is a schematic illustration of paths 81 and 86 of the
arrangement of Figure 6A which acts to change the orientation of the objects.
Figure '14A is a schematic illustration of sorting objects by orientation
with a tangential step.
Figure 148 is a schematic illustration of rotating objects in a plane with
a protrusion.
Figure 14C is a schematic illustration of sorting objects by orientation
tangentially with a slot.
DETAILED DESCRIPTION
20 As shown in figure 1A, a rotating body 50, described in more
detail
hereinafter, has one or more integral ducts 51 carried on the body 50 at
angularly
spaced portions there around. Thus, each duct is rotated about an axis at the
center
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31
of the body. The ducts are fed with objects 52 by supply conduit 53 and act to
singulate the objects so that they are fed in a row one behind the other.
Supply
conduit 53 indiudes a gate 531 that regulates the flow of objects onto
rotating body
50. Objects become aligned with the longitudinal direction along the duct axis
either
parallel to the duct as indicated at 521 or antiparallel as indicated at 522
as objects
move from the inner end of a duct to the outer end.
In the example shown, each object has a longitudinal axis and is
shaped so that the object has first and second different orientations of the
longitudinal axis. That is in one example applied to screws or similar
fasteners, the
14) objects have a head 523 and a shank 524 and the longitudinal axis is
longitudinal of
the shank so that when the longitudinal axis aligns with the longitudinal
direction of
the duct, the head can be first or last.
On the device therefore, the objects are formed into a stream of the
objects which are singulated each from the next by passing the objects along
the
.. singulation duct and rotating the singulation duct about the axis 55 such
that
centrifugal forces generated by the rotation act to drive the objects along
the
singulation duct and to cause pressure on the objects against a wall 56 of the
singulation duct 51 to slide along the wall 56.
In order to orient the objects so that the longitudinal axis of the object
is transverse to the length of the duct, a section of the duct indicated at 57
contains
a slot 58 shaped and designed to permit only part of the object such as the
shank to
enter while the head remains in the duct and cannot enter the slot. As better
shown
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in figure 1B, section of duct 57 is movable to direct objects to a first
buffer (-31 or a
second buffer 62.
That is the orienting is effected by an abutment structure, in this
example the slot 58, which engages the objects while in the singulation duct
and
acts to rotate the longitudinal axis about the transverse axis.
The objects experience a torque about the portion of the object that
cannot enter the slot due to Coriolis forces and rotate so as to orient the
object
relative to both the duct and slot. Thus, the heads and the shanks are aligned
at
right angles to the diroction of movement.
A detector 59 examines passing objects while in the duct and
communicates with a diverter 60 at the end of the duct. The diverter 60
operates to
direct objects into different paths upwardly or downwardly. The diverter can
take
different forms. The diverter 60 as shown in figure 1B comprises a short duct
portion
which operates by changing the angle of the duct either upward to buffer 61 or
.. downward to buffer 62. Another form of diverter is shown in figure 4, which
is the
preferred form for ejecting defective objects shown al 591 generally proximate
to
detector 59. The diverter can direct objects to a buffer 61 rotating
synchronously (at
the same angular velocity) with the rotating body or to a reject bin (not
shown). As
can be seen more easily in figure 1B, the diverter can direct objects along
different
paths to buffer A 61 and buffer B 62. Only two buffers are shown for
illustrative
purposes, but more, preferably three are present. Each buffer has three
possible
states. Firstly, the buffer can be rotating synchronously with the rotating
body and
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receiving objects for storage in an ordered array. Secondly, the buffer can be
undergoing angular acceleration. Thus, the objects are transferred from the
singulation duct 56 to a buffer container 63 in which the objects are halted
to form a
feed supply of the objects. The objects in buffer container 63 may be used by
a tool
as a side by side array or be discharged shank first into a tube for use by a
tool.
The angular acceleration either brings the buffer to rest with respect to
a stationary frame of reference or brings the buffer to synchronization with
the
rotating body. Thirdly, the buffer can be at rest. While at rest, the objects
in the
buffer can be transferred into another stationary buffer. Referring to figure
1B,
in objects from duct 56 are directed to buffer A rotating synchronously.
Detector 59
counts objects entering buffer A and generates a signal to accelerate buffer B
to
synchronous motion when a threshold number of objects are stored in buffer A.
When the detector count reaches a second threshold count corresponding to
buffer
A full, the diverter directs objects to buffer B. Note
that the object count is
.. understood to represent the number of objects entering the buffer and does
not
include objects diverted to a reject bin based on a measured parameter. While
objects are being diverted to buffer B, buffer A is brought to rest and then
emptied.
When empty, buffer A is ready to take the place of buffer B to receive
objects. Each
buffer thus cycles between the three states aforementioned. To provide a
.. continuous supply of objects, at least three buffers are required, one for
each state.
As shown in Figure 1A, six buffers 63 are angularly spaced to line up
with duct exits. In an alternative arrangement, a plurality of buffers 63 may
be
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associated with each duct exit by locating buffers at angles intermediate
between
duct exits. For example, there could instead be four or more buffers arranged
at
angles between each pair of duct exits. In this alternate embodiment, each
time a
buffer is full; the ring of buffers rotates to the next empty buffer in the
ring. Full
5 buffers in the ring may be transferred individually as described above or
a group by
replacing the ring with another when all buffers in the ring are full.
The apparatus for feeding objects based on a measurable parameter
of the objects shown in figures 2 and 3 comprises a supply conduit 10 carrying
objects to be singulated and oriented from a feed supply 10A (Figure 3) which
to supplies the objects in a continuous stream for presentation through the
conduit to a
rotary body 11 rotatable around an axis 12. In the embodiment shown the rotary
body is a fiat disk with the axis 12 arranged vertical so that the disk
provides an
upper horizontal surface onto which the objects '13 are supplied in the stream
from
the conduit 10. The conduit is arranged at the centre of the disk so that the
objects
15 are deposited onto the centre of the position where the disk is rotating
but where
there is little outward velocity. The object velocity at this point is from
the flow in the
supply conduit 10. The velocity at a point on the disk is v=wr where w is the
angular
velocity and r is the radius. If objects are deposited in a region where the
change in
velocity is too high, they bounce and the flow is chaotic. Objects are
deposited in
20 .. the central region to minimize the change in velocity.
On the upper surface of the disk forming the rotary body is provided
one or more ducts 14 (Figure 3) each extending from an inner end 15 adjacent
the
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axis outwardly to an outer end 16 spaced at a greater radial distance
outwardly from
the axis than the inner end. In this embodiment the outer end 16 of the ducts
is
arranged adjacent to but spaced inwardly from the edge 17 of the disk 11. In
this
embodiment each duct 14 extends from a position closely adjacent the centre to
the
periphery 17 of the disk so that the centre of the ducts are arranged
immediately
side by side and the ducts diverge outwardly so that at the outer end 16 they
are
spaced around the periphery 17.
The inner ends 15 are thus arranged in an array adjacent to the axis so
that the supply conduit 10 acts to deposit the objects to be sorted at the
inner ends
in 15 of the ducts for entry of the objects to be singulated and oriented
into the inner
ends. As the inner ends are immediately adjacent at the centre of the disk,
the
objects there form a pile at the centre which is automatically sorted evenly
into the
open mouths of the ducts at their inner ends Assuming a continuous pile of the
objects at the centre, the rotation of the disk will act to evenly sort the
objects into
Is the individual ducts in a stream defined by the dimensions of the mouth
relative to
the dimensions of the objects. AL the outset of the path along the duct, the
objects
will be immediately adjacent or overlapping. However, passage of the objects
along
the duct while they are accelerated by the centrifugal forces will act to
spread the
objects each from the next to form a line of objects with no overlap. As the
forces
20 increase with increasing radial distance from the axis 12, the objects
will be
increasingly accelerated and thus the distance between objects will increase
along
the length of the duct. The objects align with the duct axially in the first
part of the
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duct and the object length defines an initial center to center spacing with
some
variation due to differences in object orientation. The centrifugal
acceleration is
uniform at a given radius. The frictional forces scale with the Coriolis force
=uN
(u=coefficient of friction, N= normal force to duct wall supplied primarily by
the
Coriolis force). As set out above, the duct can be shaped to minimize the
normal
force and friction by curving the duct along the line of net force (mentioned
in text
earlier). Conversely, the object acceleration can be reduced by curving the
duct to
increase normal forces, curving the duct to constant or even decreasing
radius, or
increasing the coefficient of friction of a selected portion of a duct by
changing the
ia .. texture and/or material.
The singulated objects may be totally separated each from the next
defining a space, may be immediately behind one another or may even be
slightly
overlapped.
Thus, the ducts are shaped and arranged so that the objects are
1 5 .. accelerated as they pass from the inner end to the outer end so as to
cause the
objects to be aligned one after the other in a row as they move toward the
outer end.
The outer ends 1Ã are arranged in an angularly spaced array at an
outer periphery of the rotary body so that the objects of the row of objects
in each
duct are released by centrifugal force from the disk outwardly from the axis
of the
2() .. disk. The openings all lie in a common radial plane of the disk. The
ducts can be
formed either as grooves cut into the upper surface of a thicker disk or by
additional
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walls applied on to the top surface of the disk; or Iwo-dimensional and/or
three-
dimensional shaped guides.
An array 20 of object separating devices 21 is arranged in an annulus
at the outer edge 17 of the disk so that the individual separating devices 21
are
arranged at angularly spaced positions around the disk.
Each separating device is operable to direct each object into one of a
plurality of paths as determined by operation of the separating devices. In
the
example shown the separating devices are arranged to direct the objects
upwardly
or downwardly relative to the plane of the outlets 16. As shown in figure 2
and figure
in 4A the separating device 21 can take up an initial intermediate or
starting position
where the objects are not separated to one direction or the other. As shown in
figure
413, the separating device can be moved upwardly so as to direct the objects
downwardly into a path 22 for collection within a collecting chamber 25.
Similarly,
when the separating device is moved to a lowered position as shown in figure
40,
1 5 the objects are moved upwardly over the top of the separating device
along a path
24 for collection within a chamber 23. Chambers 23 and 25 may be a reject bin,
a
section of duct, a packaging operation, a marking operation or a buffer. The
two
paths 22 and 24 are separated by a guide plate 26 which ensures that the
objects
move to one or other of the chambers 23, 25. The guide plate 26 and the walls
of
20 the chambers 23, 25 may be covered with a soft material to reduce impact
forces on
objects. Objects may be slowed by air flow or a curtain of compliant material
on
entry to containers 23, 25.
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3(.;
in order to control the separating devices 21, there is provided a
measuring system generally indicated at 28 which is used to measure a selected
parameter or parameters of the objects as those objects move from the end of
the
duct at the edge of the disk toward the separating devices. The measuring
devices
are carried on a mounting ring 28A.
The measuring system can be of any suitable type known in this
industry for example optical measuring systems which detect certain optical
characteristics of the objects to determine the particular parameters required
to be
measured. Other measuring systems can also be used since the type of system to
be used and the parameters to be selected are not part of the present
invention.
Each separating device 21 is associated with a respective detecting
device 28, which may include multiple detecting components, operable to
measure
the parameter of the objects and in response to the parameters measured by the
associated detecting device, the respective or separating device is operated
to
is .. select the path 22 or the path 24.
It will be appreciated that the number of paths can be modified to
include more than two paths if required depending upon the parameters to be
measured. Such selection to an increased number of paths can be carried out by
providing subsequent separating devices 21 positioned downstream of the
initial
.. separation. In this way one or both of the paths can be divided into two or
more
subsidiary paths with all of the separating devices being controlled by a
control
system 29 receiving the data from the measuring device is 28.
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The disk 11 thus has a front face 30 facing the supply conduit and the
ducts 14 lie in a radial plane of the disk and extend outwardly from the axis
to a
periphery 17 of the disk 11.
As shown in figure 2, the ducts 14 are curved so that the outer end 16
5 is angularly retarded relative to the inner end 15. This forms a side
surface of each
duct which is angularly retarded relative to the direction of rotation in the
clockwise
direction as shown at D. This curvature of the ducts is arranged to follow
substantially the Coriolis and centrifugal forces so that the objects follow
along the
duct without excessive pressure against either side wall of the duct. However,
the
to shape of the duct is arranged so that the Coriolis forces tend to drive
the object
against the downstream side of the duct 14.
As shown best in figure 2, the ducts 14 are immediately side by side at
the inner ends 15 adjacent the axis and increase in spacing toward the outer
ends
16. At the inner ends 15 the ducts are immediately side by side so that the
maximum
15 number of ducts is provided by dividing rpi by the angle subtended by
the width of
the duct ends at the opening 15. The number of ducts can be increased, in an
arrangement not shown, where the ducts include branches so that each duct
divides
along its length into one or more branches.
In the embodiment of figures 2 and 3, the detection device 28 and the
20 separating device 21 are both located within the periphery 17 of the
disk. In this way
the objects are guided as they pass from the outer end of the ducts to the
array of
separating devices. As shown in Figure 2. a wall 98 may be used to halt the
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4]
outward motion C)f objects. The wall 98 may for example be located at the end
of a
buffer. Preferably the wall 98 has a layer of soft compliant material 99 such
as
rubber to cushion the impact of objects and reduce probability of damage to
the
objects.
As best shown in the figures 4A, 4B and 40, each separating device
comprises a separating head 40 having a front edge 41 lying generally in a
radial
plane of the disk 11 so that objects released from the outer ends 15 move
toward
the front edge 41. The separating head 40 includes the inclined guide surfaces
42
and 43 on respective sides of the front edge 41. In this way the separating
head 40
is generally wedge shaped. The separating head is mounted on a lever 44
mounted
inside a tube 45 so that the lever and the actuating mechanism for the lever
arc
protected inside the tube which is located behind and protected by the
separator
head. An actuator 46 is provided for moving the front edge 41 between first
and
second positions above and below the radial plane 47 defined by the path of
the
object 13. Thus, in figure 4A a central and neutral position is shown. In
figure 48 the
front edge 41 has moved upwardly which is arranged to direct the object to a
side of
the radial plane below the radial plane. In the position shown in figure 40,
the front
edge is moved downwardly to a second side of the radial plane and is arranged
to
direct the object to the first or upper side of the radial plane. This
movement of the
wedge shaped head and its front edge requires little movement of the front
edge 41
arid uses the momentum of the object itself to cause the separation simply by
the
object sliding over the guide surfaces 42 and 43. The separation head
therefore
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42
does not need to move into impact with the object or to generate transverse
forces
on the object since the head merely needs to move into position allowing the
object
to generate the required separation forces.
In view of the provision of the lever, the actuator 46 is required to
generate only small distance movements and hence can be moved by piezo
electric
members_ Alternatively, the movements can be carried out by a small
electromagnetic coil. This design allows the use of components which can
generate
the necessary high-speed action to take up the two positions of figures 4B and
4C
sufficiently quickly to accommodate high-speed movement of the objects. As
shown
io the actuator 46 is located outward of the separating head and lies in a
radial plane of
the separating head.
The arrangement of the present invention therefore provides a system
for singulation and orientation of the objects, for example screws, where the
objects
are supplied in a feed zone and are separated by the ducts and the inlet of
the ducts
so as to form a plurality of streams of the objects
As best shown in Figure 1, the object buffering device 63 provides a
supply of the objects which are transferred as shown at 65 to a transfer
member 66
for transferring the singulated oriented objects from the object buffering
device 63 to
an operating tool 67 such as a screw driver.
As an alternative to the driver 67, the objects from the buffer 63 can be
supplied as indicated at 70 to an operating device 71 such as a marker to
apply an
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action to the oriented objects so that the action takes place on each object
in the
same orientation.
As shown in Figure 5, there is shown an alternative arrangement
wherein the orienting is located beyond an end of the singulatinn duct rather
than in
the duct itself.
In this arrangement there is a rotating body 75 onto which objects 74
are deposited in the central region by a feed conduit 77.
In this arrangement, the feed conduit 77 can include an agitating
device 70 so that the supply duct is agitated to ensure the objects enter the
io singuiation duct or ducts and do not lock up due to friction or
interlocking.
The objects move along the duct 76 integral to the rotating body 75
from the inner opening to the outer opening under the influence of centrifugal
force.
Objects are aligned against a duct wall 78 by Coriolis force. Objects exiting
the duct
traverse an air gap 80 and are directed into a stationary duct 81, which
constitutes
the object buffer in this embodiment, by a series of wedges 82 and the
orientation of
each object is measured by a detector 83. Objects determined to be within a
desired orientation range continue into the stationary duct 81, objects
otherwise
oriented are rejected (and possibly re-introduced to feed di.K.:t 77) by
diverter 84. In
a related form (not shown), a diverter 84 directs objects with different
orientations
into different buffers For example, a first buffer could be a tube filled end
to ond
with objects oriented with an orientation vector parallel to the tube axis and
a second
buffer could be filled end to end with objects oriented antiparallel to the
tube axis.
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After filling, both tubes are removed and the second tube is rotated 180
degrees to
bring the orientation of all objects in the second tube into alignment with
objects in
the first tube.
The stationary duct preferably has a cross section slightly larger than
the object so that the walls of the stationary duct tend to preserve the
object
orientation. The stationary duct is preferably curved such that objects
entering come
up against a duct wall on one side of the duct. The duct wall aligns the
object
longitudinally. In some embodiments the objects are buffered and used end to
end.
In some embodiments, the duct wall includes an abutting structure such as a
slot for
object alignment. Objects entering the stationary duct will tend to collide
with the
walls of the stationary duct at grazing angles and lose momentum, ultimately
coming
to rest. The object may optionally be conveyed further by a difference in air
pressure between the entrance and exit of the stationary duct.
Figures 6A to 60 illustrate alternative methods to bring a stream of
objects with different orientations to a common orientation in an object
buffer. In
figure 6A, a stream of objects moving from left to right under the influence
of
centrifugal force and is singulated. The objects are initially oriented
parallel and
antiparailel to the duct wall by Coriolis force. The orientation of each
object is
determined by the detector proximate to the stream which communicates with a
2.o diverter. If the object is a desired orientation, the object continues
along a first path.
Otherwise the object is diverted into another path by a diverter 84. In one
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arrangement (not shown) the path operates to engage the objects which are not
correctly oriented and they are returned to the supply conduit.
The arrangement shown in Figure 6A is a IT radians object rotator
about an axis orthogonal to the longitudinal axis that can be used separately
or in
5 .. combination with preceding or following orientation methods. In this
arrangement,
the diverter 84 operates to direct objects oriented antiparallel follow path
81 and
objects oriented parallel to follow path 86. Path 86 feeds objects into a
buffer from
the top. Path 81 feeds objects into a buffer from the bottom. Objects entering
the
buffer are propelled to the right. The buffer is shaped to preserve the
orientation of
lo .. objects entering along path 81 and path 86. Because objects enter from
opposite
directions with opposite orientation, objects in the buffer have the same
orientation
as shown.
Thus, the objects are operated upon to change the orientation thereof
depending on the detected orientation and the objects are directed along first
and
15 second paths 81,86 depending on the detection of the first and second
orientations.
The first path 81 is arranged to change the orientation of the objects therein
relative
to the second path so that the objects are combined into a common stream 63
from
the first and second paths in the same orientation.
The arrangement shown in Figure 6B is a 7:12 radians object rotator
20 about an axis orthogonal to the longitudinal axis that can be used
separately or in
combination with preceding or following orientation methods. The case shown in
this arrangement is a surface mount integrated circuit chip 100 with 4-fold
rotational
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46
symmetry. The dot 101 conventionally represents the position of pin 1 and can
be in
any one of eight positions following singulation: four orientations facing
toward the
sing ulation duct wall and four orientations facing away from the singulation
duct wall.
Detector 83 determines the object orientation. The diverted' 34 operates to
direct
objects with pin 1 in the upper right and lower right corners into paths 811
and 861
respectively. Path 861 feeds objects into a buffer from the top. Path 811
feeds
objects into a buffer directly. Objects entering the buffer are propelled to
the right.
The buffer is shaped to preserve the orientation of objects entering along
paths.
Because objects enter from orthogonal directions, objects in the buffer have
the
same orientation as shown. It should be appreciated that -.-c/2 and - it/2
radians
object rotations are mirror images of one another in the arrangement shown in
Figure 6B. Oriented objects in the buffer are fed to a packaging operation
generally
indicated at 103. Objects are placed into pockets 104 on a tape 105. The path
lengths or travel time along the two paths 811 and 861 is arranged to be the
same
.. so that an object extracted onto the path 861 is inverted and returned into
the path
811 at the same location that it was removed. All of the paths 76, 811 and 861
can
be mounted on a common rotating body or the paths 861 and 811 may be held
stationary while the path 76 rotates to provide the singulating action.
The arrangement shown in Figure 60 is a re radians object rotator
about a longitudinal axis that can be used separately or in combination with
preceding or following orientation methods. Objects oriented facing away from
the
singulation wall are diverted into path 811 and travel directly to a buffer.
Objects
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oriented facing the singulation wall are diverted to path 861 which has a n
radians
twist 862. The duct walls of path 861 are shaped to constrain objects to
follow the
path axis. Hence, a a radians twist in the path 861 at 862 flips the
orientation of the
object by a radians and then deposits the object in a buffer. Oriented objects
in the
buffer might for example, pass a marking operation 864 where the marked
objects
are then directed to a packaging operation 103 in which the objects are placed
in
pockets 104 on a tape 105
Although Figures SA to SC show orthogonal object rotations, it should
be appreciated that other angles of rotation are possible and that the
rotations can
lo .. be applied sequentially in any order to achieve a desired object
orientation.
Figure 7 illustrates a method to convert a radial stream of singulated
and oriented objects in the duct 89 carried on the body 88 rotating around
axis 824
into an axial stream of singulated and oriented objects flowing along an exit
duct gO.
Objects are deposited in the central region of a rotating body and enter a
duct as
1 5 shown in more detail in figures 1 to 3. The objects are oriented in a
region near the
periphery of the rotating body by methods better shown in figures 1, 6A, 6B
and 60
in region 'termed the alignment zone. Objects exiting the alignment zone enter
a
duct labeled path 91 which curves radially inward toward the axis 824 becoming
axial at the terminal end 90. Centrifugal force and friction resist the motion
of
20 .. objects along path 91, so it is necessary to provide a motive force in
the direction of
path 91. The motive force can be supplied by a pressure gradient generated by
applying vacuum to the terminal end 91A of path 91 at outlet 90. Other methods
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may be used such as air pressure delivered to path 91 at some point (not
shown)
along the direction of travel of the objects. Path 91 can also, for example,
take the
form of a moving belt with receptacles to receive objects (not shown).
It should be noted that the arrangement shown can induce a spin in the
:5 .. object at the terminal end. An optional end section 91B linked with a
rotating joint
can be made to rotate in the opposite direction to reduce object spin,
Thus the objects are fed from the singulation duct 89 to a supply duct
91 having an end portion 90 lying on the axis of rotation of the singulation
duct such
that the objects are supplied at the end portion 90 in a stream with the same
in orientation (by including, for example the arrangement in Figure 6A
within path 91)
for feeding to a tool or driver 67. The arrangement shown can produce an axial
stream of objects in any orientation because gravity is small compared with
the
inertial forces generated in the singulation duct.
Figures 8A and 8r3 show arrangements suitable for singulating and
1 3 orienting different typeS of objects. Figure 8A shows a rotating body
901 with two
ducts 911 and 912. Duct 911 is fed with objects through supply conduit 921
connected with a bulk supply (not shown) CY: a first object type. Duct 912 is
ted with
objects through supply conduit 922 oonneaed with a bulb supply (not shown) or
a
second object type. The concentric supply cnriduits stationary and are not
attached
20 .. to rotating body 001 in some embodiments. a duct 911 is cne'osod as
indicated at
D-14 to constrain the object orientation, Hence with the arrangement in Figure
8A
sindulatc,.d streams of two d fferent types of objects can be supplied at. the
same lure
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through ducts 911 and 912 Figure 8B shows an alternative arrangement wherein
supply conduits 921; 922, and 923 feed objects from the side !nto the cents
regions
of rotating bodies 901, 902, nd 903. respectively, Ih(-3 suppli conduits may
be
flexible hoses or rigid pipes. The supply conduits are stationary and not
attadhud to
the rotary bodies. The rotating bodies 901, 902 and 90$ contain ducts 911, 912
and
913 respectively. Th e rotating bodies may rotate at diffi::?rerri: rates so
as to supply
different types of objects to a downstream operation in the quantities
required.
Alternately, rotary bodies 901, 002 and 903 may rotate synchronously as a
single
body.
Figures OA to 9C show a series of steps of another method for
changing object orientation and placing objects into a buffer end to end. A
detector
106 determines the object orientation in singulation duct 107. Objects aligned
antiparallel enters a slot 108 in a rotating body 111. Preferably the slot 108
contains
a spring 109 that compresses storing the kinetic energy of the object_ As the
spring
is being compressed, the rotating body rotates and the slot 108 moves to a
release
position 110 shown in Figure 9B. Stored energy in the spring 109 then ejects
the
object with reversed orientation and substantially the same kinetic energy as
it
entered with. It should be noted that the spring 109 may be mechanical or
electromagnetic. Preferably the rotating body 111 has the slots on opposing
faces
to limit the range of angular motion required to catch a second object. For
objects
aligned parallel to the singulation duct axis, the rotating body rotates to
provide path
112 for the object to pass straight through to a buffer.
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When the detector determines the object is in a first orientation, the
second rotary body 111 is rotated to a first position to align the duct 112
through the
rotary body with the object path 107 and the object passes through unimpeded
retaining first orientation into a supply duct or buffer 114. Supply duct 114
is a tube
5
cartridge. When the detector determines the object is in a second orientation,
the
second rotary body is rotated to a second position to align a depression in
the rotary
body with the object path. The object enters the depression and acts against a
spring so as to transfer the kinetic energy of the object into potential
energy in the
spring.
to The
second rotary body 111 rotates to a release position where the
object is released with a different orientation. In some cases, the second
rotary
body has a casement (not shown) that retains the object during rotation to the
release position. At the release position, potential energy stored in the
spring is
transferred to kinetic energy of the object. The arrangement shown provides an
axis
15 116 of
rotation of the body 111 which is a significant distance from the object
itself,
In some oases. the axis 116 may be at the center of mass of the object or
within the
object so as to reduce the energy required to move between the positions of
Figures
9A and 9B.
The spring 109 can also bc provided by an electromagnetic spring.
20 For
objects that have a net electrical charge or a net charge separation (dipole),
an
electric field is optionally applied to retain the spring in a fixed position,
or even to
increase the energy stored in the spring to a pre-deternnired level. The
second
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rotary body then rotates to a release position and the electric field is
switched off or
reversed. The potential energy in the spring is transferred to the object and
the
object is ejected from the depression with a different orientation. The
kinetic energy
of the object may be further increased at the release position by reversing
the
electric field.
Figures 10A and 10B show a two-step process wherein objects are
singuleted by a duct 120 on a rotating body 121 and released in all directions
around
the periphery. Objects are caught by a funnel structure 123 preferably made of
compliant material to reduce the object's kinetic energy.
io In Figure 10A, the funnel directs objects to release duct 124 where
detector 125 measures object presence generating a signal causing a second
rotary
body 126 to rotate to align orientation duct 127 with the release duct so as
to capture
object 125. The orientation duct 127 is shaped to guide the object toward an
abutting slot 130. The rotary body and integral orientation duct are then
rotated
?5 about axis 131 generating inertial forces that cause a part of the
object to enter the
abutting slot and orient the longitudinal axis of the object normal to the
duct wall in
the same manner as described with reference to Figure 1A. Radial motion of the
object due to centrifugal forces is prevented by a casing around the second
rotary
body (not shown). Aligned objects are released into a buffer 132 at release
position
20 133 The buffer supplies singulated arid oriented objects to tool 134.
In Figure 10w, the funnel constrains the orientation of objects to states
with longitudinal axis parallel and antiparallel to the funnel axis, Detector
125
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measures the object orientation and generates a signal causing diverter 135 to
direct
objects oriented antiparallel to buffer 137 and objects oriented parallel to
an
alignment wheel 138 with pockets 138 that retain the parallel orientation. The
wheel
then rotates by a distance of one pocket position so as to present an empty
pocket
for the next parallel oriented object. An outer casing retains the objects in
pockets
between the capture position 139 and release position 140. Once the pockets
between the capture and release positions are filled, each increment of the
wheel
captures one object and releases one object into a direction angularly
displaced
from the capture position. Thus as shown, the objects are captured in a
parallel
io orientation and released on a path 141 to buffer 137 in a substantially
antiparallel
orientation. Objects are fed from buffer 137 to tool 134.
The constructions of Figures 11A and 11B are very similar to the
constructions of Figures 10A and 10B and use the same orienting systems as
shown
in those embodiments. Like the embodiment shown in Figure 7, objects are
.. deposited in the central region of a rotating body 88 and enter a duct 89
as shown in
more detail in figures 1 to 3. Objects are singulated in the duct 89 carried
on the
body 88 rotating around axis 824. In the embodiment of Figure 7, objects are
brought to a common orientation on the rotating body whereas in the
embodiments
of Figures 11A and 11B objects are brought to a common orientation after
exiting an
axial port 90. Specifically, objects with a longitudinal axis enter the axial
port 90 with
either parallel or antiparallel orientation with respect to the axis of
rotation.
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In Figure 11A, the axial port directs objects to supply duct 91 where
detector 125 measures the object presence generating a signal causing a second
rotary body 126 to rotate to align orientation duct 127 with the supply duct
91 so as
to capture object 128. The orientation duct 127 is shaped to guide the object
toward
an abutting slot 130. The rotary body and integral orientation duct are then
rotated
about axis 131 generating inertial forces that cause a part of the object to
enter the
abutting slot and orient the longitudinal axis of the object normal to the
duct wall in
the same manner as described with reference to Figure 1A. Radial motion of the
object due to centrifugal forces is prevented by a casing around the second
rotary
io body (not shown). Aligned objects are released into a buffer 132 at
release 133.
In Figure 11B, the detector 125 measures the object orientation
proximate to axial port 90 and generates a signal causing dlyerter 135 to
direct
objects oriented antiparallel to buffer 137 and objects oriented parallel to
an
alignment wheel 136 with pockets shaped to capture objects at position 139 and
[5 retain the parallel orientation. The wheel then rotates one pocket
position presenting
an empty pocket for the next parallel oriented object. An outer casing retains
the
objects in pockets between the capture position 139 and release position 140.
Once
the pockets between the capture and release positions are filled, each
increment of
the wheel captures one object and releases one object into a direction
angularly
20 .. displaced from the capture position. Thus as shown, the objects are
captured in a
parallel orientation and released to buffer 137 in a substantially
antiparallel
orientation by transfer means 141. Objects are fed from buffer 137 to tool
134.
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In add Won to the sot arrangement 58 (Figure 1A) described above for
orienting the objects within the duct, which can be either the singulation
duct or in a
downstream separate duct, many other arrangements for changing the orientation
are possible. In one arrangement (not shown) the object may be oriented by
simple
friction between the object and the wall over which it is travelling, provided
sufficient
space is provided within the duct for the object to turn. In this arrangement,
where
the object has areas of greater and lesser friction, friction causes the area
of the
object which has the most frictional effect with the wall to be located at a
position
where that area is trailing and the area of lesser frictional effect is
leading.
i 0 Other
arrangements can use a rebounding effect described below.
Many other surface arrangements can be designed which engage the object and
can rotate it about a certain axis to obtain change in orientation. It will
also be
appreciated that some objects have many different axes about which the
orientation
can be changed and the arrangements described herein can be used repeatedly to
re-orient the object about all of the axes to obtain a selected one of eight
different
orientations.
Turning now to Figure 12, there is shown another arrangement similar
to that of Figures 6A, 6B and 6C where the orientation of the object is
determined by
the sensor 83 and directed by the deflector 84 into one of two separate paths.
in
70 one of
the paths the orientation is maintained arid in the other of the paths the
orientation is reversed. In Figure 12, the second path is shown at 142 and the
orientation is changed by introducing the object 148 into a path 145 which
includes a
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rebound device 146. The object passes through an air gap 143 at which a
detector
144 is boated to sense the character or orientation of the object. The rebound
device is arranged to impact the object at a required location so that its
bounce
causes it to change orientation. Thus, as shown if the head impacts the
rebound
device first, the object is reversed in direction in the path 145 so that the
shank or tail
is first. The rebound device 146 can be moved or actuated to change the
direction of
rebound to different paths depending on data from the sensor 144.
In Figure 13 is shown another arrangement similar to that of Figure 6.
In this arrangement the deflector 84 is replaced by a rebound deflector 821
which is
in movable between two different positions depending on the dE.:teclion of
the
orientation of the object by the sensor 83. In one position where the
orientation is
determined to be a required orientation, the defector 821 moves away from the
path
and allows the object to pass from the path 76 onto the path 81 while
maintaining
the same orientation. In the second position the rebound deflector impacts the
object which is determined to he of the opposite orientation and impacts the
object in
a manner which causes the object to enter the path 86 while at the same time
reversing the orientation in the rebound.
Figure 14A shows a radial section of duct 825 rotating about axis 824
generating centrifugal and Coriolis inertial forces along the duct and into
the duct
wall respectively, as indicated. ihe duct geometry as shown is for simplicity
of
illustration only. The duct wall may in general may be curved having both
radial and
tangential components. Objects 826 and 827 are moving along pathway 828
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accelerated by centrifugal force which tends to increase the spacing between
objects. Object 826 in a first orientation is stable along pathway 828 as 3
normal
force from the duct wall on pathway 828 counters the Coriolis force into the
duct
wall. Object 827 in a second orientation is unstable along pathway 828 and
tends
.. toward pathway 829 due to a tangential step in the duct wall 830. Object
827
experiences a torque about axis 831 toward pathway 829. Hence objects with
different orientation are sorted vertically in the direction of the duct
rotation axis onto
different pathways by the arrangement shown in Figure 14A.
Figure 14B shows another arrangement suited for changing the
it' .. orientation of objects moving along pathway 833. In one arrangement a
protrusion
834 is positioned to engage objects with the orientation of object 827 and
generate a
torque to rotate object by 90 degrees. Object 826 passes under protrusion 834
and
retains the same orientation. In a second arrangement a detector (not shown)
measures the orientation of each object and depending upon the measured
orientation a control system actuates protrusion 835 to engage and rotate
selected
objects from a first orientation to a second orientation.
Figure 14C shows an arrangement for sorting objects tangentially
depending upon object orientation. Objects 826 and 827 are accelerated along
pathway 836 by centrifugal force and are held against the duct wall of pathway
836
by Coriolis force. Object 827 encounters slot 839 and is supported above and
below
slot 839 by sections of duct wall indicated at 840 and 841. In some
embodiments
slot 839 may be opened and closed by an actuator in response to a sensor
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measurement of object orientation. Hence object 826 continues along pathway
836.
Object 826 encounters slot 839 and is supported only by the strip of duct wall
indicated at 840. Hence object 826 is pulled through slot 839 by Coriolis
force and
crosses into the gap between pathways 838 and proceeds along pathway 837.
Hence objects with different orientation are sorted tangentially by the
arrangement
shown in Figure 14C
The arrangements shown in Figures 14A, 14B and 140 may be used
in any combination with each other and in any combination with arrangements
discussed above within the scope of the present invention.
