System and method for sorting items

• US 10,099,256 B2
• Filed: 10/02/2015
• Issued: 10/16/2018
• Est. Priority Date: 10/26/2006
• Status: Active Grant

• Current Assignee: Align Technology Incorporated
• Original Assignee: Align Technology Incorporated
• Inventors: Culp, James Clete, Sankaran, Stanley E.
• Primary Examiner(s): Rodriguez, Joseph C
• Assistant Examiner(s): Kumar, Kalyanvenkateshware
• Application Number:
  US14/874,083
• Publication Number:
  US 20160023249A1
• Time in Patent Office: 1,110 Days
• Field of Search: 209509, 209552-599, 209900
• CPC Class Codes: B07C 3/02 Apparatus characterised by the means used for distribution
• CPC Class Codes: B07C 5/34 Sorting according to other particular properties material testing per se G01N; quality control G07C3/14
• CPC Class Codes: B07C 5/3412 according to a code applied to the object which indicates a property of the object, e.g. quality class, contents or incorrect indication sorting according to size measured by light-responsive means B07C5/10; sorting according to optical properties B07C5/342; for packages B65D79/02; for information carriers G06K7/00
• CPC Class Codes: G05B 19/41865 characterised by job scheduling, process planning, material flow
• CPC Class Codes: G06Q 10/087 Inventory or stock management, e.g. order filling, procurement or balancing against orders
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A system and associated method is provided for sorting parts, which includes a conveyor system for receiving and circulating a plurality of randomly presented parts, a sorting buffer for accumulating selected parts from the plurality of randomly presented parts in an assigned buffer location, and a sequencing system for sequencing the accumulated selected parts.

Claims

1. A sorting and sequencing system for mass-produced, customized objects, each of the objects being marked with a unique machine-readable code, wherein the code for each of the objects includes group data and sequence data indicating a sequence position within a group, the system comprising:

a plurality of object carriers, each having a unique identity that associates each of the plurality of object carriers with one of the objects;

a code-reading mechanism operable to read the code on each of the objects;

a computer operative with the code-reading mechanism so as to map the code of each of the objects to the identity of an associated one of the plurality of object carriers;

a placement mechanism operatively associated with the computer and operable to place each of the objects on its associated object carrier using the code of each object and the identity of its associated object carrier;

a sorting mechanism responsive to the code-reading mechanism and operable to direct each of the object carriers into an assigned one of a plurality of buffer locations based on the group data of the object placed thereon, thereby sorting the objects into a plurality of groups, each group of objects being held in an assigned buffer location, wherein the sorting mechanism is operable to direct each of the object carriers carrying an object into one of the plurality of buffer locations based on the group data of the object carried thereon, thereby sorting the object carriers into the plurality of groups, each group of object carriers being held in an assigned buffer location; and

a sequencing mechanism responsive to the code-reading mechanism and operable to receive each group of objects from its assigned buffer location and to place each of the objects in each of the groups into a sequence based only on the sequence data of the objects, wherein the sequencing mechanism is operable to receive each group of object carriers from its assigned buffer location and to place each of the object carriers in each of the groups into a sequence based on the sequence data of the object carried thereon.

2. The sorting and sequencing system of claim 1, wherein the code-reading mechanism is further operable to determine if the code on an object is unreadable, wherein the computer is operative to map the object with the unreadable code to an object carrier, and wherein the system further comprises a quality control station operable to receive the object carrier on which the placement mechanism has placed the object with the unreadable code.

3. The sorting and sequencing system of claim 1, wherein the identity of each object carrier is provided by an RFID device.

4. The sorting and sequencing system of claim 1, further comprising:

an indexing table operable to receive a plurality of randomly-presented objects; and

an orientation mechanism operable to orient each of the objects on the indexing table into a desired orientation;

wherein the placement mechanism is operable to receive the oriented objects from the indexing table and to place each of the oriented objects on its associated object carrier.

5. The sorting and sequencing system of claim 1:

wherein the code-reading mechanism is operable to associate each of the objects with an associated object carrier based on the group data and the sequence data;

wherein the sorting mechanism is operable to determine the unique identity of each of the object carriers and to direct each of the object carriers holding its associated object into one of the plurality of buffer locations based on an association of the unique identity of each of the object carriers with the group data of the object carried thereon; and

wherein the sequencing mechanism is operable to determine the unique identity of each of the object carriers and to place the object carriers in each of the carrier groups into a sequence based on an association of each of the object carriers in each of the carrier groups with the sequence data of the object carried thereon.

6. The sorting and sequencing system of claim 4, wherein the orientation mechanism comprises:

a vision station operable to determine whether the objects on the indexing table are in the desired orientation; and

an orienting device responsive to the vision station and operable to manipulate into the desired orientation objects that are determined not to be in the desired orientation.

7. The sorting and sequencing system of claim 6, wherein the indexing table includes a plurality of object holders, and wherein the orienting device is operable to (a) remove from an object holder of the indexing table an object that is determined not to be in the desired orientation, (b) manipulate the removed object into the desired orientation, and (c) replace the manipulated object into the same object holder from which it was removed.

8. The sorting and sequencing system of claim 1, further comprising a storing mechanism configured to receive an incomplete group of object carriers from the sorting mechanism, to store the incomplete group of object carriers until a complete group is formed by further object carriers received from the sorting mechanism, and to send the complete group to the sequencing mechanism.

9. The sorting and sequencing system of claim 8, wherein the storing mechanism comprises:

a loading mechanism operable to load the incomplete group of object carriers received from the sorting mechanism onto a pallet; and

a routing mechanism operable to route the pallet to a storage location.

10. The sorting and sequencing system of claim 5, wherein the sorting mechanism comprises:

a sorting reader operable to determine the unique identify of each of the object carriers and to assign each of the object carriers to one of the buffer locations based on the association of the unique identity of each of the object carriers with the group data of the object carried thereon; and

a carrier grouping mechanism operable to move each of the object carriers to its assigned buffer location.

11. The sorting and sequencing system of claim 10, wherein the carrier grouping mechanism comprises:

a buffer location selection device operable to place each of the object carriers into one of the buffer locations selected in accordance with the assignment provided by the sorting reader, whereby each of the buffer locations contains a single carrier group.

12. The sorting and sequencing system of claim 5, wherein the sequencing mechanism comprises:

a sequencing reader operable to determine the unique identify of each of the object carriers in each of the carrier groups and to assign each of the object carriers in each of the carrier groups to a sequencing location based on the association of the unique identity of each of the object carriers in each of the carrier groups with the sequence data of the object carried thereon; and

a carrier sequencing device operable to move each of the object carriers to its assigned sequencing location until the object carriers in each of the carrier groups are positioned in a predetermined sequence in accordance with the sequencing data of the objects carried thereon.

13. The sorting and sequencing system of claim 1, further comprising:

a conveyor operable to receive a plurality of randomly-presented objects;

an indexing table having a plurality of object holders, each of the holders being configured to receive one of the objects;

a vision system operable to identify the objects by their location on the conveyor; and

a robot picker operable to pick objects identified by the vision system from the conveyor and to place each them into one of the object holders;

wherein the placement mechanism is operable to unload the objects from the object holders and to place each of the objects on its associated object carrier.

14. The sorting and sequencing system of claim 13, wherein the vision system is further operable to identify the objects on the conveyor by their orientation, and wherein the robot picker is operable to pick only objects from the conveyor that are identified by the vision system as having an orientation that conforms to a desired orientation.

15. The sorting and sequencing system of claim 13, wherein the vision system is further operable to determine whether the objects on the conveyor have an orientation that conforms to a desired orientation, and wherein the robot picker is operable to manipulate into the desired orientation objects determined not to be in the desired orientation before placing the objects onto the object holders.

16. The sorting and sequencing system of claim 5, further comprising:

a conveyor operable to receive a plurality of randomly-presented objects; and

a vision system operable to identify the objects by their location on the conveyor;

wherein the placement mechanism is operable to pick the objects identified by the vision system from the conveyor and to place each of the identified objects onto the one specific object carrier with which it has been associated.

17. The sorting and sequencing system of claim 16, wherein the vision system is further operable to identify the objects on the conveyor by their orientation, and wherein the placement system is operable to pick only objects from the conveyor that are identified by the vision system as having an orientation that conforms to a desired orientation.

18. The sorting and sequencing system of claim 16, wherein the vision system is further operable to determine whether the objects on the conveyor have an orientation that conforms to a desired orientation, and wherein the placement system is operable to manipulate into the desired orientation objects determined not to be in the desired orientation before placing the objects onto the object carriers.

19. The sorting and sequencing system of claim 4, further comprising:

a bulk supply feeder operable to dispense a batch of the objects;

a conveyor system operable to receive a metered quantity of the objects from the bulk supply feeder;

a sensor operable to sense spacing gaps between the objects on the conveyor system and to cause the bulk supply feeder to dispense additional objects onto the conveyor system in response to the spacing gaps exceeding a predetermined size; and

a pick-and-place mechanism operable to remove the objects from the conveyor system and to place them on the indexing table.

20. The sorting and sequencing system of claim 19, further comprising:

an object distribution device operable to distribute the objects into a single layer on the conveyor system.

21. The sorting and sequencing system of claim 19, wherein the pick-and-place mechanism is operable to take less than all of the objects from the conveyor system, and wherein the sorting and sequencing system further comprises:

a return conveyor operable to receive the objects from the conveyor system that are not removed by the pick-and-place mechanism; and

a return bucket assembly operable to receive the objects from the return conveyor and to transport the objects back to the conveyor system so as to be removable therefrom by the pick-and-place mechanism.

22. The sorting and sequencing system of claim 20, wherein the object distribution device comprises a dispenser on the bulk supply feeder that is operable to dispense the objects on the conveyor system in a single layer.

23. The sorting and sequencing system of claim 1, wherein the code-reading mechanism is operable to read the code on each of the objects and to associate each of the objects with the group data and the sequence data for that object, the system further comprising:

a sorting mechanism responsive to the code-reading mechanism and operable to direct each of the objects into an assigned one of a plurality of buffer locations based on the group data of the object, thereby sorting the objects into a plurality of groups, each group of objects being held in an assigned buffer location; and

a sequencing mechanism responsive to the code-reading mechanism and operable to receive each group of objects from its assigned buffer location and to place each of the objects in each of the groups into a sequence based only on the sequence data of the objects;

wherein the sorting mechanism is operable, in response to the group data, to identify a group of objects in a buffer location as an incomplete group, the system further comprising a storing mechanism configured to receive an incomplete group of objects from a buffer location with an incomplete group of objects, to store the incomplete group of objects until a complete group is formed by further objects received from the buffer locations, and to send the complete group to the sequencing mechanism.

24. The sorting and sequencing system of claim 23, wherein the storing mechanism comprises:

a loading mechanism operable to load the incomplete group of objects received from the buffer location with an incomplete group of products onto a pallet; and

a routing mechanism operable to route the pallet to a storage location.