Method and apparatus for stacking discrete planar objects
First Claim
1. A system for forming a plurality of discrete objects into a stack comprising:
- a frame having a top, a bottom and sides;
a conveyor associated with said frame and having an end edge for dispensing discrete objects;
a first support mounted on said frame near said end edge for receiving objects from said end edge and having an opening with a width smaller than the width of said objects;
a first actuator operably connected to said first support for moving said first support between first and second positions relative to said end edge;
a second actuator operably connected to said first support for moving said first support between upper and lower positions relative to said frame;
a second support mounted on said frame beneath said first support having a width less than the width of the opening in said first support;
a third actuator operatively connected to said second support for moving said second support between high and low positions, said second support high position being higher than said first support lower position;
a third support mounted on said frame at a position higher than said second support low position and having an opening wider than the width of said second support;
a fourth actuator operatively connected to said third support for moving said third support between a first position beneath said first support and a second position;
a sensor for determining the number of discrete objects in a stack, said sensor being operatively coupled to said to said third actuator; and
a controller for controlling said first, second, third and fourth actuators.
1 Assignment
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Accused Products
Abstract
A system for forming a plurality of discrete objects into a stack is disclosed which system includes a frame having a top, a bottom and sides; a conveyor associated with the frame and having an end edge for dispensing discrete objects, a first support mounted on the frame near the end edge for receiving objects from the end edge and having an opening with a width smaller than the width of the objects, a first actuator operably connected to the first support for moving the first support between first and second positions relative to the end edge; a second actuator operably connected to the first support for moving the first support between upper and lower positions relative to the frame; a second support mounted on the frame beneath the first support having a width less than the width of the opening in the first support; a third actuator operatively connected to the second support for moving the second support between high and low positions, the second support high position being higher than the first support lower position; a third support mounted on the frame at a position higher than the second support low position and having an opening wider than the width of the second support; a fourth actuator operatively connected to the third support for moving the third support between a first position beneath the first support and a second position; a sensor for determining the number of discrete objects in a stack, the sensor being operatively coupled to the to the third actuator; and a controller for controlling the first, second, third and fourth actuators. A method of using the system is also disclosed.
101 Citations
53 Claims
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1. A system for forming a plurality of discrete objects into a stack comprising:
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a frame having a top, a bottom and sides;
a conveyor associated with said frame and having an end edge for dispensing discrete objects;
a first support mounted on said frame near said end edge for receiving objects from said end edge and having an opening with a width smaller than the width of said objects;
a first actuator operably connected to said first support for moving said first support between first and second positions relative to said end edge;
a second actuator operably connected to said first support for moving said first support between upper and lower positions relative to said frame;
a second support mounted on said frame beneath said first support having a width less than the width of the opening in said first support;
a third actuator operatively connected to said second support for moving said second support between high and low positions, said second support high position being higher than said first support lower position;
a third support mounted on said frame at a position higher than said second support low position and having an opening wider than the width of said second support;
a fourth actuator operatively connected to said third support for moving said third support between a first position beneath said first support and a second position;
a sensor for determining the number of discrete objects in a stack, said sensor being operatively coupled to said to said third actuator; and
a controller for controlling said first, second, third and fourth actuators. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30)
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31. A method of forming a stream of discrete objects into a stack comprising the steps of:
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providing a frame having a top, a bottom and sides;
providing a plurality of discrete objects each having a width;
providing a first support on said frame having an opening smaller than the width of said objects, said first support being movable vertically between upper and lower positions and movable horizontally between engaged and disengaged positions;
holding said first support in said upper and engaged positions;
dropping said discrete objects onto said first support to form a stack having a top and a bottom;
moving said first support toward said lower position to maintain the top of said stack at a first level relative to said frame;
providing a second support beneath said first support having a width less than the opening in said first support, said second support being movable between a high position above said lower position and a low position;
lowering said first support over said second support until said second support passes through said opening in said first support and contacts the bottom of said stack;
moving said first support to said disengaged position;
lowering said second support to maintain the top of said stack at said first level;
providing a third support having an opening and translatable between a first position beneath said second support and a second position;
sensing for the occurrence of a stack finished condition;
upon the detection of the stack finished condition, lowering said second support until said second support passes thought the opening in said third support and said third support contacts the stack bottom. - View Dependent Claims (32, 33, 34, 35, 36, 37, 38)
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39. A method of forming a stream of discrete disk-like objects into a stack comprising the steps of:
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providing a frame having a top, a bottom and sides;
providing a conveyor having an end edge;
providing a plurality of discrete disk-like objects each having a diameter on said conveyor;
providing a first support on said frame adjacent said end edge comprising first and second spaced pins separated by a distance less than the diameter of said objects, said first support being movable vertically between upper and lower positions and pivotable between engaged and disengaged positions;
holding said first support in said upper position and in said engaged position;
operating said conveyor to cause said objects to fall over the end edge of the conveyor and onto said first support to form a stack having a top and a bottom;
incrementing a counter each time one of said disk-like objects passes a given location on the conveyor;
moving said first support toward said lower position each time said counter is incremented;
providing a second support beneath said first support having a width less than the distance between said pins, said second support being movable between a high position above said lower position and a low position;
lowering said first support over said second support until said second support passes between said pins and contacts the bottom of said stack;
pivoting said first support to said disengaged position;
lowering said second support each time said counter is incremented when said stack is in contact with said second support;
providing a third support having an opening wider than said second support and being translatable between a first position beneath said second support and a second position;
when said counter reaches a predetermined count, lowering said second support until said second support passes thought the opening in said third support and said third support contacts the stack bottom;
moving said first support to said upper position and said engaged position after the top of the stack drops beneath said lower position;
moving said third support to said second position and releasing said stack into a stack holder after said third support contacts the stack bottom;
raising said second support to said high position after said third support moves from said third support first position; and
returning said third support to said third support first position after the stack is released into the stack holder.
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40. A method of forming a plurality of rows of discrete objects into a plurality of stacks comprising the steps of:
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providing a frame having a top, a bottom and sides;
providing a plurality of discrete objects, each having a width, arranged in rows;
providing a first support on said frame having a plurality of spaced apart openings smaller than the width of said objects, said first support being movable vertically between upper and lower positions and movable horizontally between engaged and disengaged positions, each of said plurality of openings being aligned with one of said plurality of rows;
holding said first support in said upper and engaged positions;
dropping the discrete objects onto said first support over said plurality of openings to form a plurality of stacks each having a top and a bottom;
moving said first support toward said lower position to maintain the tops of said stacks at a first level relative to said frame;
providing a second support beneath said first support comprising a plurality of fingers, each said finger being aligned with and having a width less than the width of the openings in said first support, said second support being movable between a high position above said lower position and a low position;
lowering said first support over said second support until said plurality of fingers on said second support pass through said openings in said first support and contact the bottoms of said stacks;
moving said first support to said disengaged position;
lowering said second support to maintain the top of said stacks at said first level;
providing a third support having a plurality of openings wider than and aligned with said plurality of fingers and translatable between a first position beneath said second support and a second position;
sensing for the occurrence of a stack finished condition;
upon the detection of the stack finished condition, lowering said second support until said fingers pass thought the openings in said third support and said third support contacts the bottoms of said stacks;
covering said stacks on said third support; and
pivoting said third support to invert the stacks on said third support while translating said third support toward a discharge location.
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41. A system for forming a plurality of discrete objects arranged in rows into a plurality of stacks comprising:
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a frame having a top, a bottom, a first side having an inner wall and a second side having an inner wall facing said first side inner wall, said first side inner wall and said second side inner wall each including a guide track;
a first cam and a second cam mounted on said frame;
a drive for rotating said first cam and said second cam;
a conveyor associated with said frame and having an end edge for dispensing rows of discrete objects;
a first support mounted on said frame near said end edge, for receiving objects from said end edge, having a plurality of rods spaced by a distance less than the width of said objects, a guide wheel received in each of said guides on said frame first wall and said frame second wall, and a cam follower movable into engagement with said first cam;
a first actuator operably connected to said first support for moving said first support between first and second positions relative to said end edge;
a second actuator operably connected to said first support for moving said first support between upper and lower positions;
a second support mounted on said frame beneath said first support comprising a plurality of fingers each having a width less than the distance between said first support rods;
a third actuator operatively connected to said second support for moving said second support between high and low positions, said second support high position being higher than said first support lower position;
a third support mounted on said frame at a position higher than said second support low position comprising a frame portion and a tray portion, said tray portion including a bottom wall having a plurality of openings wider than the width of said fingers;
a fourth actuator operatively connected to said third support for moving said third support between a first position beneath said second support and a second position;
a sensor for counting the number of objects passing a point on said conveyor, said sensor being operatively connected to said drive for rotating said first cam and said second cam; and
a controller for controlling said first, second, third and fourth actuators and said drive.
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42. A system for forming a plurality of discrete objects into a stack comprising:
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a frame having a top, a bottom and sides;
a conveyor associated with said frame and having a generally horizontal surface and an end edge for dispensing discrete objects; and
a receiver mounted on said frame near said end edge for receiving objects from said end edge, said receiver being angled with respect to said surface and extending below said surface, whereby a stack of objects formed on said receiver is positioned partially beneath said surface.
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43. A stacker for forming a plurality of objects into stacks comprising:
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a frame;
a first support mounted on said frame having an opening with a width smaller than the width of said objects and being shiftable between an upper position and a lower position relative to said frame; and
a second support mounted on said frame beneath said first support, said second support being aligned with said opening in said first support, having a width less than the width of said opening in said first support, and being shiftable between a first position above said first support lower position and a second position;
whereby shifting said first support from said upper position to said lower position while said second support is in said first position causes said second support to pass through said opening. - View Dependent Claims (44, 45, 46, 47, 48, 50, 51, 52)
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49. A transfer mechanism for receiving a stack of objects, the stack having a top, a bottom and a side, from a stacker and moving the stack to a location away from the stacker comprising:
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a support having an opening wider than a stack-supporting element of the stacker;
a wall normal to said support for engaging the side of the stack;
a cover shiftable between a first position adjacent the top of the stack and a second position; and
an actuating mechanism for moving said cover to said first position and said support toward the location while inverting said support to bring the stack bottom into a position above the stack top.
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53. A system for forming a plurality of discrete objects into a stack comprising:
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a frame having a top, a bottom and sides;
a conveyor associated with said frame and having a generally horizontal surface movable in a first direction for moving a plurality of objects in said first direction toward and over an end edge; and
a movable receiver mounted on said frame near said end edge for receiving objects from said end edge, said movable receiver being angled with respect to said surface, whereby objects supported on said movable receiver move in a direction opposite to said first direction.
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Specification