HIGH SPEED COUNTER

• US 20110132721A1
• Filed: 06/29/2009
• Published: 06/09/2011
• Est. Priority Date: 07/02/2008
• Status: Active Grant

• Current Assignee: Monsanto Technology LLC (Bayer AG)
• Original Assignee: Monsanto Technology LLC (Bayer AG)
• Inventors: Kevin, Deppermann, Elias, Yannakakis J., Brian, Forinash J.
• Granted Patent: US 8,925,762 B2
• Time in Patent Office: Days
• US Class Current: 198/349
• CPC Class Codes: A01C 7/046 with perforated seeding discs
• CPC Class Codes: B65B 35/28 by pneumatic conveyors
• CPC Class Codes: B65B 35/30 Arranging and feeding articles in groups
• CPC Class Codes: B65B 35/48 by pneumatic conveyors
• CPC Class Codes: B65B 57/20 Applications of counting devices for controlling the feed of articles other applications B65B65/08
• CPC Class Codes: B65G 11/088 for bulk
• CPC Class Codes: B65G 37/00 Combinations of mechanical conveyors of the same kind, or of different kinds, of interest apart from their application in particular machines or use in particular manufacturing processes series of co-operating belt conveyor units B65G15/22; series of co-operating chain conveyor units B65G17/26; sequence control of combined conveyors B65G43/10
• CPC Class Codes: B65G 47/08 spacing or grouping the articles during feeding during transit by conveyor B65G47/28
• CPC Class Codes: B65G 47/46 and distributing, e.g. automatically, to desired points in tube mail systems B65G51/36
• CPC Class Codes: B65G 47/848 the article-engaging elements being suction or magnetic means
• CPC Class Codes: G05B 15/02 electric
• CPC Class Codes: G07F 17/0092 for assembling and dispensing of pharmaceutical articles medical dispensers for private use, A61J7/00
• CPC Class Codes: G16H 20/10 relating to drugs or medications, e.g. for ensuring correct administration to patients

Abstract

The present disclosure provides systems and methods for counting a plurality of objects and parsing the objects into groups of varying quantities. In various embodiments, the system includes a singulating and counting module operable to singulate and count a plurality of objects from a large volume of the objects. Additionally, the system includes a diverter and accumulator module operable to receive the singulated objects, parse the objects into groups of varying quantities, and direct each group into a selected one of a plurality of discharge funnels. Furthermore, the system includes an object collection module operable to sequentially position each one of a plurality of object collection receptacles adjacent the discharge funnels such that each group of objects is deposited into a respective corresponding one of the object collection receptacles.

Claims

1. A system for counting small objects, said system comprising:

a singulating and counting module structured and operable to singulate a plurality of objects from a large volume of the objects and count the singulated objects;

a diverter and accumulator module structured and operable to sequentially receive the singulated objects, sequentially separate the received objects into groups of objects such that each group of objects comprises an automatically controlled number of objects and at least one of the groups of objects comprises a different number of objects than at least one other group of objects, and direct each group of singulated objects into a selected one of a plurality of discharge funnels of the diverter and accumulator module; and

an object collection module structured and operable to automatically sequentially position each one of a plurality of object collection receptacles adjacent to the discharge funnels such that each group of objects is deposited into a respective corresponding one of the object collection receptacles.

2. The system of claim 1, wherein the singulating and counting module comprises:

a bulk object hopper unit mounted to a singulating and counting module platform for retaining the large volume of objects;

a singulating vacuum wheel unit mounted to the singulating and counting module platform adjacent the bulk object hopper unit for singulating the plurality of objects from the bulk object hopper; and

an object off-load and counting device positioned between the object bulk hopper unit and the singulating vacuum wheel unit for removing and counting the singulated objects from the singulating vacuum wheel unit.

3. The system of claim 2 wherein the singulating and counting module platform includes a hopper evacuation opening located beneath the bulk object hopper unit and the bulk object hopper unit is slidably mounted to the singulating and counting module platform such that the bulk object hopper unit can be moved from a singulating position to a hopper evacuation position in which the objects within the bulk object hopper unit fall through the hopper evacuation opening into an evacuation container to evacuate all objects from the bulk object hopper unit.

4. The system of claim 2, wherein the bulk object hopper unit comprises:

a hopper for retaining the large volume of objects, the hopper including an object egress opening; and

an object singulation chamber positioned between the hopper and a singulating vacuum wheel of the singulating vacuum wheel unit for receiving objects from the hopper, via the egress opening, and presenting the objects to the singulating vacuum wheel for singulation of the objects in the object singulation chamber, via the singulating vacuum wheel.

5. The system of claim 4, wherein the bulk object hopper unit further comprises an object baffle adjustably mounted to the hopper to adjustably cover a portion of the egress opening to control an amount of pressure on the objects in the object singulation chamber against the singulating vacuum wheel caused by the weight of the objects in the hopper.

6. The system of claim 5, wherein the singulating vacuum wheel comprises a plurality of vacuum ports spaced apart in a circle radially inward from a perimeter of the singulating vacuum wheel and extending through a face of the singulating vacuum wheel, each vacuum port communicatively coupled to a vacuum source and the singulating vacuum wheel rotationally mounted in a substantially vertical plane such that during operation of the singulating and counting module a portion of the singulating wheel rotates past the object singulation chamber as a vacuum is provided at each of the vacuum ports to draw objects to the singulating vacuum wheel face at each vacuum port, extract the objects from the object singulation chamber, and carry the extracted objects to the object off-load and counting device.

7. The system of claim 6, wherein selected ones of the vacuum ports are a different radial distance from a center of the singulating vacuum wheel than selected other ones of the vacuum ports.

8. The system of claim 6, wherein vacuum ports comprise recessed vacuum ports such that the singulating vacuum wheel face includes a recess at each vacuum port.

9. The system of claim 6, wherein the face of the singulating vacuum wheel includes a plurality of object agitating cavities for agitating the objects in the object singulation chamber as the singulating vacuum wheel rotates.

10. The system of claim 6, wherein the bulk hopper unit further comprises an excess object removal device structured and operable to dislodge at least one of a plurality of objects drawn to and extracted by any of the vacuum ports such that each object vacuum port holds a single object to the face of the singulating vacuum wheel as each respective object is carried to the object off-load and counting device.

11. The system of claim 10, wherein the excess object removal device comprises at least one brush positioned adjacent the face of the singulating vacuum wheel such that when a plurality of objects are drawn to a particular vacuum port and extracted from the object singulation chamber, the at least one brush will contact and dislodge at least one of the plurality of objects extracted by the particular vacuum port.

12. The system of claim 6, wherein the singulating vacuum wheel unit further comprises a single object verification sensor operable to determine whether each vacuum port is carrying only a single object to the object off-load and counting device.

13. The system of claim 6, wherein the object off-load and counting device comprises a hollow tubular body and an object stripping plate mounted to a top portion of a first side of the tubular body, the object off-load and counting device positioned between the object bulk hopper unit and the singulating vacuum wheel unit having the stripping plate in close proximity to the face of the singulating vacuum wheel such that as the singulating vacuum wheel rotates, each extracted object will contact the stripping plate, be dislodged from the face of the singulating vacuum wheel and fall into the tubular body.

14. The system of claim 13, wherein the object stripping plate includes a substantially V-shaped leading edge that is chamfered inward toward a center of the tubular body and the object off-load and counting device is located with respect to the singulating vacuum wheel such that as the singulating vacuum wheel rotates each object will contact a first side of the substantially V-shaped leading edge and be pushed radially outward to dislodge each object from the respective vacuum port allowing each object to fall into and travel through the tubular body.

15. The system of claim 14, wherein the object off-load and counting device further comprises a counting device mounted to a bottom portion of the tubular body, the counting device operable to:

sense each dislodged object as each respective object travels through the tubular body and passes the counting device; and

send a corresponding signal to a control system as each object passes the counting device, the control system operable to count the signals, compare the count with a programmed number (electronic spreadsheet) of objects to be included in a respective group of singulated objects and control and coordinate the operations of the singulating and counting module, the diverter and accumulator module and the object collection module to deposit the programmed number of objects (stipulated by the electronic spreadsheet) into the respective corresponding object collection receptacle.

16. The system of claim 15, wherein the counting device comprises a photoelectric sensor.

17. The system of claim 13, wherein the bulk object hopper unit further comprises a forced air object travel assist device operable to inject a stream of air into the tubular body to assist the travel of each object through the tubular body.

18. The system of claim 1, wherein the diverter and accumulator module comprises a diverter unit including a diverter head slidingly engaged with a diverter base to selectively direct the number of singulated objects in each group of singulated objects to a respective corresponding one of a plurality of diverting funnels of the diverter base.

19. The system of claim 18, wherein the diverter head comprises a plurality of object diverting channels extending through the diverter head in different directions.

20. The system of claim 19, wherein the plurality of object diverting channels comprise a pair of object diverting channels that angularly extend through the diverter head in opposing directions with respect to a length of the diverter head.

21. The system of claim 19, wherein each object diverting channel includes a respective upper end and opposing lower end, and the diverter unit additionally includes a diverter head actuator operable to selectively slidingly transition the diverter head along a top of the diverter base to align the upper end of a selected one of the diverting channels with an off-load and count device of the singulating and counting module and the lower end of the selected diverting channel with a corresponding one of the divert funnels of the diverter base.

22. The system of claim 18, wherein the diverter unit further includes a plurality of diverting tubes, each diverting tube extending from a distal end of a respective corresponding one of the diverting funnels and terminating above a corresponding respective one of the discharge funnels.

23. The system of claim 22, wherein the diverter and accumulator module further comprises an accumulator unit including an accumulator base that includes the discharge funnels and a sluice plate slidingly engaged with the accumulator base, the sluice plate including a plurality of apertures and selectively movable between:

an object dispensing position, wherein the each of the sluice plate apertures align with a corresponding one of the diverting tubes such that selected groups of singulated objects are allowed to pass through the diverting tubes and sluice plate apertures into the respective discharge funnels; and

an object accumulating position, wherein the diverting tubes are covered by the sluice plate such that selected groups of are blocked by the sluice plate from passing through the diverting tubes into the respective discharge funnel.

24. The system of claim 1 further comprising a control system operable to control and coordinate the operations of the singulating and counting module, the diverter and accumulator module and the object collection module, wherein each collection receptacle comprises an information device including information stored for access by the control system to control the number of objects to be deposited into each respective corresponding collection receptacle.

25. The system of claim 24, wherein each information device includes information (read into the electronic spreadsheet) indicative of the number of objects to be deposited into each respective collection receptacle.

26. The system of claim 24, wherein the object collection module comprises one or more collection receptacle racks for removably retaining the object collection receptacles, each rack including:

a top plate having a plurality of tubular receptacle spouts extending from a plurality of apertures in the top plate, each spout for removably retaining a top portion of a respective one of the object collection receptacles and directing a group of objects from a respective one of the discharge funnels into the respective collection receptacle; and

a bottom plate comprising a plurality of recessed bays, each recessed bay for removably retaining a bottom portion of a respective one of the object collection receptacles.

27. The system of claim 26, wherein the collection module further comprises a linear stage structured and operable to controllably move a collection receptacle rack mounting carriage along a length of the linear stage, the collection receptacle rack mounting carriage structured to removably retain at least one collection receptacle rack.

28. The system of claim 27, wherein the collection receptacle rack mounting carriage comprises a plurality of locating pins structured to removably mate with a plurality of locating pin receivers included in the bottom plate of each collection receptacle rack to removably retain each collection receptacle rack on the collection receptacle rack mounting carriage in a substantially precise location and orientation such that the linear stage can be controlled to sequentially position each of the top plate apertures under a respective one of the discharge funnels to deposit each group of singulated objects in the respective corresponding one of the object collection receptacles.

29. The system of claim 1, wherein the small objects comprise objects.

30. A method for counting small objects, said method comprising:

singulating a plurality of objects from a large volume of the objects and counting the singulated objects, the singulating and counting performed utilizing a singulating and counting module;

sequentially receiving the singulated objects, sequentially separating the received objects into groups of objects such that each group of objects comprises an automatically controlled number of objects and at least one of the groups of objects comprises a different number of objects than at least one other group of objects, and directing each group of singulated objects into a selected one of a plurality of discharge funnels of a diverter and accumulator module, the sequentially receiving, separating and directing performed utilizing an automatically controlled diverter head of the diverter and accumulator module; and

automatically sequentially positioning each one of a plurality of object collection receptacles adjacent the discharge funnels such that each group of objects is deposited into a respective corresponding one of the object collection receptacles the automatically sequentially positioning performed utilizing an object collection module.

31. The method of claim 30, wherein the singulating and counting comprises:

retaining the large volume of objects in a bulk object hopper unit mounted to a singulating and counting platform of the singulating and counting module;

singulating the plurality of objects from the bulk object hopper utilizing a singulating vacuum wheel unit mounted to the singulating and counting module platform adjacent the bulk object hopper unit for; and

removing and counting the singulated objects from the singulating vacuum wheel unit utilizing an object off-load and counting device positioned between the object bulk hopper unit and the singulating vacuum wheel unit.

32. The method of claim 31, wherein the method further comprises evacuating all objects from the bulk object hopper unit by moving the bulk object hopper from a singulating position to a hopper evacuation position to expose a hopper evacuation opening located in the singulating and counting module platform beneath the bulk object hopper unit such that the objects within the bulk object hopper unit fall through the hopper evacuation opening into an evacuation container.

33. The method of claim 31, wherein retaining the large volume of objects in a bulk object hopper unit comprises:

retaining the large volume of objects in a hopper of the bulk object hopper unit, the hopper including an object egress opening;

transferring a plurality of the objects from the hopper into an object singulation chamber positioned between the hopper and a singulating vacuum wheel of the singulating vacuum wheel unit, via the egress opening; and

presenting the objects to the singulating vacuum wheel for singulation of the objects in the object singulation chamber, via the singulating vacuum wheel.

34. The method of claim 33, wherein transferring the plurality of the objects from the hopper into an object singulation chamber comprises adjustably covering a portion of the egress opening utilizing an object baffle adjustably mounted to the hopper to control an amount of pressure on the objects in the object singulation chamber against the singulating vacuum wheel caused by the weight of the objects in the hopper.

35. The method of claim 34, wherein presenting the objects to the singulating vacuum wheel comprises:

rotating a portion of the singulating vacuum wheel past the object singulation chamber as a vacuum is provided at each of a plurality of vacuum ports within the singulating vacuum wheel to draw objects to the singulating vacuum wheel face at each vacuum port, the vacuum ports spaced apart in a circle radially inward from a perimeter of the singulating vacuum wheel and extending through a face of the singulating vacuum wheel;

extracting the objects from the object singulation chamber, via rotation of the singulating vacuum wheel; and

carrying the extracted objects to the object off-load and counting device, via rotation of the singulating vacuum wheel.

36. The method of claim 35, wherein extracting the objects from the object singulation chamber comprises utilizing a singulation vacuum wheel having selected ones of the vacuum ports located a different radial distance from a center of the singulating vacuum wheel than selected other ones of the vacuum ports.

37. The method of claim 35, wherein extracting the objects from the object singulation chamber comprises utilizing a singulation vacuum wheel having recessed vacuum ports such the singulating vacuum wheel face includes a recess at each vacuum port.

38. The method of claim 35, extracting the objects from the object singulation chamber comprises utilizing a singulation vacuum wheel having the face of the singulating vacuum wheel including a plurality of object agitating cavities for agitating the objects in the object singulation chamber as the singulating vacuum wheel rotates.

39. The method of claim 35, wherein carrying the extracted objects to the object off-load and counting device comprises dislodging at least one of a plurality of objects drawn to and extracted by any one of the vacuum ports such that each object vacuum port holds a single object to the face of the singulating vacuum wheel as each respective vacuum port travels toward the object off-load and counting device.

40. The method of claim 39, wherein dislodging at least one of a plurality of objects comprises utilizing at least one object removal brush positioning adjacent the face of the singulating vacuum wheel to contact and dislodge at least one of the plurality of objects from a particular vacuum port that has drawn and extracted a plurality of objects from the object singulation chamber such that each object vacuum port carries only a single object to the object off-load and counting device.

41. The method of claim 35, wherein carrying the extracted objects to the object off-load and counting device comprises determining whether each vacuum port is carrying only a single object to the object off-load and counting device utilizing a single object verification sensor.

42. The method of claim 35, wherein singulating and counting comprises sequentially dislodging each extracted object from the face of the singulating vacuum wheel utilizing a stripping plate of the object off-load and counting device placed in close proximity to the face of the singulating vacuum wheel such that as the singulating vacuum wheel rotates, each extracted object will contact the stripping plate, be dislodged from the face of the singulating vacuum wheel and fall into a hollow tubular body of the object off-load and counting device.

43. The method of claim 42, wherein sequentially dislodging each object from the face of the singulating vacuum wheel utilizing a stripping plate comprises contacting each object with a first side of a substantially V-shaped leading edge of the object stripping plate as the vacuum wheel rotates such that each object is pushed radially outward to dislodge each object from the respective vacuum port allowing each object to fall into and travel through the tubular body, the V-shaped leading edge being chamfered inward toward a center of the tubular body.

44. The method of claim 43, wherein the singulating and counting further comprises:

sensing each dislodged object as each respective object travels through the tubular body and passes a counting device mounted to a bottom portion of the tubular body;

sending a corresponding signal, via the counting device, to a control system as each object passes the counting device;

counting the signals, via the control system, and comparing the count with a programmed number (electronic spreadsheet) of objects to be included in a respective group of separated objects; and

controlling and coordinating the operations of the singulating and counting module, the diverter and accumulator module and the object collection module to deposit the programmed number of objects (stipulated by the electronic spreadsheet) into the respective corresponding object collection receptacle.

45. The method of claim 42, wherein sequentially dislodging each object from the face of the singulating vacuum comprises injecting a stream of air into the tubular body to assist the travel of each object through the tubular body.

46. The method of claim 30, wherein the diverter and accumulator module includes a diverter unit having a diverter head slidingly engaged with a diverter base, and the receiving, separating and directing each group of separated objects comprises selectively directing each group of singulated objects to a respective corresponding one of a plurality of diverting funnels extending through the diverter base by controllably moving the diverter head to one of a plurality of diverting positions.

47. The method of claim 46, wherein the diverter head comprises a plurality of object diverting channels extending through the diverter head in different directions, and selectively directing the plurality of singulated objects comprises slidingly transitioning the diverter head along a top of the diverter base to align an upper end of a selected one of the diverting channels with an off-load and counting device of the singulating and counting module and align a lower end of the selected diverting channel with a corresponding one of the diverting funnels of the diverter base.

48. The method of claim 47, wherein the diverter unit further comprises a plurality of diverting tubes extending from diverting funnels, and wherein receiving, separating and directing each group of separated objects further comprises selectively moving a sluice plate slidingly engaged with an accumulator base of the accumulator unit between:

an object dispensing position, wherein each of a plurality of apertures within the sluice plate align with a corresponding one of the diverting tubes such that each group of singulated objects are allowed to pass through the diverting funnels and sluice plate apertures into the respective discharge funnels, and

an object accumulating position, wherein the discharge funnels are covered by the sluice plate such that selected groups of singulated objects are blocked by the sluice plate from passing through the diverting tubes into the respective discharge funnel.

49. The method of claim 30, wherein automatically sequentially positioning each one of the plurality of object collection receptacles comprises:

reading an information device included on each collection receptacle, each information device including information indicative of the number of objects in the group of objects to be deposited into each respective collection receptacle;

storing the read information into a control system (to compile an electronic spreadsheet utilized by the control system) operable to control and coordinate the operations of the singulating and counting module, the diverter and accumulator module and the object collection module; and

controlling the number of objects in each respective group of objects deposited into each respective corresponding collection receptacle based on the stored information.

50. The method of claim 49, wherein automatically sequentially positioning each one of the plurality of object collection receptacles further comprises automatically controllably moving a collection receptacle rack that removably retains the plurality of collection receptacles along a length of a linear stage positioned beneath the discharge funnels to sequentially position each of the receptacles removably retained within the rack beneath a respective one of the discharge funnels to receive the respective corresponding group or objects.

51. The method of claim 50, wherein automatically controllably moving the collection receptacle along the length of a linear stage comprises:

positioning the collection receptacle rack on a mounting carriage of the linear stage such that a plurality of locating pins of the mounting carriage are received in a plurality of locating pin receivers included in a bottom plate of the collection receptacle rack to removably retain the collection receptacle rack on the mounting carriage in a substantially precise location and orientation such that the linear stage can be controlled to sequentially position each of the collection receptacles under a respective one of the discharge funnels to deposit each group of separated objects into the respective corresponding one of the object collection receptacles.

52. A system for counting small objects, said system comprising:

a singulating and counting module structured and operable to singulate a plurality of objects from a large volume of the objects and count the singulated objects;

a diverter and accumulator module structured and operable to sequentially receive the singulated objects, sequentially separate the received objects into groups of objects such that each group of objects comprises an automatically controlled number of objects and at least one of the groups of objects comprises a different number of objects than at least one other group of objects and direct each group of singulated objects into a selected one of a plurality of discharge funnels of the diverter and accumulator module;

an object collection module structured and operable to automatically sequentially position each of a plurality of object collection receptacles adjacent to the discharge funnels such that each group of objects is deposited into a respective corresponding one of the object collection receptacles, each collection receptacle comprising an information device including information indicative of the number of objects to be included in each group of objects to be deposited into each respective collection receptacle, at least one of the groups of objects having a different number of objects than at least one other group of objects; and

a control system operable to read each information device, store the read information in an electronic spreadsheet and control and coordinate the operations of the singulating and counting module, the diverter and accumulator module and the object collection module to deposit each group of objects into the respective corresponding collection receptacle based on the information stored in the electronic spreadsheet.