U.S. patent application number 14/118584 was filed with the patent office on 2014-06-19 for systems and methods for packaging small objects.
This patent application is currently assigned to MONSANTO TECHNOLOGY LLC. The applicant listed for this patent is Kevin L. Deppermann, Brian J. Forinash, Travis J. Frey, Mike J. Graham, Jeffrey W. Hartsook, Matthew J. Weis. Invention is credited to Kevin L. Deppermann, Brian J. Forinash, Travis J. Frey, Mike J. Graham, Jeffrey W. Hartsook, Matthew J. Weis.
Application Number | 20140165506 14/118584 |
Document ID | / |
Family ID | 47217680 |
Filed Date | 2014-06-19 |
United States Patent
Application |
20140165506 |
Kind Code |
A1 |
Deppermann; Kevin L. ; et
al. |
June 19, 2014 |
SYSTEMS AND METHODS FOR PACKAGING SMALL OBJECTS
Abstract
A small object packaging system including a small object
container marking and loading station configured to singulate a
plurality of small object containers, mark each with at least one
information label, and load each marked container into a respective
one of a plurality of container transport pallets. The system
additionally includes at least one small object counting station
configured to deposit a specified amount of small objects into each
marked container. The system further includes a capping station
configured to secure a cap onto a marked container. The system
includes an offloading station configured to remove the loaded
containers and place them into a container packing case.
Inventors: |
Deppermann; Kevin L.; (St.
Charles, MO) ; Forinash; Brian J.; (Kirkwood, MO)
; Frey; Travis J.; (Madison, WI) ; Weis; Matthew
J.; (St. Louis, MO) ; Hartsook; Jeffrey W.;
(Madrid, IA) ; Graham; Mike J.; (St. Louis,
MO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Deppermann; Kevin L.
Forinash; Brian J.
Frey; Travis J.
Weis; Matthew J.
Hartsook; Jeffrey W.
Graham; Mike J. |
St. Charles
Kirkwood
Madison
St. Louis
Madrid
St. Louis |
MO
MO
WI
MO
IA
MO |
US
US
US
US
US
US |
|
|
Assignee: |
MONSANTO TECHNOLOGY LLC
St. Louis
MO
|
Family ID: |
47217680 |
Appl. No.: |
14/118584 |
Filed: |
May 23, 2012 |
PCT Filed: |
May 23, 2012 |
PCT NO: |
PCT/US12/39036 |
371 Date: |
March 7, 2014 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61489877 |
May 25, 2011 |
|
|
|
Current U.S.
Class: |
53/471 ;
53/55 |
Current CPC
Class: |
B65B 7/28 20130101; B65B
43/44 20130101; B65B 5/101 20130101; B65B 7/16 20130101; B65B
2210/02 20130101; B65B 57/20 20130101; B65B 65/003 20130101 |
Class at
Publication: |
53/471 ;
53/55 |
International
Class: |
B65B 7/16 20060101
B65B007/16 |
Claims
1. A system for packaging small objects, said system comprising: a
small object container marking and loading station structured and
operable to singulate a plurality of small object containers, mark
each singulated small object container with at least one
information label, and load each marked small object container into
a respective one of a plurality of container transport pallets; at
least one small object counting station that is structured and
operable to deposit a selected amount of small objects into each
marked small object container based on data provided by the
respective information label; a capping station structured and
operable to singulate a plurality of container caps and secure each
singulated cap onto a respective marked small object container
after the selected amount of small objects have been deposited
therein; an offloading station structured and operable to remove
each capped small object container from the respective container
transport pallet and place each removed small object container into
a container packing case; and a main hub conveyor structured and
operable to transport the loaded container transport pallets from
the small object container marking and loading station, to the at
least one small object counting station, to the capping station and
to the offloading station, and then transport the empty container
transport pallets back to the small object container marking and
loading station.
2. The system of claim 1 further comprising a small object
treatment station structured and operable to apply a small object
treatment to the small objects prior to the selected amount of
small objects being deposited into each marked small object
container.
3. The system of claim 1, wherein the selected amount of small
objects being deposited into each marked small object container
comprises a selected volume of small objects.
4. The system of claim 1, wherein the selected amount of small
objects being deposited into each marked small object container
comprises a selected number of small objects.
5. The system of claim 1, wherein the small object container
marking and loading station comprises: a container singulator
structured and operable to receive a plurality of randomly oriented
small object containers, singulate the small object containers,
orient the singulated small object containers in a desired
orientation, and dispense the oriented small object containers into
a container transfer chute; and a marking and loading assembly
structured and operable to receive the oriented small object
containers from the container singulator, via the container
transfer chute, dispose at least one container specific information
label on at least one surface of each respective small object
container, and load each marked small object container into a
respective container transport pallet.
6. The system of claim 5, wherein each container transport pallet
includes a programmable RFID tag structured and operable to be
programmed with information corresponding to information provided
by the at least one container specific information label of the
respective small object container loaded therein.
7. The system of claim 1, wherein each small object counting
station comprises: a small object counter structured and operable
to receive a plurality of a selected type of small objects,
singulate the small objects, and deposit the selected amount of the
small objects into a particular small object container designated,
via the respective container transport pallet RFID tag, to receive
the selected amount and type of small objects; and a counting
station conveyor and a diverter gate, the diverter gate structured
and operable to divert selected container transport pallets off of
the main hub conveyor and onto the counting station conveyor, the
counting station conveyor structured and operable to transport
selected container transport pallets to and from the small object
counter.
8. The system of claim 7, wherein each small object counting
station further comprises a small object accumulator structured and
operable to receive the selected amount of small objects from the
small object counter, temporarily retain the selected amount of
small objects, and deposit the selected amount of small objects
into the designated small object container.
9. The system of claim 1, wherein the capping station comprises: a
cap singulator structured and operable to receive a plurality of
randomly oriented container caps, singulate the container caps,
orient the singulated container caps in a desired orientation, and
dispense the oriented container caps into a cap transfer chute; and
a robotic capping assembly structured and operable to sequentially
remove the oriented caps from the cap transfer chute and install
each cap on a respective container after the container has had the
selected amount of small objects deposited therein.
10. The system of claim 1, wherein the offloading station
comprises: a robotic container removal and disposition assembly
structured and operable to remove each capped container from the
respective container transport pallet and deposit each removed
container into a container packing case positioned within a deposit
target zone; and a packing case transport assembly structured and
operable to position at least one container packing case within the
deposit target zone.
11. A system for packaging small objects, said system comprising: a
small object container marking and loading station structured and
operable to singulate a plurality of small object containers, mark
each singulated small object container with at least one
information label, and load each marked small object container into
a respective one of a plurality of container transport pallets,
each container transport pallet including a programmable RFID tag
structured and operable to be programmed with information
corresponding to information provided by the at least one container
specific information label of the respective small object container
loaded therein; a plurality of small object counting stations, each
small object counting station structured and operable to deposit a
selected amount of a selected type of small objects into selected
marked small object containers based on data stored in the
respective container transport pallet RFID tag; a capping station
structured and operable to singulate a plurality of container caps
and secure each singulated cap onto a respective marked small
object container after the selected type and amount of small
objects have been deposited therein; an offloading station
structured and operable to remove each capped small object
container from the respective container transport pallet and place
each removed small object container into a selected one of a
plurality container packing cases based on data stored in the
respective container transport pallet RFID tag; and a main hub
conveyor structured and operable to transport the loaded container
transport pallets from the small object container marking and
loading station, to a selected one of the small object counting
stations based on data stored in the respective container transport
pallet RFID tag, from the selected small object counting station to
the capping station, and from the capping station to the offloading
station, and then transport the empty container transport pallets
back to the small object container marking and loading station.
12. The system of claim 11 further comprising a small object
treatment station structured and operable to apply a small object
treatment to the small objects prior to the selected amount of
small objects being deposited into each marked small object
container.
13. The system of claim 11, wherein the selected amount of small
objects being deposited into each marked small object container
comprises a selected volume of small objects.
14. The system of claim 11, wherein the selected amount of small
objects being deposited into each marked small object container
comprises a selected number of small objects.
15. The system of claim 11, wherein the small object container
marking and loading station comprises: a container singulator
structured and operable to receive a plurality of randomly oriented
small object containers, singulate the small object containers,
orient the singulated small object container in a desired
orientation, and dispense the oriented small object containers into
a container transfer chute; and a marking and loading assembly
structured and operable to receive the oriented small object
containers from the container singulator, via the container
transfer chute, dispose at least one container specific information
label on at least one surface of each respective small object
container, load each marked small object container into a
respective container transport pallet, and program the
respective.
16. The system of claim 11, wherein each small object counting
station comprises: a small object counter structured and operable
to receive a plurality of a selected type of small objects,
singulate the small objects, and deposit the selected amount of the
small objects into a particular small object container designated,
via the respective container transport pallet RFID tag, to receive
the selected amount and type of small objects; and a counting
station conveyor and a diverter gate, the diverter gate structured
and operable to divert selected container transport pallets off of
the main hub conveyor and onto the respective counting station
conveyor, based on data stored in the respective container
transport pallet RFID tag, the counting station conveyor structured
and operable to transport selected container transport pallets to
and from the small object counter.
17. The system of claim 16, wherein each small object counting
station further comprises a small object accumulator structured and
operable to receive the selected amount of small objects from the
respective small object counter, temporarily retain the selected
amount of small objects, and deposit the selected amount of small
objects into the designated small object container.
18. The system of claim 11, wherein the capping station comprises:
a cap singulator structured and operable to receive a plurality of
randomly oriented container caps, singulate the container caps,
orient the singulated container caps in a desired orientation, and
dispense the oriented container caps into a cap transfer chute; and
a robotic capping assembly structured and operable to sequentially
remove the oriented caps from the cap transfer chute and install
each cap on a respective container after the container has had the
selected amount of small objects deposited therein.
19. The system of claim 11, wherein the offloading station
comprises: a robotic container removal and disposition assembly
structured and operable to remove each capped container from the
respective container transport pallet and deposit each removed
container into a selected one of a plurality of container packing
cases positioned within a deposit target zone; and a packing case
transport assembly structured and operable to position each of the
container packing cases within the deposit target zone.
20. A method for packaging small objects, said system comprising:
singulating a plurality of small object containers, marking each
singulated small object container with at least one information
label, and loading each marked small object container into a
respective one of a plurality of container transport pallets
utilizing a small object container marking and loading station of a
small object packaging system; depositing a selected amount of
small objects into each marked small object container based on data
provided by the respective information label utilizing a small
object counter of at least one small object counting station of the
small object packaging system; singulating a plurality of container
caps and securing each singulated cap onto a respective marked
small object container after the selected amount of small objects
have been deposited therein utilizing a capping station of the
small object packaging system; removing each capped small object
container from the respective container transport pallet and
placing each removed small object container into a container
packing case using an offloading station of the small object
packaging system; and transporting the loaded container transport
pallets from the small object container marking and loading station
to the at least one small object counting station, to the capping
station and to the offloading station, and then transporting the
empty container transport pallets back to the small object
container marking and loading station utilizing a main hub conveyor
of the small object packaging system.
21. The method of claim 20 further comprising applying a small
object treatment to the small objects prior to the selected amount
of small objects being deposited into each marked small object
container utilizing a small object treatment station of the small
object packaging system.
22. The method of claim 20, wherein depositing a selected amount of
small objects into each marked small object container comprises
depositing a selected volume of small objects into each marked
small object container based on data provided by the respective
information label.
23. The method of claim 20, wherein depositing a selected amount of
small objects into each marked small object container comprises
depositing a selected number of small objects into each marked
small object container based on data provided by the respective
information label.
24. The method of claim 20, wherein singulating, marking and
loading each small object container into a respective one of the
container transport pallets comprises: receiving a plurality of
randomly oriented small object containers into a container
singulator of the small object container marking and loading
station, then singulating the small object containers, orienting
the singulated small object container in a desired orientation, and
dispensing the oriented small object containers into a container
transfer chute utilizing the container singulator; and receiving
the oriented small object containers from the container singulator,
via the container transfer chute, disposing at least one container
specific information label on at least one surface of each
respective small object container, and loading each marked small
object container into a respective container transport pallet
utilizing a marking and loading assembly of the small object
container marking and loading station.
25. The method of claim 24, wherein singulating, marking and
loading each small object container into a respective one of the
container transport pallets further comprises programming an RFID
tag of each container transport pallet with information
corresponding to information provided by the at least one container
specific information label of the respective small object container
loaded therein.
26. The method of claim 20, depositing a selected amount of small
objects into each marked small object container comprises receiving
a plurality of a selected type of small objects in a small object
counter of the small object counting station, then singulating the
small objects and depositing the selected amount of the small
objects into a particular small object container designated, via
the respective container transport pallet RFID tag, to receive the
selected amount and type of small objects utilizing the small
object counter.
27. The method of claim 26, wherein depositing a selected amount of
small objects into each marked small object container further
comprises receiving the selected amount of small objects from the
small object counter in a small object accumulator of the small
object counting station, temporarily retaining the selected amount
of small objects in the accumulator, and depositing the selected
amount of small objects into the designated small object container
utilizing the accumulator.
28. The method of claim 20, wherein singulating a plurality of
container caps and securing each singulated cap onto a respective
marked small object container comprises: receiving a plurality of
randomly oriented container caps into a cap singulator of the
capping station, then singulating the container caps, orienting the
singulated container caps in a desired orientation, and dispensing
the oriented container caps into a cap transfer chute utilizing the
cap singulator; and sequentially removing the oriented caps from
the cap transfer chute utilizing a robotic capping assembly of the
capping station, and installing each cap on a respective container
after the container has had the selected amount of small objects
deposited therein.
29. The method of claim 1, wherein removing each capped small
object container from the respective container transport pallet and
placing each removed small object container into the container
packing case of the offloading station comprises removing each
capped container from the respective container transport
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a National Stage of International
Application No. PCT/US2012/039036, filed May 23, 2012, which claims
priority to U.S. Provisional Application No. 61/489,877, filed on
May 25, 2011, the disclosures of which are incorporated herein by
reference in their entirety.
FIELD
[0002] The present teachings relate to automated systems and
methods for packaging small objects, such as seeds, pharmaceutical
tablets or capsules, and any other agricultural, manufactured or
produced small objects.
BACKGROUND
[0003] The statements in this section merely provide background
information related to the present disclosure and may not
constitute prior art.
[0004] The packaging of small agricultural, manufactured and/or
produced objects such as seeds, pharmaceutical tablets or capsules,
small electrical components, ball bearings, small food products,
etc. can be cumbersome, painstakingly tedious, and wrought with
human error.
[0005] For example, in seed breeding, selected quantities of
various types of seeds must be culled from large numbers of various
seed types and then packaged for transfer to a storage facility or
to the field for planting. Generally, the select amounts of seeds
are manually separated from bulk quantities of the selected types
of seeds and then manually packaged for transfer to a storage
facility or to the field for planting. Hence, such packaging
processes are typically painstakingly performed by hand, which is
extremely time consuming and subject to human error.
SUMMARY
[0006] The present disclosure provides automated systems and
methods for packaging small objects, such as seeds, pharmaceutical
tablets or capsules, and any other agricultural, manufactured or
produced small objects.
[0007] In various embodiments, an exemplary small object packaging
system is provided that includes a small object container marking
and loading station structured and operable to singulate a
plurality of small object containers, mark each singulated small
object container with at least one information label, and load each
marked small object container into a respective one of a plurality
of container transport pallets. The system additionally includes at
least one small object counting station that is structured and
operable to deposit a selected amount of small objects into each
marked small object container based on data provided by the
respective information label. The system further includes a capping
station structured and operable to singulate a plurality of
container caps and secure each singulated cap onto a respective
marked small object container after the selected amount of small
objects have been deposited therein. Furthermore, the system
includes an offloading station structured and operable to remove
each capped small object container from the respective container
transport pallet and place each removed small object container into
a container packing case. Still further, the system includes a main
hub conveyor structured and operable to transport the loaded
container transport pallets from the small object container marking
and loading station, to the at least one small object counting
station, to the capping station and to the offloading station, and
then transport the empty container transport pallets back to the
small object container marking and loading station.
[0008] In various other embodiments, an exemplary small object
packaging system is provided that includes a small object container
marking and loading station structured and operable to singulate a
plurality of small object containers, mark each singulated small
object container with at least one information label, and load each
marked small object container into a respective one of a plurality
of container transport pallets. Each container transport pallet
includes a programmable RFID tag structured and operable to be
programmed with information corresponding to information provided
by the at least one container specific information label of the
respective small object container loaded therein. The system
additionally includes a plurality of small object counting
stations, each small object counting station structured and
operable to deposit a selected amount of a selected type of small
objects into selected marked small object containers based on data
stored in the respective container transport pallet RFID tag.
[0009] The system further includes a capping station structured and
operable to singulate a plurality of container caps and secure each
singulated cap onto a respective marked small object container
after the selected type and amount of small objects have been
deposited therein. Furthermore, the system includes an offloading
station structured and operable to remove each capped small object
container from the respective container transport pallet and place
each removed small object container into a selected one of a
plurality container packing cases based on data stored in the
respective container transport pallet RFID tag. Still further the
system includes a main hub conveyor structured and operable to
transport the loaded container transport pallets from the small
object container marking and loading station, to a selected one of
the small object counting stations based on data stored in the
respective container transport pallet RFID tag, from the selected
small object counting station to the capping station, and from the
capping station to the offloading station, and then transport the
empty container transport pallets back to the small object
container marking and loading station.
[0010] In various yet other embodiments, an exemplary method for
packaging small objects is provided that includes singulating a
plurality of small object containers, marking each singulated small
object container with at least one information label, and loading
each marked small object container into a respective one of a
plurality of container transport pallets utilizing a small object
container marking and loading station of a small object packaging
system. The method additionally includes depositing a selected
amount of small objects into each marked small object container
based on data provided by the respective information label
utilizing a small object counter of at least one small object
counting station of the small object packaging system. The method
further includes singulating a plurality of container caps and
securing each singulated cap onto a respective marked small object
container after the selected amount of small objects have been
deposited therein utilizing a capping station of the small object
packaging system. Furthermore, the method includes removing each
capped small object container from the respective container
transport pallet and placing each removed small object container
into a container packing case using an offloading station of the
small object packaging system. Still further, the method includes
transporting the loaded container transport pallets from the small
object container marking and loading station to the at least one
small object counting station, to the capping station and to the
offloading station, and then transporting the empty container
transport pallets back to the small object container marking and
loading station utilizing a main hub conveyor of the small object
packaging system.
[0011] Further areas of applicability of the present teachings will
become apparent from the description provided herein. It should be
understood that the description and specific examples are intended
for purposes of illustration only and are not intended to limit the
scope of the present teachings.
DRAWINGS
[0012] The drawings described herein are for illustration purposes
only and are not intended to limit the scope of the present
teachings in any way.
[0013] FIG. 1 is an isometric view of an automated small object
packaging system, in accordance with various embodiments of the
present disclosure.
[0014] FIG. 1A is an isometric view of a main hub conveyor assembly
of the small object packaging system shown in FIG. 1, in accordance
with various embodiments of the present disclosure.
[0015] FIG. 2 is an isometric view of a small object container
nested within a container transport pallet of the small object
packaging system shown in FIG. 1, in accordance with various
embodiments of the present disclosure.
[0016] FIG. 3 is an isometric view of a small object container
marking and loading station of the small object packaging system
shown in FIG. 1, in accordance with various embodiments of the
present disclosure.
[0017] FIG. 3A is a side view of a marking and loading assembly of
the small object container marking and loading station shown in
FIG. 3, in accordance with various embodiments of the present
disclosure.
[0018] FIG. 4 is an isometric view of a counting station of the
small object packaging system shown in FIG. 1, in accordance with
various embodiments of the present disclosure.
[0019] FIG. 4A is a side view of the counting station shown in FIG.
4, in accordance with various embodiments of the present
disclosure.
[0020] FIG. 5 is an isometric view of a capping station of the
small object packaging system shown in FIG. 1, in accordance with
various embodiments of the present disclosure.
[0021] FIG. 5A is a side view of the capping station shown in FIG.
5, in accordance with various embodiments of the present
disclosure.
[0022] FIG. 6 is an isometric view of an offloading station of the
small object packaging system shown in FIG. 1, in accordance with
various embodiments of the present disclosure.
[0023] FIG. 6A is an overhead view of the offloading station shown
in FIG. 6, in accordance with various embodiments of the present
disclosure.
[0024] FIG. 6B is a front view of the offloading station shown in
FIG. 6, in accordance with various embodiments of the present
disclosure.
[0025] FIG. 7 is a block diagram of a central control system of the
automated small object packaging system shown in FIG. 1, in
accordance with various embodiments of the present disclosure.
[0026] Corresponding reference numerals indicate corresponding
parts throughout the several views of drawings.
DETAILED DESCRIPTION
[0027] The following description is merely exemplary in nature and
is in no way intended to limit the present teachings, application,
or uses. Throughout this specification, like reference numerals
will be used to refer to like elements.
[0028] Referring to FIG. 1, an automated small object packaging
system 10 is provided for separating selected amounts of small
object from bulk quantities of various types of small objects,
depositing the selected amounts into one or more containers,
capping the containers and placing the capped containers into
selected packing cases. The system 10 includes a main hub conveyor
assembly 14, a small object container marking and loading station
18 operatively connected to the main hub conveyor assembly 14, one
or more small object counting stations 22 operatively connected to
the main hub conveyor assembly 14, at least one capping station 26
operatively connected to the main hub conveyor assembly 14, at
least one offloading station 30 operatively connected to the main
hub conveyor assembly 14, and a computer based central control
system 32. The control system 32 is operable to directly or
indirectly control and coordinate the automated and cooperative
functions and operations of the main hub conveyor assembly 14, the
small object container marking and loading station 18, the one or
more small object counting stations 22, the at least one capping
station 26, and the at least one offloading station 30.
[0029] Generally, the small object container marking and loading
station 14 is structured and operable to singulate a plurality of
small object containers 34 (shown in FIG. 2) mark each singulated
small object container 34 with at least one information label 38
(shown in FIG. 2), and load each marked small object container 34
into a respective one of a plurality of container transport pallets
42 (shown in FIG. 2). Each small object counting station 22 is
structured and operable to deposit a selected amount of small
objects into each marked small object container 34 based on small
object profile information and data provided by the respective
information label 38. The capping station 26 is structured and
operable to singulate a plurality of container caps 46 (shown in
FIG. 2) and secure each singulated cap 46 onto a respective marked
small object container 34 after the selected amount of small
objects have been deposited therein. Each offloading station 30 is
structured and operable to remove the capped small object
containers 34 from the respective container transport pallet 42 and
place each removed small object container 34 into a container
packing case 50 (best shown in FIG. 6). And, the main hub conveyor
assembly 14 is structured and operable to transport the loaded
container transport pallets 42 from the small object container
marking and loading station 18, to a selected one of the one or
more small object counting stations 22, to the capping station 26
and to a selected one of the offloading stations 30, and then
transport the empty container transport pallets 42 back to the
small object container marking and loading station 18.
[0030] Referring now to FIGS. 1A, 2 and 3, in various embodiments,
the small object container marking and loading station 18 includes
a container singulator 54 and a marking and loading assembly 58
operatively connected to the container singulator 54. The container
singulator 54 is structured and operable to receive a plurality of
randomly oriented small object containers 34, singulate the small
object containers 34, orient the singulated small object containers
34 in a desired orientation, and dispense the oriented small object
containers 34 into a container transfer chute 62. For example, in
various embodiments, the container singulator 54 can comprise a
vibratory bowl feeder having a center bowl 66 disposed
substantially in the center of a spiraled outer deck 70. The center
bowl 66 is structured to receive and retain a plurality of the
small object containers 34. The vibratory bowl feeder 54 further
includes a motor (not shown) operable to vibrate the center bowl 66
and outer deck 70 such that the containers 34 are vibrated out of
the center bowl 66 and move along the spiraled outer deck around
center bowl 54.
[0031] As each of the containers 34 travel along the outer deck 70
a plurality of air jets 74 and singulating panels 78 singulate the
containers 34 and orient them in a desired orientation. As used
herein, the term `singulate` means to automatically, e.g.,
robotically, sequentially separate objects one-at-a-time from a
plurality of objects. The plurality of objects can include any
number of objects greater than one. That is, the plurality of
objects can include any number of objects from several or numerous
objects, i.e., more than a single object, to a large volume of
objects, i.e., a bulk quantity of the objects.
[0032] More particularly, the singulating panels 78 and air jets 74
separate each container 34 from the plurality of containers 34,
orient them in a desired position, e.g., having a bottom of each
container 34 oriented fore as the containers 34 travel around the
center bowl 66, and feed them single-file into the container
transfer chute 62. Each air jet 74 injects a stream of air into the
path of the containers 34 as they move along the outer periphery of
the outer deck 70. If the bottom of a particular container 34 is
not the leading side of the respective container 34 as it travels
past a particular air jet 74, the respective stream of air will
rotate, or flip, the container 34 such that bottom of the
respective container 34 becomes the leading side. Each singulating
panel 78 is mounted to a bottom surface of the outer deck 70 in
such a manner so as to define a continuously narrowing pathway for
the travel of the containers 34 as the containers 34 move around
the outer deck 70.
[0033] That is, each singulating panel 78 continuously restricts,
or narrows, the distance between the respective singulating panel
78 and a sidewall 82 of the outer deck 70 such that the distance
between a respective singulating panel 78 and the outer deck
sidewall 82 near an ingress end 62A of the transfer chute 82 is
only slightly larger than the width of a single container 34.
Therefore, as containers 34 move around the outer deck 70 towards
the container transfer chute 62, the singulating panels 78
progressively limit the number of containers 34 that can travel
abreast of each other as they travel along the outer deck 70.
Eventually, the singulating panels 78 force the containers 34
against the sidewall 82 such that, as the containers 34 approach
the ingress end 62A of the transfer chute 62, the containers 34 are
forced to travel single-file along the outer deck 70 between the
respective singulating panel 78 and the sidewall 82, thereby
feeding the containers 34 single-file into the transfer chute
ingress end 62A.
[0034] Once the containers 34 enter the transfer chute 62, they
travel along the transfer chute 62, via a conveyor belt, vibration,
air or otherwise, to an egress end 62B of the transfer chute 62.
The containers 34 are then selectively dispensed, i.e., dispensed
one-at-a-time at selected intervals, onto a conveyor deck 86 of the
marking and loading assembly 58. Once a container 34 is dispensed
onto the conveyor deck 86, the respective container 34 is
transported, via a conveyor belt, vibration, air or otherwise,
along a length of the conveyor deck 86, whereby each container 34
has at least one container information label 38 disposed
thereon.
[0035] For example, in various embodiments, once a container 34 is
dispensed onto the conveyor deck 86, the respective container 34 is
oriented in a first orientation, via any suitable orienting means,
mechanism or system. For example, in various embodiments, the
respective container 34 is oriented such that longitudinal side of
the container 34 is oriented forward as the respective container 34
travels along the length of the conveyor deck 86. The respective
container 34 is then transported along the conveyor deck 86 to a
first marking zone adjacent a first marking assembly 90 where the
respective container 34 has a first container information label 38A
disposed on a first side of the respective container 34, e.g., a
bottom side of the container 34.
[0036] Each first container information label 38A provides small
object profile information and data regarding the small objects
that are to be deposited within the respective container 34 and/or
information regarding the respective container 34 once it is
filled. For example, in various embodiments, the profile
information and data can provide pertinent, statistical information
such as the particular type, history, quantity of small objects
that are to be deposited the respective container 34, and a future
destination or site location of the each respective filled
container 34.
[0037] The first marking assembly 90 can be structured and operable
in any manner suitable to dispose the first container information
label 38A on the first side of each container 34. For example, in
various embodiments, the first marking assembly 90 can includes a
retention mechanism structured and operable to temporarily retain,
or hold, each container 34 at the first marking zone, and an inkjet
printer structured and operable to print the first container
information label 38A on the first side of each container 34 while
each respective container 34 is being retained by the retention
device. Additionally, the first container information label 38A can
be any label or marking printed on or adhered to the container 34
that provides the respective profile information and data, i.e.,
pertinent information and data regarding the particular type,
history, quantity of small objects that are to be deposited within
the respective container 34, and/or any other pertinent
information. For example, in various embodiments, each first
container information label 38A comprises data matrix barcode
and/or human readable text that provide the pertinent
information.
[0038] The profile information to be included in the first
container information label 38A is retrieved from the control
system 32, i.e., from a database 94 (shown in FIG. 7) of the
control system 32, on demand, a respective container 34 is
positioned at the first marking zone. That is, as the respective
container 34 is being positioned at the first marking zone, a
control subsystem 98 of the container marking and loading station
18 requests the profile information and data to be included in the
respective first container information label 38A from the control
system 32. The control system 32 then accesses a particular look-up
table or spreadsheet stored in the database 94 and returns the
profile information and data to be included in the respective first
container information label 38A.
[0039] More particularly, a plurality of look-up tables and/or
spreadsheets are stored in the central control system database 94,
wherein each look-up table and/or spreadsheet comprises data
delineating the requirements of a particular small object packaging
project, e.g., the number of containers 34 required for the
particular project, the type, characteristics and amount (i.e.,
number or volume) of small objects to be deposited in each of the
containers 34, a destination or site location of the each
respective filled container 34, etc. The small object packaging
system 10 further includes an operator control station 102
communicatively connected to the control system 32. Utilizing the
operator control station 102, an operator can input requests to
initiate a particular small object packaging project, and also
enter data and/or information setting parameters and/or limits for
the requested small object packaging project.
[0040] Hence, once an operator inputs a small object packaging
project request, and sets any desired parameters and/or limits,
operation of the small object packaging system 10 begins. At which
point, containers 34 are singulated and dispensed into the
container marking and loading assembly 58, as described above.
Then, as each respective container 34 is positioned at the first
marking zone, the marking and loading station control subsystem 98
requests and receives from the control system 32 the information
and data stored in the requested packaging project look-up table
and/or spreadsheet that provides the profile information and data
to be included in the first container information label 38A to be
disposed on the particular container 34.
[0041] In various embodiments, the marking and loading assembly 58
additionally includes a first container information label
verification assembly 104 that is structured and operable to verify
that the first container information label 38A disposed on each
respective container 34 is valid, i.e., legible and correct. More
specifically, after a container 34 is marked with the first
container information label 38A, the respective first container
information label 38A is read or scanned by the first container
information label verification assembly 104 to ensure that each
respective first container information label 38A is valid before
each respective container is allowed to be further processed by the
small object packaging system 10, as described below. If the first
container information label verification assembly 104 determines
that a particular first container information label 38A is invalid,
i.e., incorrect or not legible, a first rejection assembly 106
discards the respective container 34, i.e., removes the respective
container 34 from the conveyor deck 86. If a first container
information label 38A is found to be invalid and is discarded, a
subsequent container 34 is marked with a first container
information label 38A containing the same information and data as
that disposed on the discarded container 34 and the respective
container 34 is verified, via the first container information label
verification assembly 104. This process is repeated until a first
container information label 38A containing the subject information
and data is found to be valid.
[0042] The first container information label verification assembly
104 can include any one or more devices, mechanisms, systems or
apparatuses suitably structured and operable to verify each first
container information label 38A. For example, in various
embodiments, the first container information label verification
assembly 104 comprises an imaging device, e.g., a data matrix
barcode reader and/or digital imaging device, communicatively
coupled to the control system 32. The imaging device is operable to
acquire image data of the respective first container information
label 38A. The acquired image data is communicated to the control
system 32 where it is determined whether the acquired image data is
legible, and if so, whether the acquired image data provides the
correct information and data, i.e., the information and data
intended to be provided by the respective first container
information label 38A.
[0043] Additionally, in various embodiments, after the first
container information label 38A has been disposed on the first side
of a container 34, the respective container 34 is reoriented to a
second orientation, via any suitable orienting means, mechanism or
system. For example, in various embodiments, the respective
container 34 is rotated 90.degree. such that the bottom side of the
container 34 is oriented forward as the respective container 34
travels along the length of the conveyor deck 86. The container 34
is then transported along the conveyor deck 86 to a second marking
zone adjacent a second marking assembly 110 where the respective
container 34 has a second container information label 38B disposed
on a second side of the respective container 34, e.g., the
longitudinal side of the container 34. The second container
information label 38B can be any label or marking printed on or
adhered to the container 34 that provides profile information or
data regarding the small objects that are to be deposited within
the respective container 34 and/or information regarding the
respective container 34 once it is filled. For example, in various
embodiments, the second container information label 38B can contain
a data matrix barcode and/or human readable text that provide
substantially the same information provided by the first container
information label 38A.
[0044] In the various embodiments wherein the marking and loading
assembly 58 includes the second marking assembly 110, the marking
and loading assembly 58 can further include a second container
information label verification assembly 114 that is structured and
operable to verify that the second container information label 38B
disposed on each respective container 34 is valid, i.e., legible
and correct. More specifically, after a container 34 is marked with
the second container information label 38B, the respective second
container information label 38B is read or scanned by the second
container information label verification assembly 114 to ensure
that each respective second container information label 38B is
valid before each respective container is allowed to be further
processed by the small object packaging system 10, as described
below. If the second container information label verification
assembly 114 determines that a particular second container
information label 38B is invalid, i.e., incorrect or not legible, a
second rejection assembly 118 discards the respective container 34,
i.e., removes the respective container 34 from the conveyor deck
86. If a second container information label 38B is found to be
invalid and is discarded, a subsequent container 34 is marked with
a first and second container information label 38A and 38B
containing the same information and data as that disposed on the
discarded container 34 and the respective container 34 is verified,
via the first and second container information label verification
assemblies 104 and 114. This process is repeated until first and
second container information labels 38A and 38B containing the
subject information and data are found to be valid.
[0045] The second container information label verification assembly
114 can include any one or more devices, mechanisms, systems or
apparatuses suitably structured and operable to verify each second
container information label 38B. For example, in various
embodiments, the second container information label verification
assembly 114 comprises an imaging camera, e.g., a data matrix
barcode reader and/or digital imaging device, communicatively
coupled to the control system 32. The imaging device is operable to
acquire image data of the respective second container information
label 38B. The acquired image data is communicated to the control
system 32 where it is determined whether the acquired image data is
legible, and if so, whether the acquired image data provides the
correct information and data, i.e., the information and data
intended to be provided by the respective second container
information label 38B.
[0046] Now referring to FIGS. 1, 1A, 2, 3 and 3A, once a respective
container 34 has been marked with at least one information label
38, i.e., a first information label 38A and/or a second information
label 38B, the marked container 34 is transported along the
conveyor deck 86 to a loading assembly 122. The loading assembly is
structured and operable to transfer each marked container 34 from
the conveyor deck 86 into a respective container transport pallet
42 positioned beneath the loading assembly 122 on a conveyor track
126 of the main hub conveyor assembly 14. More particularly, prior
to, or substantially simultaneous with, a marked container 34 being
transported to the loading assembly 122, an empty transport pallet
42 is conveyed along the main hub conveyor track 126 to a container
loading pallet locator 130 (best shown in FIG. 1A) of the main hub
conveyor assembly 14. The pallet locator 130 is structured and
operable, as controlled by the control system 32, to grasp and
retain the respective transport pallet 42 beneath the loading
assembly 122.
[0047] More particularly, when a transport pallet 42 is transported
to a position under the loading assembly 122, the pallet locator
130 stops the transport pallet 42 and grasps the transport pallet
42 such that the transport pallet 42 is accurately located at a
loading zone located beneath a loading receptacle 134 of the
loading assembly 122. The pallet locator 130 then slightly lifts
the respective transport pallet 42 off the main hub conveyor track
126. The loading assembly additionally includes a linear actuator
138 that is structured and operable, as controlled by the control
system 32, to bidirectionally move a seating ram 142 in the Y.sup.+
and Y.sup.- directions. Once a container 34 has been properly
marked with at least one container information label 38, the
container 34 is transported to the loading receptacle 134 where
each respective container 34 is positioned to be loaded in a
respective transport pallet 42 by the seating ram 142.
[0048] More specifically, upon completion of the marking process,
each marked container 34 is oriented such that the bottom side is
oriented forward as the respective container 34 travels along the
conveyor deck 86. Each container 34 is then is transported to a
distal end of the conveyor deck 86 where the loading receptacle 134
is located such that each respective container 34 will fall, or be
placed, `bottom side down`, `open top side up` into the loading
receptacle 134. The loading receptacle 134 includes a first half
134A connected to a first actuator 144A and a second half 134B
connected to a second actuator 144B. The first and second linear
actuators 144A and 144B are operable, as controlled by the control
system 32, to bidirectionally move the respective loading
receptacle first and second halves 134A and 134B in the X.sup.+ and
X.sup.- directions.
[0049] When the first and second actuators 144A and 144B are in a
fully extended position, i.e., a Closed position, the respective
loading receptacle first and second halves 134A and 134B form a
Closed loading receptacle 134. The Closed loading receptacle 134 is
generally structured as a square, or rectangular, funnel having
angled interior sides and a distal end opening that is
substantially same size and shape as a lateral cross-section of the
container 34. Hence, when a marked container 34 falls into the
Closed loading receptacle 134, the respective container 34 will
slide down the sides of the loading receptacle 134 and stop, due to
friction, with the bottom end of the container at, or near, the
open distal end of the loading receptacle 134. In various
implementations, the loading assembly 122 can include a plurality
of loading receptacles and seating rams 142, whereby more than one
marked container 34 can be positioned in preparation for loading
into respective transport pallets 42.
[0050] To load a marked container 34 into a respective transport
pallet 42 positioned beneath the loading receptacle 134, once a
container is positioned within the Closed loading receptacle 134,
the linear actuator 138, as controlled by the control system 32,
lowers the seating ram 142 in the Y.sup.- direction such that a
seating head 146, connected to an distal end of the seating ram
142, pushes the container 34 partially out of the distal end
opening of the loading receptacle 134 and into a container nest 150
of the respective transport pallet 42. The container nest 150 is
generally structured as a square or rectangular cup having angled
interior sides such that as the container 34 is pushed into the
container nest 154, the angled interior sides center the bottom end
of the container 34 within the container nest 150. Additionally, as
the bottom end of the container 34 is pushed into the bottom of the
container nest 150, the angled interior sides slightly compress and
grasp, i.e., positively secure, the bottom portion of the
respective container 34 via friction.
[0051] Once the removed container 34 is seated, i.e., positively
secured, within respective transport pallet container nest 150, the
first and second linear actuator 144A and 144B retract to Open the
loading receptacle 134. In the Open position the loading receptacle
first and second halves 134A and 134B are moved away from the
respective container 34 such that the respective transport pallet
42 along with the seated container 34 can be moved along the main
hub conveyor track 126 toward the one or more counting stations 22.
Subsequently, the first and second linear actuator 144A and 144B
extend to return the loading receptacle first and second halves
134A and 134B to the Closed position to receive a subsequent marked
container 34.
[0052] Referring now to FIGS. 1A and 2, to link each marked
container with the respective transport pallet 42, each transport
pallet 42 includes a pallet identification tag 154 disposed
thereon. Each pallet identification tag 154 is programmed with, or
comprises, pallet identification data that is linked, tied,
correlated or associated with the marked container 34 seated with
the container nest 150 of the respective transport pallet 42 within
the database of the control system 32. More particularly, each
pallet identification tag 154 includes, or is programmed with, a
unique identifier, i.e., information or data, that is unique to and
identifies the respective transport pallet 42. Accordingly, each
transport pallet 42 is linked, tied, correlated or associated with
the respective container 34 disposed therein, and more particularly
with the profile information and data provided by the at least one
container information label 38 of the respective container 34.
[0053] Additionally, the small object packaging system 10 includes
a plurality of pallet identification tag reader/writers 158
disposed at various locations along the main hub conveyor assembly
14. Particularly, a marking and loading station pallet
identification tag reader/writer 158P is located at or near the
pallet locator 130 such that as a marked container 34 is seated
into the container nest 150 of a transport pallet 42, the
identification tag 154 of the transport pallet 42 is programmed
with a unique identifier, or has a preprogrammed unique identifier
read, by the marking and loading station tag reader/writer 158P to
identify the particular transport pallet 42. The particular
transport pallet unique identifier is communicated to the control
system 32 where the pallet unique identifier is linked, tied,
correlated or associated with the respective container 34, and more
particularly, with the profile information and data provided by the
at least one container information label 38 of the respective
container 34.
[0054] Therefore, as each transport pallet 42 and respective
container 34 are transported along the conveyor track 126 of main
hub conveyor assembly 14 the various pallet identification tag
reader/writers 158 read the respective identification tags 154 such
that location and status of each container/pallet 34/42 within the
small object packaging system 10 is known by the control system 32
throughout the small object packaging process of each respective
container/pallet 34/42, as described herein. Moreover, the linking
of the particular transport pallet unique identifier with the
profile information and data associated with the container
information label(s) 38 of the respective container 34 is used to
guide the flow/travel path of each respective transport pallet 42
and container 34 within the small object packaging system 10 based
on the particular profile information and data associated with the
information label(s) 38 disposed on the respective container
34.
[0055] The pallet identification tags 154 can be any device or item
suitable for storing and providing unique identification
information for each respective transport pallet 42. For example,
in various embodiments, each pallet identification tag 154 can
comprise a radio frequency identification (RFID) tag programmable
to have the unique identifier, i.e., information and/or data,
electronically stored therein. In such instances, the pallet
identification tag reader/writers 158 comprise RFID reader/writers
operable to write and read the unique identifier of each transport
pallet 42 at the various selected points throughout the small
object packaging process. In various other embodiments, any other
suitable machine-readable pallet identification tags 154 can be
used, such as two-dimensional matrix codes or other
machine-readable/writeable tags or devices in which the data can
been written to and/or received from, via wireless communication,
such as optical signals, e.g., infrared signals, or magnetic
fields.
[0056] Once a marked container 34 has been loaded into a transport
pallet 42, the respective pallet identification tag 154 has been
programmed with a unique identifier, or has had a preprogrammed
unique identifier read therefrom, and the pallet unique identifier
has been linked to the profile information and data associated with
the respective container information label(s) 38, the respective
container/pallet 34/42 is released from the pallet locator 130 and
transported, via the main hub conveyor track 126, to a particular
one of the small object counting station(s) 22. Although, in
various embodiments, the small object packaging system 10 can
include only a single counting station 22, for exemplary purposes,
hereafter, the small object packaging system 10 will be described
as including a plurality, i.e., exemplarily three, small object
counting stations 22. As illustrated in FIG. 1, in such
embodiments, the three counting stations 22 are spaced apart and
sequentially connected adjacent each other to the main hub conveyor
assembly 14. The three counting stations 22 will be referred to
herein as the first counting station 22A, the second counting
station 22B and the third counting station 22C. Each of the first,
second and third counting stations 22A, 22B and 22C are
substantially identical in structure and operation. Hence, the
counting station illustrated in FIGS. 4 and 4A, and the
corresponding description herein, exemplifies the structure and
operability of each counting station 22 of the small object
packaging system 10.
[0057] Referring now to FIGS. 1, 1 A, 4 and 4A, as a
container/pallet 34/42 travels along the main hub conveyor track
126 toward the first counting station 22A the container/pallet
34/42 will pass a first counting station tag reader/writer 158A. As
the container/pallet 34/42 passes the first counting station tag
reader/writer 158A, the pallet unique identifier is acquired from
respective pallet identification tag 154 and communicated to the
control system 32 by the first counting station tag reader/writer
158A. Then, the control system 32 accesses the profile information
and data linked to the particular pallet unique identifier to
determine whether the container/pallet 34/42 is to be routed to
first counting station 22A.
[0058] In various embodiments, each of the counting stations 22 can
be configured to deposit the same small objects, i.e., small
objects of the same type, quality, genetic characteristics, etc.,
into the containers 34 routed to the respective counting stations
22. Or, in other embodiments, at least two of the counting stations
22 can be configured to deposit the different small objects, i.e.,
small objects of different types, and/or having different
qualities, genetic characteristics, etc., into the containers 34
routed to the respective counting stations 22.
[0059] If, based on the respective profile information and data,
the control system 32 determines that the container/pallet 34/42 is
not to be routed to the first counting station 22A, a diverter gate
162 of the first counting station 22A, as controlled by the control
system 32, will be placed in a Closed position, as shown in FIG. 4.
Accordingly, the container/pallet 34/42 will travel past the first
counting station 22A pass a second counting station tag
reader/writer 158B where the pallet unique identifier is again
acquired from respective pallet identification tag 154 and
communicated to the control system 32. Then, based on the
respective profile information and data, the control system 32
determines whether the container/pallet 34/42 is to be routed to
second counting station 22B.
[0060] If it is determined that the container/pallet 34/42 is not
to be routed to the second counting station 22B, a diverter gate
162 of the second counting station 22B, as controlled by the
control system 32, will be placed in a Closed position, as shown in
FIG. 4. Accordingly, the respective container/pallet 34/42 will
travel past the first counting station 22A and pass a second
counting station tag reader/writer 158B where the pallet unique
identifier is again acquired from respective pallet identification
tag 154 and communicated to the control system 32. Then, based on
the respective profile information and data, the control system 32
determines whether the respective container/pallet 34/42 is to be
routed to second counting station 22A.
[0061] If it is determined that the container/pallet 34/42 is not
to be routed to the second counting station 22B, a diverter gate
162 of the second counting station 22B, as controlled by the
control system 32, will be placed in a Closed position, as shown in
FIG. 4. Accordingly, the respective container/pallet 34/42 will
travel past the second counting station 22B and pass a third
counting station tag reader/writer 158C where the pallet unique
identifier is again acquired from respective pallet identification
tag 154 and communicated to the control system 32. Then, based on
the respective profile information and data, the control system 32
determines whether the respective container/pallet 34/42 is to be
routed to third counting station 22B.
[0062] Once it is determined that a container/pallet 34/42 is to be
routed to particular counting station 22, respective diverter gate
162 of the counting station 22 will be placed in an Open position
where by the diverter gate is moved to extend over the main hub
conveyor track 126 such that the container/pallet 34/42 is diverted
onto a counting station conveyor track 166. The container/pallet
34/42 is then transported to a counting depot pallet locator 170
located beneath a small object counter 174 where the
container/pallet 34/42 is stopped and a particular amount of small
objects are deposited into the respective container 34. The amount
of small objects deposited is determined and controlled by the
control system 32 based on the respective profile information and
data of the respective container 34. The particular amount of small
objects can be a particular volume of small objects or a particular
number of small objects.
[0063] More specifically, when a container/pallet 34/42 is
transported to a position under the small object counter 174, the
depot pallet locator 170 stops the container/pallet 34/42 and
grasps the respective transport pallet 42 such that the respective
container 34 is accurately located beneath an output port 178 of
the counter 174. The depot pallet locator 170 then slightly lifts
the respective container/pallet 34/42 off the counting station
conveyor track 166, whereafter the amount of small objects
specified by the respective container profile information/data are
deposited into the respective container 34. More particularly, in
various embodiments, the counting station 22 includes a pallet
identification tag reader 182 that is substantially identical in
structure and operation as the main hub pallet identification tag
readers 158. The counting station pallet identification tag reader
182 is located such that the pallet identification tag 154 of the
container/pallet 34/42 being transported along the counting station
conveyor track 166 is read prior to the container/pallet 34/42
reaching the depot pallet locator 170. Hence, prior to, or
substantially simultaneous with, the respective container 34 being
located beneath the counter output port 178, the unique identifier
of the respective transport pallet 42 is used to access the
respective container 34 profile information/data to specify the
amount of small objects to be deposited into the respective
container 34.
[0064] Generally, the counter 174 is structured to receive a
plurality, or bulk quantity, of small objects in a hopper 184 of
the counter 174. Additionally, as controlled by the control system
32, the counter 174 operates to singulate the plurality, or bulk
quantity, of small objects and count and dispense the specified
amount of small objects dictated by the respective container
profile information and data. Therefore, a container/pallet 34/42
that is diverted to a particular counting station 22 will be
transported along the respective counting station conveyor track
166, past the respective counting station pallet identification tag
reader 182 and be positioned beneath the respective counter output
port 178 by the respective depot pallet locator 170. As the
container/pallet 34/42 passes the respective counting station
pallet identification tag reader 182, the respective pallet
identification tag 154 is read and the respective pallet unique
identifier is communicated to the control system 32. Then, based on
the pallet unique identifier, the control system 32 determines the
respective container profile information/data, which includes the
specified amount of small objects to be deposited into the
respective container 34. Subsequently, the specified amount of
small objects to be deposited into the respective container 34 is
communicated to the respective counter 174. The respective counter
174 then singulates, counts and dispenses the specified amount of
small objects in the respective container 34.
[0065] The counter 174, generally described herein, is
substantially similar in structure and operation to the high speed
counter described in co-pending PCT patent application serial
number PCT/US09/48992, filed Jun. 29, 2009 and titled High Speed
Counter, which claims priority to U.S. Provisional Application Ser.
No. 61/077,766, filed Jul. 2, 2008, each of which is incorporated
by reference herein in their entirety.
[0066] In various embodiments, each counting station 22
additionally includes an accumulator/diverter device 186 disposed
beneath the respective counter output port 178 such that the
respective counter 174 dispenses the singulated and counted small
objects into the accumulator/diverter device 186. Each
accumulator/diverter device 186 is structured and operable to
accumulate, i.e., aggregate, and retain the singulated small
objects counted and dispensed by the respective counter 174, then
dispense the accumulated small objects into the waiting container
34, via an output port 190. More particularly, each
accumulator/diverter device 186 comprises a plurality of interior
accumulating chambers (not shown) and a diverter mechanism (not
shown). The diverter mechanism is structured and operable to
divert, i.e., direct, small objects singulated and counted by
respective counter 174 into one of the accumulating chambers.
[0067] More specifically, as the respective counter 174 singulates,
counts and dispenses a specified amount of small objects based on
the profile information/data of a particular container 34 that has
passed the pallet identification tag reader of the respective
counting station 22, the diverter directs the dispensed small
objects to a first one of the accumulating chambers. Then, while
retaining the small objects in the first accumulating chamber, the
diverter, as controlled by the control system 32, is moved to
direct singulated, counted and dispensed small objects to be
deposited in another container 34 that has passed the pallet
identification tag reader of the respective counting station 22
into a second one of the accumulating chambers. Each accumulator
further includes a flow control device (not shown) that is
structured and operable, as controlled by the control system 32, to
control the release of the accumulated small objects from each of
the accumulating chambers.
[0068] Hence, once a first container/pallet 34/42 passes the pallet
identification tag reader 182 of a particular counting station 22,
the respective counter 174 will singulate, count and dispense the
designated amount of small objects for the respective first
container 34 into the respective accumulator/diverter device 186.
As described above, the accumulator/diverter device 186 will
accumulate the small objects in a first one of the accumulating
chambers. The first container/pallet 34/42 will then be transported
to the respective depot pallet locator 170. During this time, a
second container/pallet 34/42 can pass the identification tag
reader 182 and the respective counter 174 can singulate, count and
dispense the designated amount of small objects for the respective
second container 34 into the respective accumulator/diverter device
186, which accumulates the small objects in a second one of the
accumulating chambers. Substantially simultaneously with
singulating, counting and accumulating the specified amount of
small objects in the second accumulating chamber, the flow control
device of the accumulator can release of the accumulated small
objects from the first accumulating chamber, thereby depositing the
small objects in the first container 34.
[0069] The depot pallet locator 170 can the release the first
container/pallet 34/42 and then position the second
container/pallet 34/42 beneath the accumulator output port 190.
Then, substantially simultaneously with the small objects being
released from the second accumulator chamber and deposited into the
second container 34, a third group of small objects for a third
container 34 can be singulated, counted and accumulated the first
accumulating chamber, and so on.
[0070] Once the stipulated amount of small objects has been
deposited in a container 34, the respective container/pallet 34/42
is released by the depot pallet locator 170 and transported along
the respective counting station conveyor track 166 toward the
respective diverter gate 162. As filled container/pallet 34/42
approaches the diverter gate 162, the control system 32 moves the
diverter gate 162 to the Closed position such that the filled
container/pallet 34/42 is directed back onto the main hub conveyor
track 126, whereby the filled container/pallet 34/42 is transported
to the capping station 26.
[0071] As described above, the specified amount of small objects to
be deposited in each respective container 34 can be a particular
volume of small objects or a particular number of small objects. In
the implementations where a particular volume of small objects are
to be deposited, one or more optical sensors (not shown) can be
disposed adjacent the counting depot 170 or, in embodiments
including the accumulator/diverter device 186, within each of the
interior accumulating chambers of the accumulator/diverter device
186. The optical sensor(s), as controlled by the control system 32,
would determine when the particular volume of small objects, as
specified by the small object profile corresponding the respective
container 34, has been deposited into the respective container 34,
or the respective accumulator chamber. Once the specified volume of
small objects has been deposited into the respective container 34
or accumulator chamber, the control system 32 ceases operation of
the counter 174, until a subsequent container 34 has been
positioned beneath the counter output port 178, or the accumulator
diverter mechanism has been moved to direct subsequent small
objects into a second interior accumulating chamber of the
accumulator/diverter device 186. In such implementations, the
counter 174 can count the number of small objects dispensed to
comprise the specified volume, and communicate that number to the
central control system where the particular number would be stored
in the look-up tables and/or spreadsheet and become part of the
respective container small object profile.
[0072] In the implementations where a particular number of small
objects are to be deposited in each container 34, the counter
dispenses the specified number of small objects into the respective
container 34 or, in embodiments including the accumulator/diverter
device 186, into one of the accumulator interior accumulating
chambers. Once the specified number of small objects has been
deposited into the respective container 34 or accumulator chamber,
the control system 32 ceases operation of the counter 174, until a
subsequent container 34 has been positioned beneath the counter
output port 178, or the accumulator diverter mechanism has been
moved to direct subsequent small objects into a second interior
accumulating chamber of the accumulator/diverter device 186.
[0073] In various embodiments, the each counting station 22 can
include a container tamping linear actuator 194 and a tamping
pallet locator 198. In such embodiments, the tamping pallet locator
198 is located before the depot pallet locator in the travel path
of the container/pallets 34/42 along the counting station conveyor
track 166. The tamping pallet locator 198 is structured and
operable to stop the respective container/pallet 34/42 such that
the respective container 34 is accurately located beneath a tamping
plate 202 of the tamping linear actuator 194. The tamping linear
actuator 194 is structured and operable, as controlled by the
controls system 32, to bidirectionally move tamping plate 202 in
the Y.sup.+ and Y.sup.- directions. More particularly, as a
container/pallet 34/42 is transported along the counting station
conveyor track 166 toward the counter 174, the container/pallet
34/42 is stopped, grasped and lifted by the tamping pallet locator
198. The tamping linear actuator 194 then lowers the tamping plate
202 in the Y.sup.- direction such that the tamping plate contacts
the top of the respective container 34 and slightly pushes down, in
the Y.sup.- direction, on the respective container 34, thereby
ensuring that the respective container 34 is properly seated in the
container nest 150 of the respective pallet 42. Subsequently, the
tamping linear actuator 194 then raises the tamping plate 202 in
the Y.sup.+ direction, the tamping pallet locator 198 releases the
container/pallet 34/42 and the container/pallet 34/42 is
transported to the counting depot pallet locator 170 to have the
specified amount of seeds deposited into the respective container
34, as described above.
[0074] Referring now to FIGS. 5 and 5A, once the specified amount
of small objects have been deposited into a container 34 and the
respective container/pallet 34/42 has been transported back onto
the main hub conveyer 126, the container/pallet 34/42 is
transported to the capping station 26. More particularly, the
container/pallet 34/42 is transported to a capping pallet locator
214, whereby the container/pallet 34/42 is stopped, grasped and
lifted adjacent the capping station 26. The capping station 26
generally includes a container cap singulator 206 and a robotic
capping assembly 210.
[0075] The cap singulator 206 is structured and operable to receive
a plurality of randomly oriented containers caps 46, singulate the
caps 46, orient the singulated caps 46 in a desired orientation,
and dispense the oriented caps 46 into a cap transfer chute 218.
For example, in various embodiments, the cap singulator 206 can
comprise a vibratory bowl feeder having a center bowl 222 disposed
substantially in the center of a spiraled outer deck 226. The
center bowl 222 is structured to receive and retain a plurality of
the container caps 46. The vibratory bowl feeder 206 further
includes a motor (not shown) operable to vibrate the center bowl
222 and outer deck 226 such that the container caps 46 are vibrated
out of the center bowl 222 and move along the spiraled outer deck
226 around center bowl 222. The vibratory bowl feeder 206 further
includes at least one air jet 230 and at least one singulating
panel 234. The vibratory bowl feeder 206 operates to singulate and
properly orient the caps 46, i.e., container insert lip down and
solid top up, then feed the singulated and oriented caps
single-file into the cap transfer chute 218, in substantially the
same manner as the vibratory bowl feeder operates to singulate and
properly orient the container 34 then feed the singulated and
oriented containers single-file into the container transfer chute
62, as described above.
[0076] Once the caps 46 enter the transfer chute 218, they travel
along the transfer chute 218, via a conveyor belt, vibration, air
or otherwise, to an staging receptacle 236 disposed at a distal end
of the transfer chute 218. The caps 46 are then selectively
removed, i.e., removed one-at-a-time at selected intervals, from an
egress end 218B of the transfer chute 218 and placed on
corresponding containers 34 by the robotic capping assembly
210.
[0077] More specifically, once the specified amount of small
objects have been deposited into a container 34 and the respective
container/pallet 34/42 has been transported back onto the main hub
conveyer 126, the container/pallet 34/42 is transported to the
capping pallet locator 214. The capping pallet locator 214 stops,
grasps and lifts the container/pallet 34/42 adjacent the robotic
capping assembly 210 such that the respective container 34 is
positioned beneath a cap gripping head 238 of a capping head linear
actuator 242 of the robotic capping assembly 210. The robotic
capping assembly 210 additionally includes a boom arm linear stage
246 that includes a carriage 250 to which the capping head linear
actuator 242 is mounted and a cap presentation linear actuator 254.
The boom arm linear stage 246 is structured and operable, as
controlled by the control system 32, to bidirectionally move the
carriage 250 and capping head linear actuator 242 in the X.sup.+
and X.sup.- directions. The capping head linear actuator 242 is
structured and operable, as controlled by the control system 32, to
bidirectionally move a cap gripping head 238 in the Y.sup.+ and
Y.sup.- directions.
[0078] Once a container 34 has been positioned beneath the cap
gripping head 238, the cap presentation linear actuator 254, as
controlled by the control system 32, raises a presentation pedestal
258 in the Y.sup.+ direction to lift a cap 46 resting in the
staging receptacle 236 slightly out of the staging receptacle 236.
Substantially simultaneously, the capping head linear actuator 242,
as controlled by the control system 32 raises the cap gripping head
238 in the Y.sup.+ direction such that the cap gripping head 238 is
at a level higher than cap 46. The boom arm linear stage 246, as
controlled by the control system 32, then moves the carriage 250
and capping head linear actuator 242 along the boom arm 246 in the
X.sup.+ direction until the cap gripping head 238 is positioned
directly above the container 34 to be removed. The presentation
pedestal 258 then raises the cap 46 in the Y.sup.+ direction until
the cap gripping head 238 receives the cap 46.
[0079] The cap gripping head 238 is generally structured as a
square, or rectangular, cup having angled interior sides such that
as the cap gripping head 238 is lowered over the respective cap 46
the angled interior sides center the cap within the cap gripping
head 238 as the cap 46 enters the cap gripping head 238. Then, as
the cap 46 is pushed into the bottom of the cap gripping head 238,
the angled interior sides slightly compress the edges of the cap 46
to grasp, i.e., positively secure, the cap 46 via friction.
[0080] The presentation pedestal 258 then lowers in the pedestal
258 then lowers in the Y.sup.- direction until it is clear from the
impending motion of the cap grippng head 238 by translation of the
boom are linear stage 246.
[0081] The boom arm linear stage 246, then moves the carriage 250,
capping head linear actuator 242 and removed cap 46 along the boom
arm 246 in the X.sup.+ direction until the removed container cap 46
is positioned directly above the container 34 of the
container/pallet 34/42 being retained by the capping pallet locator
214. The capping head linear actuator 242 then lowers the removed
cap 46 in the Y.sup.- direction until the removed cap 46 is secured
on the respective container 34. Once the cap 46 is seated, i.e.,
positively secured, on the respective container 34, the capping
head linear actuator 242 raises cap gripping head 238 to remove the
cap gripping head 238 from the cap 46. In various embodiments, the
frictional force between the cap 46 and the top of the container 34
is greater than the frictional force between the cap gripping head
238 and the edges of the cap 46. Therefore, as the cap gripping
head 238 is raised, the cap 46 will remain seated on the container
34 as the cap gripping head 238 is removed from the edges of the
cap 46. Alternatively, in various embodiments, the cap gripping
head 238 can be structured to include mechanical gripping jaws that
are operable, as controlled by the control system 32, to open and
close to engage and disengage the jaws about the respective cap 46
to remove the respective cap 46 from the presentation pedestal
and/or place the respective cap 46 on the respective container
34.
[0082] Referring now to FIG. 1A, in various embodiments, the small
object packaging station 10 includes an auxiliary conveyor track
262 mounted along side the main hub conveyor track 126 between the
capping station 26 and the offload station 30. The auxiliary
conveyor 262 can be used to park loaded and capped
container/pallets 34/42 while waiting to have the respective
containers 34 offloaded at the offload station 30, as described
below. To move selected container/pallets 34/42 between the main
hub conveyor track 126 and the auxiliary conveyor track 262, the
small object packaging station 10 includes a removal lift and
transfer assembly 266 and a return lift and transfer assembly 270.
More specifically, the removal lift and transfer assembly 266 is
structured and operable to transfer selected loaded and capped
container/pallets 34/42 from the main hub conveyor track 126 to the
auxiliary conveyor track 262. Conversely, the return lift and
transfer assembly 270 is structured and operable to transfer empty
transport pallets 42 from the auxiliary conveyor track 262 to the
main hub conveyor track 126.
[0083] The removal lift and transfer assembly 266 includes a
container/pallet stop device 272, a removal lift bridge 274 mounted
between the main hub and auxiliary conveyor tracks 126 and 262, and
a linear actuator 278 mounted to a side of the main hub conveyor
126. The stop device 272 is structured and operable, as controlled
by the control system 32, to stop selected loaded and capped
container/pallets 34/42 adjacent the linear actuator 278. Once a
selected loaded and capped container/pallet 34/42 is stopped by the
stop device 272, the removal lift bridge 274, as controlled by the
control system 32, is lowered from a Barrier position to a Bridge
position, thereby exposing a gap in a side rail of the main hub
conveyor track 126. When in the Barrier position, the removal lift
bridge 274 is raised, filling the gap in the main hub conveyor
track side rail, thereby providing a side rail for loaded and
capped container/pallets 34/42 traveling past the stop device 272.
When in the Bridge position, the removal lift bridge 274 is
lowered, exposing the gap in the main hub conveyor track side rail
and providing a bridge for the selected loaded and capped
container/pallet 34/42 to be moved from the main hub conveyor track
126 to the auxiliary conveyor track 262.
[0084] Additionally, when the removal lift bridge 274 is lowered to
the Bridge position, a gap in the side rail of the auxiliary
conveyor track 262 is exposed in the same manner as the gap in the
main hub conveyor track side rail. After a loaded and capped
container/pallet 34/42 is stopped and the removal lift bridge 274
is lowered to the Bridge position, the removal linear actuator 278
is activated, as controlled by the control system 32, to extend a
push bar 282, thereby pushing the loaded and capped
container/pallet 34/42 from the main hub conveyor track, across the
removal lift bridge 274 and onto the auxiliary conveyor track 262.
Subsequently, the removal lift bridge 274 is raised to the Barrier
position to provide the side rails for the main hub and auxiliary
conveyor tracks 126 and 262.
[0085] Similarly, the return lift and transfer assembly 270
includes a container/pallet stop device 286, a return lift bridge
290 mounted between the main hub and auxiliary conveyor tracks 126
and 262, and a linear actuator 294 mounted to a side of the
auxiliary hub conveyor 262. The stop device 286 is structured and
operable, as controlled by the control system 32, to stop emptied
pallets 42, i.e., pallets 42 that have been moved to the auxiliary
conveyor track 262 and had the respective container 34 offloaded
via the offload station 30, when the emptied pallets 42 are
transported to a position adjacent the linear actuator 294.
[0086] Once an emptied pallet 42 is stopped by the stop device 286,
the return lift bridge 290, as controlled by the control system 32,
is lowered from a Barrier position to a Bridge position, thereby
exposing a gap in a side rail of the auxiliary conveyor track 262.
When in the Barrier position, the return lift bridge 290 is raised,
filling the gap in the auxiliary conveyor track side rail, thereby
providing a side rail for emptied pallets 42 traveling to the stop
device 286. When in the Bridge position, the return lift bridge 290
is lowered, exposing the gap in the auxiliary conveyor track side
rail and providing a bridge for the emptied pallets 42 to be moved
from the auxiliary conveyor track 262 to the main hub conveyor
track 126.
[0087] Additionally, when the return lift bridge 290 is lowered to
the Bridge position, a gap in the side rail of the main hub
conveyor track 126 is exposed in the same manner as the gap in the
auxiliary conveyor track side rail. After an emptied pallet 42 is
stopped and the return lift bridge 290 is lowered to the Bridge
position, the return linear actuator 294 is activated, as
controlled by the control system 32, to extend a push bar 298,
thereby pushing the emptied pallet 42 from the auxiliary conveyor
track 262, across the return lift bridge 290 and onto the main hub
conveyor track 126. Subsequently, the return lift bridge 290 is
raised to the Barrier position to provide the side rails for the
auxiliary and main hub conveyor tracks 126 and 262. Once an emptied
pallet 42 is moved back to the main hub conveyor track 126, the
respective emptied pallet 42 can be queued to be reprocessed by the
container marking and loading station 18, loaded with another
marked container 34, as described above.
[0088] As described above, once a loaded container 34 has been
capped at the capping station 26, the loaded container/pallet 34/42
can be moved to the auxiliary conveyor track 262 and transported to
the offloading station 30 to have the respective loaded and capped
container 34 removed from the respective pallet 42. Or,
alternatively, the loaded and capped container/pallet 34/42 can
remain on the main hub conveyor and transported to the offloading
station 30 to have the respective loaded and capped container 34
removed from the respective pallet 42. More specifically, a loaded
and capped container/pallet 34/42 remaining on the main hub
conveyor track 126 will be transported to a main hub offload pallet
locator 302 for offloading of the respective loaded and capped
container 34. And, similarly, a loaded and capped container/pallet
34/42 that has been moved to the auxiliary conveyor track 262 will
be transported to an auxiliary offload pallet locator 304 for
offloading of the respective loaded and capped container 34.
[0089] Referring now to FIGS. 6 and 6A, once a loaded and capped
container/pallet 34/42 has been moved to either the main hub
offload pallet locator 302 or the auxiliary offload pallet locator
304, a Cartesian robotic offload assembly 308 removes the
respective loaded and capped containers 34 and selectively places
each offloaded loaded and capped container 34 in a container
packing case 50. In various embodiments, as described herein, the
Cartesian robotic offload assembly 308 removes the respective
loaded and capped containers 34 and selectively places each
offloaded loaded and capped container 34 in a selected one of a
plurality of container packing cases 50.
[0090] The offloading station additionally includes a box transport
assembly 316 that is structured and operable, as controlled by the
control system 32, to convey the container packing cases 50 to and
from a loading position at which the offloaded loaded and capped
containers 34 are placed into the selected container packing cases
50 boxes. Particularly, the box transport system 316 includes a
plurality of box conveyor linear stages 320 that are each
structured and operable, as controlled by the control system 32, to
convey container packing cases 50 from a box handling end 320A of
each respective box conveyor linear stage 320 to a container
loading end 320B of each respective box conveyor linear stage 320.
At the handling ends 320A, empty container packing cases 50 can be
placed onto, and loaded container packing cases 50 can be removed
from a carriage 324 of the respective box conveyor linear stage
320. Each container packing case 50 is partitioned to include a
plurality of cells 328 sized to receive and retain a single loaded
and capped container 34. For example, in various embodiments, each
container packing case 50 can include forty-eight cells 328
arranged in a 4.times.12 array.
[0091] Accordingly, an operator can place an empty container
packing case 50 on each of the linear stage carriages 324
whereafter the respective box conveyor linear stage 320 conveys the
respective carriage 324 and empty container packing case 50 to the
respective loading end 320B where the container packing cases 50
are positioned to have loaded and capped containers 34 selectively
placed into the respective cells 328. Moreover, in various
embodiments, each container packing case 50 can include an
identification label (not shown), e.g., a barcode label, disposed
thereon that can be scanned or read by a shipping/storage box
identification label scanner/reader (not shown) that is
communicatively connected to the control system 32. Hence, prior to
placing each container packing case 50 on a linear stage carrier
324, the operator can scan the shipping/storage box information
label, via the shipping/storage box identification label
scanner/reader. Box identification information obtained from the
respective shipping/storage box identification label can then be
stored in the control system database to track the particular
loaded and capped containers 34 that are loaded into each
respective container packing case 50.
[0092] Once a container packing case 50 has been conveyed to the
respective loading end 320B of the respective box conveyor linear
stage 320, the Cartesian robotic offload assembly 308 can begin to
offload, i.e., remove, loaded and capped containers 34 from the
respective pallets 42 positioned, i.e., stopped, grasped and
lifted, by the main hub and auxiliary offload pallet locators 302
and 304. The offload assembly 308 includes a pair of opposing
X-axis linear stages 332, a Z-axis linear stage 336 and a
pick-and-place assembly 340. The opposing X-axis linear stages 332
are simultaneously controlled by the control system 32 to
bidirectionally move the Z-axis linear stage 336 in the X.sup.+ and
X.sup.- directions and the Z-axis linear stage 336 is controlled by
the central control system 32 to bidirectionally move
pick-and-place assembly in the Z.sup.+ and Z.sup.- directions.
Hence, via the control system 32, the pick-and-place assembly 340
can be moved anywhere within a Cartesian coordinate system
encompassing the main hub and auxiliary offload pallet locators 302
and 304 and the area covering each container packing case 50 when
positioned at the loading end 320A of each respective box conveyor
linear stage 320.
[0093] The pick-and-place assembly 340 includes a linear actuator
344 that is structured and operable, as controlled by the control
system 32, to bidirectionaly move a mechanical loaded container
gripping head 348 in the Y.sup.+ and Y.sup.- directions. The
mechanical loaded container gripping head 348 is operable to grasp,
hold and release the loaded and capped containers 34 to offload the
loaded and capped containers 34 from the respective pallets 42 and
place the offloaded containers into selected container packing
cases 50. More specifically, once a loaded and capped
container/pallet 34/42 has been positioned by the main hub and/or
the auxiliary offload pallet locators 302 and/or 304, the control
system 32, controls the operation of the X-axis and Z-axis linear
stages 332 and 336 to position the loaded container gripping head
348 above a loaded and capped container 34 positioned by one of the
main hub or the auxiliary offload pallet locators 302 and/or
304.
[0094] Importantly, prior to a respective loaded and capped
container/pallet 34/42 being positioned each of the main hub and
the auxiliary offload pallet locators 302 and/or 304 each
respective loaded and capped container/pallet 34/42 passed a
respective one of a main hub offload pallet identification tag
reader 158MO and an auxiliary offload pallet identification tag
reader 158AO. Accordingly, via reading of each respective pallet
identification tag 154 by the respective main hub offload pallet
identification tag reader 158MO or the auxiliary offload pallet
identification tag reader 158AO, the control system knows what
particular loaded and capped container 34 is positioned for
offloading at the respective main hub and/or the auxiliary offload
pallet locators 302 and/or 304.
[0095] After the loaded container gripping head 348 has been
positioned above a selected loaded and capped container 34, the
control system 32 opens the loaded container gripping head 348 and
lowers the opened loaded container gripping head 348, in the
Y.sup.- direction, around the cap and top portion of the respective
container 34. The loaded container gripping head 348 is then closed
to grasp the loaded and capped container 34 and the pick-and-place
linear actuator 344 is operated to raise the loaded container
gripping head 348 and grasped loaded and capped container 34 in the
Y.sup.+ direction, thereby removing the loaded and capped container
34 from the respective pallet 42.
[0096] Then, via control of the X-axis and Z-axis linear stages 332
and 336, the control system 32 positions the offloaded loaded and
capped container directly above a selected one of the cells 328 of
a selected one of the container packing cases 50. The
pick-and-place linear actuator 344 then lowers the offloaded loaded
and capped container 34 into the selected cell 328 and the loaded
container gripping head 348 is opened to deposit the offloaded
loaded and capped container 34 in the selected cell 328.
Subsequently, the loaded container gripping head 348 is raised and
moved back to a position above another loaded and capped container
34 positioned for offloading at either of the main hub or the
auxiliary offload pallet locators 302 or 304.
[0097] The offloading process, as described above, is continued
until all subsequent loaded and capped containers 34 specified by
the control system in accordance with the small object packaging
project request input by the operator at the operator control
station 102. Once a particular container packing case 50 and had
all designated loaded and capped containers 34 deposited therein,
the control system will convey the respective container packing
case 50 to the handling end 320A of the respective box conveyor
linear stage 320 where and operator can remove the respective
container packing case 50 and replace it with an empty container
packing case 50.
[0098] Referring now to FIG. 7, in various embodiments, the central
control system 32 is a computer based system that generally
includes at least one processor 360 suitable to execute all
functions of the central control system 32 to automatically, or
robotically, control the operation of the small object packaging
system 10, as described herein. The central control system 32
additionally includes at least one electronic storage device 364
that comprises a computer readable medium, such as a hard drive or
any other electronic data storage device for storing such things as
software packages or programs, algorithms and digital information,
data, look-up tables, spreadsheets and databases, e.g., the
database 94 having stored thereon the look-up tables or
spreadsheets described above. Furthermore, the central control
system 32 includes a display 368 for displaying such things as
information, data and/or graphical representations, and at least
one user interface device 372, such as a keyboard, mouse, stylus,
and/or an interactive touch-screen on the display 368. In various
embodiments the central control system 32 can further include a
removable media reader 376 for reading information and data from
and/or writing information and data to removable electronic storage
media such as floppy disks, compact disks, DVD disks, zip disks,
flash drives or any other computer readable removable and portable
electronic storage media. In various embodiments the removable
media reader 376 can be an I/O port of the central control system
32 utilized to read external or peripheral memory devices such as
flash drives or external hard drives.
[0099] In various embodiments, the central control system 32, i.e.,
the processor 360 can be communicatively connectable to a remote
server network 380, e.g., a local area network (LAN), via a wired
or wireless link. Accordingly, the central control system 32 can
communicate with the remote server network 380 to upload and/or
download data, information, algorithms, software programs, and/or
receive operational commands. Additionally, in various embodiments,
the central control system 32 can be structured and operable to
access the Internet to upload and/or download data, information,
algorithms, software programs, etc., to and from Internet sites and
network servers.
[0100] In various embodiments, the central control system 32 can
include one or more system control algorithms, or programs 382,
stored on the storage device 364 and executed by processor 360. The
one or more system control algorithms 382 utilize the small object
profile information and data provided in the look-up tables and/or
spreadsheets stored in the database 94 and returns the profile
information and data to be included in the respective first
container information label 38A. Additionally, the one or more
system control algorithms 382 are executed by the processor 360 to
utilize the inputs from the various pallet identification readers
158 to control the course of each container/pallet 34/42 along the
main hub and auxiliary conveyors 126 and 262 and onto and off of
the respective counting station conveyor 166. Furthermore, the one
or more system control algorithms 382 are executed by the processor
360 to utilize various other inputs from various components and
sensors of the various systems, subsystems, assemblies and
subassemblies of the small object packaging system 10 to
automatically operate the small object packaging system 10 as
described herein.
[0101] In various embodiments, the small object packaging system
can include a small object treatment station (not shown)
operatively connected to the main hub conveyor assembly 14 that is
structured and operable to treat the small objects with a desired
treatment of coating prior to being counted at one of the counting
stations 22. For example, in various embodiments, the small objects
can comprise seeds, e.g., corn, soybean or cotton seeds, wherein it
is desirable to apply a treatment or coating, e.g., a pesticide,
insecticide, fungicide or herbicide, to the seeds prior to being
counted and deposited into the containers 34 at the counting
stations, as described above. Additionally, in various
implementations, the treatment station can further be structured
and operable to remove the seeds from the respective plants. For
example, the treatment station can be structured and operable to
remove corn seeds from a plurality of ears of corn, then apply a
desired treatment to the corn seeds and dry the seeds. Then the
treated and treated seeds can be conveyed, automatically or
manually, to the hopper 184 of a selected counter 174.
[0102] Furthermore, in various embodiments, the small object
packaging system 10 can include a plurality of traffic control
optical sensors (not shown) mounted at various locations to the
main hub conveyor assembly 14. In such embodiments, the control
system 32 would execute a traffic control program or subroutine
that utilizes the traffic control optical sensors to control the
flow of container/pallets 34/42 as the container/pallets 34/42 are
routed about the main hub conveyor 126 and routed off of and onto
the main hub conveyor 126 to and from the various counting, capping
and offloading stations 22, 26 and 30. Accordingly, the collisions
of the various container/pallets 34/42 being processed by the small
object packaging system 10, as described herein, will be
avoided.
[0103] The description herein is merely exemplary in nature and,
thus, variations that do not depart from the gist of that which is
described are intended to be within the scope of the teachings.
Such variations are not to be regarded as a departure from the
spirit and scope of the teachings.
* * * * *