U.S. patent application number 15/229321 was filed with the patent office on 2016-11-24 for automated small object sorting systems and methods.
The applicant listed for this patent is Monsanto Technology LLC. Invention is credited to Kevin L. Deppermann, David W. Finley, Elias J. Yannakakis.
Application Number | 20160339481 15/229321 |
Document ID | / |
Family ID | 44673525 |
Filed Date | 2016-11-24 |
United States Patent
Application |
20160339481 |
Kind Code |
A1 |
Deppermann; Kevin L. ; et
al. |
November 24, 2016 |
AUTOMATED SMALL OBJECT SORTING SYSTEMS AND METHODS
Abstract
In various embodiments, a small object sorting system includes
an object tray cart docking station configured to dock an object
tray cart here within. The system additionally includes an
automated tray removal and positioning subsystem configured to
remove an object tray from the object tray cart, selectively
position the tray such that selected small objects can be extracted
therefrom, and replace the object tray into the object tray cart.
Furthermore, the system includes an automated collection assembly
positioning subsystem configured to selectively position a
collection assembly such that the selected extracted small objects
can be deposited into selected object receptacles, and an automated
object extraction subsystem configured to extract the selected
small objects and deposit each extracted small object into the
selected object receptacles.
Inventors: |
Deppermann; Kevin L.; (St.
Charles, MO) ; Finley; David W.; (Crestwood, MO)
; Yannakakis; Elias J.; (Chesterfield, MO) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Monsanto Technology LLC |
St. Louis |
MO |
US |
|
|
Family ID: |
44673525 |
Appl. No.: |
15/229321 |
Filed: |
August 5, 2016 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13637505 |
Dec 7, 2012 |
9448968 |
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PCT/US2011/025847 |
Feb 23, 2011 |
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15229321 |
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61317967 |
Mar 26, 2010 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B07C 2501/009 20130101;
B07C 3/02 20130101; B07C 5/3425 20130101; G06F 17/00 20130101 |
International
Class: |
B07C 5/342 20060101
B07C005/342; B07C 3/02 20060101 B07C003/02 |
Claims
1. An automated method for sorting small objects, said method
comprising: docking an object tray cart within an object tray cart
docking station of an automated small object sorting system;
removing an object tray from the object tray cart utilizing an
automated tray removal and positioning subsystem of the automated
small object sorting system, wherein the object tray includes a
plurality of wells and a plurality of small objects stored within
the wells; selectively positioning the removed tray utilizing the
automated tray removal and positioning subsystem such that selected
ones of the small objects can be extracted from the removed object
tray; selectively positioning a collection assembly of the
automated small object sorting system utilizing an automated
collection assembly positioning subsystem of the automated small
object sorting system such that the selected one or more small
objects extracted from the removed object tray can be deposited
into selected one or more of a plurality of object receptacles of
the collection assembly; and extracting the selected one or more
small objects from the object tray and depositing each extracted
small object into the selected one or more object receptacles
utilizing an automated object extraction subsystem of the automated
small object sorting system; and replacing the removed object tray
into the object tray cart after the selected small objects have
been extracted utilizing the automated tray removal and positioning
subsystem.
2. The method of claim 1 further comprising verifying that the
object extraction subsystem extracted each of the selected small
objects from the object tray utilizing an object extraction
verification assembly of the automated small object sorting
system.
3. The method of claim 2, wherein verifying that the object
extraction subsystem extracted each of the selected small objects
comprises: capturing image data of one or more nozzle heads of the
object extraction subsystem utilizing one or more imaging devices
of the object extraction verification assembly; and communicating
the image data to a central control system of the automated small
object sorting system to verify whether selected ones of a
plurality of nozzles of the nozzle head have an extracted small
objected retained on a tip of each selected nozzle.
4. The method of claim 1, wherein removing the object tray from the
object tray cart comprises: removing selected object trays from the
docked object tray cart, selectively positioning the removed object
tray such that selected ones of the small objects can be extracted
from the removed object tray, and reinserting the removed object
trays into the docked object tray cart after the selected small
objects have been extracted utilizing a tray locating assembly
structured and operable of the tray removal and positioning
subsystem; and selectively raising and/or lowering the tray
locating assembly utilizing a tray locating assembly lift of the
tray removal and positioning subsystem.
5. The method of claim 4, wherein removing the object tray from the
object tray cart further comprises read a tray information tag
affixed to each object tray stored in the cart utilizing a tray
information tag reader of the tray removal and positioning
subsystem, each tray information tag including: information
identifying each respective object tray; identifying information of
each small object stored in each respective object tray; and a
location, within the respective object tray, of the well in which
each respective small object is stored.
6. The method of claim 1, wherein extracting the selected one or
more small objects from the object tray comprises extracting the
selected one or more small objects from the object tray removed by
the tray removal and positioning subsystem and depositing each
extracted small object into the selected one or more object
receptacles of the collection assembly utilizing a pair of opposing
object transfer assemblies of the object extraction subsystem, the
object transfer assemblies extending between the tray removal and
positioning subsystem and the collection assembly positioning
subsystem.
7. The method of claim 6, wherein each object transfer assembly
comprises a nozzle head removably mounted to a nozzle head carriage
mounted to a carriage transporter, and extracting the selected one
or more small objects from the object tray comprises moving the
nozzle head carriage and nozzle head between the tray removal and
positioning subsystem and the collection assembly positioning
subsystem utilizing the carriage transporter.
8. The method of claim 7, wherein extracting the selected one or
more small objects from the object tray further comprises
magnetically mounting the nozzle head to the nozzle head carriage
utilizing one or more magnets included in at least one of the
nozzle head carriage and the nozzle head comprise.
9. The method of claim 7, wherein extracting the selected one or
more small objects from the object tray further comprises
selectively providing a vacuum to a tip of each of a plurality of
nozzles in a nozzle array of each nozzle head, the vacuum used to
extract the selected one or more small objects from the object tray
and retain the one or more extracted small objects when the nozzle
head is moved from the tray removal and positioning subsystem to
the collection assembly positioning subsystem to transport the one
or more extracted small objects from the object tray to the
collection assembly.
10. The method of claim 7, wherein each carriage transporter
comprises a linear motor, and extracting the selected one or more
small objects from the object tray further comprises producing a
controllable linear force, utilizing the linear motor, to
controllably move the nozzle head carriage and nozzle head between
the tray removal and positioning subsystem and the collection
assembly positioning subsystem.
11. The method of claim 9 further comprising controlling operation
of the tray removal and positioning subsystem and the object
extraction subsystem utilizing a central control system operable to
utilize electronically stored data, to position the respective
nozzle head and the object tray relative to each other and to
stipulate specific ones of the nozzles to which the vacuum is
provided such that the selected one or more small objects are
extracted from the object tray, wherein the data comprises data
identifying particular traits or characteristics of each small
object in the object tray and the location of each respective small
object within the object tray such that the small objects are
extracted based on the traits or characteristics of each respective
small object.
12. The method of claim 11, wherein positioning the collection
assembly comprises utilizing a single axis stage of the collection
assembly positioning subsystem to selectively positioning the
collection assembly along a longitudinal axis of the single axis
stage.
13. The method of claim 12, wherein the collection assembly
comprises a multi-receptacle object receiving fixture including the
one or more object receptacles, and a multi-funnel object
disposition fixture that includes a plurality of funnels, and
wherein positioning the collection assembly further comprises
receiving the one or more extracted small objects in selected ones
of the funnels whereby the one or more small objects are deposited
into the selected one or more object receptacles.
14. The method of claim 12, wherein the single axis stage comprises
a linear motor, and positioning the collection assembly further
comprises producing a controllable linear force to selectively
position the collection assembly along a longitudinal axis of the
linear motor such that the selected ones of the funnels are
positioned beneath a selected one of the nozzle heads, whereby the
one or more extracted small objects can be deposited into the
selected one or more object receptacles.
15. The method of claim 12 further comprising controlling operation
of the object extraction subsystem and the collection assembly
positioning subsystem via the central control system utilizing the
electronically stored data to position the respective nozzle head
and the multi-funnel object disposition fixture relative to each
other and to stipulate specific ones of the nozzles for which the
vacuum is terminated such that the selected one or more small
objects are released from the respective nozzle into a selected one
of the funnels such that each small object is deposited into a
corresponding selected object receptacle.
16. The method of claim 13, wherein the one or more object
receptacles comprises a plurality of containers and the
multi-receptacle object receiving fixture is structured to retain
and position the containers, and wherein selectively positioning
the collection assembly further comprises aligning an open end of
each container with a dispensing end of a corresponding one of the
funnels such that selected small objects can be deposited into
selected containers.
17. The method of claim 13, wherein the one or more object
receptacles comprises a plurality of plant-ready cups and the
multi-receptacle object receiving fixture includes an alignment
platform structured to retain and position the plant-ready cups,
and wherein selectively positioning the collection assembly further
comprises aligning an open end of each plant-ready cup with a
dispensing end of a corresponding one of the funnels such that
selected small objects can be deposited into selected plant-ready
cups.
18. The method of claim 2, wherein the small objects comprise
seeds, the object tray comprises a seed tray, and the object
receptacles comprise seed receptacles.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. patent application
Ser. No. 13/637,505 filed on Dec. 7, 2012, which is a National
Stage of International Application No. PCT/US2011/025847, filed
Feb. 23, 2011, which claims priority to U.S. Provisional
Application No. 61/317,967 filed on Mar. 26, 2010. The disclosures
of the above applications are incorporated herein by reference in
its entirety.
[0002] Additionally, the present application is related in general
subject matter to U.S. application Ser. No. 11/769,318, filed Jun.
27, 2007, and titled "Small Object Sorting System and Method",
which is assigned to the assignee of the present application.
FIELD
[0003] The present disclosure relates generally to a system and
method for sorting small objects, such as seeds, pharmaceutical
tablets or capsules, and any other agricultural, manufactured or
produced small objects.
BACKGROUND
[0004] The statements in this section merely provide background
information related to the present disclosure and may not
constitute prior art.
[0005] The sorting 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.
[0006] For example, in seed breeding, large numbers of seeds are
sampled and analyzed to determine whether the seeds possess a
particular genotype or traits of interest. Generally, seeds are
sampled by removing a small portion of each seed, while leaving the
remaining seed viable for planting. The removed portions, or chips,
and the corresponding `donor` seeds are then cataloged to track the
seeds and the respective corresponding chips. Each chip is then
analyzed to identify various attributes of the respective chip and
donor seed, such as DNA characteristics and/or traits.
[0007] After the seeds are sampled and the chips have been
analyzed, the seeds are individually sorted according to attributes
of each respective seed. Typically, the sorting process is
painstakingly performed by hand, which is extremely time consuming
and subject to human error.
SUMMARY
[0008] The present disclosure provides automated systems and
methods for sorting small objects, such as seeds, pharmaceutical
tablets or capsules, and any other agricultural, manufactured or
produced small objects.
[0009] In various embodiments, an exemplary small object sorting
system includes an object tray cart docking station that is
structured and operable to receive and engage an object tray cart
to dock the object tray cart within the object tray cart docking
station. The system additionally includes an automated tray removal
and positioning subsystem that is structured and operable to remove
an object tray from the object tray cart, wherein the object tray
including a plurality of wells and a plurality of small objects
stored within the wells. The automated tray removal and positioning
subsystem is further structured and operable to selectively
position the removed tray such that selected ones of the small
objects can be extracted from the removed object tray, and replace
the removed object tray into the object tray cart after the
selected small objects have been extracted. Furthermore, the system
includes an automated collection assembly positioning subsystem
that is structured and operable to selectively position a
collection assembly such that the selected one or more small
objects extracted from the removed object tray can be deposited
into selected one or more of a plurality of object receptacles of
the collection assembly. The system still further includes an
automated object extraction subsystem that is structured and
operable to extract the selected one or more small objects from the
object tray and deposit each extracted small object into the
selected one or more object receptacles.
[0010] In various other embodiments, an exemplary small object
sorting method includes docking an object tray cart within an
object tray cart docking station of an automated small object
sorting system and removing an object tray from the object tray
cart utilizing an automated tray removal and positioning subsystem
of the automated small object sorting system, wherein the object
tray includes a plurality of wells and a plurality of small objects
stored within the wells. The method additionally includes
selectively positioning the removed tray, utilizing the automated
tray removal and positioning subsystem, such that selected ones of
the small objects can be extracted from the removed object tray.
Furthermore, the method includes selectively positioning a
collection assembly of the automated small object sorting system,
utilizing an automated collection assembly positioning subsystem of
the automated small object sorting system, such that the selected
one or more small objects extracted from the removed object tray
can be deposited into a selected one or more of a plurality of
object receptacles of the collection assembly. The method still
further includes extracting the selected one or more small objects
from the object tray and depositing each extracted small object
into the selected one or more object receptacles utilizing an
automated object extraction subsystem of the automated small object
sorting system. Further yet, the method includes replacing the
removed object tray into the object tray cart after the selected
small objects have been extracted utilizing the automated tray
removal and positioning subsystem.
[0011] In yet other embodiments, an exemplary seed sorting system
includes a seed tray cart docking station that is structured and
operable to receive and engage a seed tray cart to dock the seed
tray cart within the seed tray cart docking station. The system
additionally includes an automated tray removal and positioning
subsystem that is structured and operable to remove a seed tray
from the seed tray cart, wherein the seed tray including a
plurality of wells and a plurality of seeds stored within the
wells. The automated tray removal and positioning subsystem is
further structured and operable to selectively position the removed
tray such that selected ones of the seeds can be extracted from the
removed seed tray, and replace the removed seed tray into the seed
tray cart after the selected seeds have been extracted.
Furthermore, the system includes an automated collection assembly
positioning subsystem that is structured and operable to
selectively position a collection assembly such that the selected
one or more seeds extracted from the removed seed tray can be
deposited into selected one or more of a plurality of seed
receptacles of the collection assembly. The system still further
includes an automated seed extraction subsystem that is structured
and operable to extract the selected one or more seeds from the
seed tray and deposit each extracted seed into the selected one or
more seed receptacles. The system further yet includes a seed
extraction verification assembly that is structured and operable to
verify that the seed extraction subsystem extracted each of the
selected seeds from the seed tray.
[0012] 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
[0013] The drawings described herein are for illustration purposes
only and are not intended to limit the scope of the present
teachings in any way.
[0014] FIG. 1A is an isometric view of a front side of an automated
small object sorting system, in accordance with various embodiments
of the present disclosure.
[0015] FIG. 1B is an isometric view of a back side of the automated
small object sorting system shown in FIG. 1A, in accordance with
various embodiments of the present disclosure.
[0016] FIG. 2A is an isometric view of the automated small object
sorting system shown in FIGS. 1A and 1B, illustrating a small
object tray cart docking station, in accordance with various
embodiments of the present disclosure.
[0017] FIG. 2B is an isometric view of a front side of a small
object tray cart structured to be docked within the docking station
shown in FIG. 2A, in accordance with various embodiments of the
present disclosure.
[0018] FIG. 2C is an isometric view of a back side of the small
object tray cart shown in FIG. 2B, in accordance with various
embodiments of the present disclosure.
[0019] FIG. 2D is an isometric view of a small object sorting tray
structured to be stored in the small object tray cart shown in
FIGS. 2B and 2C, and retain small objects sorted by the automated
small object sorting system shown in FIGS. 1A and 1B, in accordance
with various embodiments of the present disclosure.
[0020] FIG. 2E is an isometric view of the docking station shown in
FIG. 2A having a small object tray cart docked therein, in
accordance with various embodiments of the present disclosure.
[0021] FIG. 3A is an isometric view of a tray removal and
positioning subsystem of the small object sorting shown in FIGS. 1A
and 1B, in accordance with various embodiments of the present
disclosure.
[0022] FIG. 3B is an isometric view of the tray removal and
positioning subsystem shown in FIG. 3A illustrating a tray shuttle
fixture, in accordance with various embodiments of the present
disclosure.
[0023] FIG. 3C is an isometric view of the tray removal and
positioning subsystem shown in FIG. 3A illustrating a tray lid
removal assembly, in accordance with various embodiments of the
present disclosure.
[0024] FIG. 4A is an isometric view of a collection assembly
positioning subsystem and a small object extraction subsystem of
the small object sorting shown in FIGS. 1A and 1B, in accordance
with various embodiments of the present disclosure.
[0025] FIG. 4B is an isometric view of an object transfer
subassembly of the small object extraction subsystem shown in FIG.
4A, in accordance with various embodiments of the present
disclosure.
[0026] FIG. 4C is an isometric view of a nozzle head of the object
transfer subassembly shown in FIG. 4B, in accordance with various
embodiments of the present disclosure.
[0027] FIG. 4D is an isometric view of a nozzle head carriage of
the object transfer subassembly shown in FIG. 4B, in accordance
with various embodiments of the present disclosure.
[0028] FIG. 4E is an isometric view of a multi-receptacle
planter-ready tray structured to be retained within a collection
assembly of the small object sorting shown in FIGS. 1A and 1B, in
accordance with various other embodiments.
[0029] FIG. 5 is an isometric view of a portion of the automated
small object sorting system shown in FIGS. 1A and 1B, illustrating
a small object extraction verification assembly, in accordance with
various embodiments of the present disclosure.
[0030] FIG. 6 is a block diagram of a central control system of the
automated small object sorting system shown in FIGS. 1A and 1B, in
accordance with various embodiments of the present disclosure.
[0031] Corresponding reference numerals indicate corresponding
parts throughout the several views of drawings.
DETAILED DESCRIPTION
[0032] 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.
[0033] Referring to FIGS. 1A and 1B, an automated small object
sorting system 10 is provided for automatically, i.e., robotically,
sorting small objects and depositing the sorted objects into
selected receptacles based on particular attributes of each sorted
object, e.g., characteristics and/or traits such as size, shape,
color, composition, quality, weight, genetic traits, etc. The
objects can be any small objects, items, parts or products that are
desired to be sorted or separated based on particular attributes of
each sorted object. For example, the sorting system 10 can be
utilized to sort such small objects such as seeds and other
agricultural products, pharmaceutical tablets or capsules, small
electrical components, ball bearings, small food products, etc.
[0034] Generally, the sorting system 10 includes a small object
tray docking station 14, an automated, or robotic, tray removal and
positioning subsystem 18, an automated, or robotic, collection
assembly positioning subsystem 22, an automated, or robotic, small
object extraction subsystem 26, a small object extraction
verification assembly 30, and a computer based central control
system 34. The control system 34 is operable to control the
automated and cooperative functions and operations of the small
object tray docking station 14, the tray removal and positioning
subsystem 18, the collection assembly positioning subsystem 22, the
small object extraction subsystem 26, and the small object
extraction verification assembly 30, i.e., the automated operation
of the sorting system 10, as described below.
[0035] The sorting system 10 additionally includes a pneumatic
supply assembly 35 that is connected to a vacuum source (not
shown). In various embodiments, the pneumatic supply assembly 35
includes a vacuum bar 36 that is connected to the vacuum source and
operates as a conduit for providing a vacuum to a plurality of
regulators 37 coupled thereto. The regulators 37, as controlled by
the central control system 34, regulate pneumatic command signals
e.g., vacuum and/or expansion/positive pressure signals, sent to
various systems, subsystems, assemblies, subassemblies, devices,
apparatuses, and components of the sorting system 10. More
particularly, the central control system 34 controls the operation
of the regulators 37 to provide, monitor, condition and/or modulate
positive pressure signals and/or vacuum signals utilized to operate
the various systems, subsystems, assemblies, subassemblies,
devices, apparatuses, and components of the sorting system 10, as
described herein. It should be understood that sorting system 10
includes a plurality of various vacuum and/or pressure line, e.g.,
flexible tubing, that connect the regulators 37 to, and communicate
the pneumatic command signals e.g., vacuum and/or
expansion/positive pressure signals to, the various systems,
subsystems, assemblies, subassemblies, devices, apparatuses, and
components of the sorting system 10. However, for clarity, many of
the vacuum and/or pressure lines are not illustrated of the various
figures described herein.
[0036] Alternatively, the various systems, subsystems, assemblies,
subassemblies, devices, apparatuses, and components of the sorting
system 10 can be operated utilizing other energy sources such as
electricity, hydraulics, etc.
[0037] Additionally, it should be understood that the sorting
system 10, as shown and described herein, includes various
stationary braces, beams, platforms, pedestals, stands, etc., to
which the various components, devices, mechanisms, systems,
subsystems, assemblies and subassemblies described herein are
supported, coupled, connected and/or mounted. Although such braces,
beams, platforms, pedestals, stands, etc., are necessary to the
construction of the sorting system 10, description of their
placement, orientation and interconnections are not necessary for
one skilled in the art to easily and fully comprehend the
structure, function and operation of the sorting system 10.
Particularly, such braces, beams, platforms, pedestals, stands,
etc., are clearly illustrated throughout the figures and, as such,
their placement, orientation and interconnections are easily
understood by one skilled in the art. Therefore, for simplicity,
such braces, beams, platforms, pedestals, stands, etc. will be
referred to herein merely as system support structures, absent
further description of their placement, orientation and
interconnections.
[0038] Referring now to FIGS. 2A, 2B, 2C and 2D, the tray cart
docking station 14 is structured and operable to receive and engage
a small object tray cart 38 such that the small object tray cart 38
is temporarily retained, i.e., docked, within the docking station
14. In various implementations, the small object tray cart 38 can
include casters, rollers or wheels 42 that allow the cart 38 to be
moved from a non-docked location into the docking station 14.
Additionally, the small object tray cart 38 includes a plurality of
tray guides 46 disposed on, i.e., formed in or attached to,
opposing sidewalls 50 of the cart 38. The tray guides 46 are
structured and disposed on the opposing sidewalls 50 such that each
of a plurality of small object sorting trays 54 can be supported
within the cart 38 by opposing guides 46 to thereby removably store
each of the trays 54 within the cart 38. Each sorting tray 54
includes a plurality of wells 86, wherein each well 86 is
structured to retain a single small object.
[0039] In various embodiments, the small object tray cart 38 can be
selected from a plurality of like small object tray carts 38,
wherein each cart 38 has retained therein selected different
sorting trays 54, each sorting tray 54 including a plurality of
small objects residing within the respective well 86.
[0040] In various embodiments, the small object tray cart 38 can
include a tray locking mechanism 58 that is structured and operable
to engage each of the small object sorting trays 54 to retain the
sorting trays 54 within the cart 38 until such time as the tray
locking mechanism 58 is operated to disengage the sorting trays 54.
The locking mechanism 58 can be any mechanism, device or assembly
operable to retain the sorting trays 54 within the cart 38 and
release the trays 54 upon a disengaging operation of the locking
mechanism 58. For example, in various embodiments the locking
mechanism 58 can include a spring loaded, or otherwise biased,
shaft 62 having a plurality of locking arms 66 radially extending
from the shaft 62. In such embodiments, the locking arms are spaced
apart a distance equal to the spacing between adjacent tray guides
46 and the shaft 62 is biased upward, via a spring or other biasing
device, to a locking position wherein each of the locking arms 66
engages a sorting tray 54 supported by a respective set of opposing
tray guides 46 (not each set of opposing tray guides necessarily
has a sorting tray 54 supported thereon).
[0041] For example, when the locking mechanism 58 is in the locking
position, each locking arm 66 can engage an appropriate one of a
pair of handling channels 70 formed at opposing ends of each
sorting tray 54. Additionally, in such embodiments, the locking
mechanism 58 can include a release lever 74 radially extending from
the shaft 62 through a slot 78 formed in a back of the cart 38.
When the cart 38 is docked within the docking station 14, as
described below, the release lever 74 is positioned adjacent and in
close proximity to a locking mechanism release actuator 82. The
locking mechanism release actuator 82 is controllably operable,
e.g., via the central controller 34, to push downward on the
release lever 74, opposing and overcoming the upward biasing force
on the shaft 62, thereby disengaging the locking arms 66 from the
handling channels 70 of each tray 54 retained within the cart 38.
Accordingly, once the cart 38 is docked in the docking station 14,
the locking mechanism 58 is disengaged, via the release actuator
82, so that each of the trays 54 can be selectively removed from
the cart 38 by the tray removal and positioning subsystem 18, as
described below.
[0042] Referring particularly to FIG. 2A, as described above, the
sorting system 10 is operable to sort small objects and deposit the
sorted objects into selected receptacles based on particular
attributes of each sorted object, e.g., characteristics and/or
traits such as size, shape, color, composition, quality, weight,
genetic traits, etc. More specifically, the sorting system 10 is
structured and operable to receive the small object tray cart 38 in
the docking station 14, automatically remove selected sorting trays
54 from the cart 38, extract selected small objects from each
removed sorting tray 54, and deposit each extracted small object
into selected receptacles 98 removably disposed on, or within, a
collection assembly 100 of the collection assembly positioning
subsystem 22.
[0043] Hence, to utilize the sorting system 10 to sort the small
objects stored within the sorting trays 54 of the cart 38, the cart
38 must be positioned within the docking station 14, either
manually or via automation. The docking station 14 includes a cart
receiving assembly 90 that is structured and operable to locate and
retain the cart 38 in a specific position and orientation relative
to the tray removal and positioning subsystem 18. In various
embodiments, the cart receiving assembly 90 includes a pair of
opposing upper guide arms 94 spaced apart a distance substantially
equal to the width of the cart 38, i.e., the distance between the
outer surfaces of the opposing cart sidewalls 50. As the cart 38 is
being positioned within the docking station 14, e.g., as the cart
38 is being pushed into the docking station 14, the guide arms 94
guide the cart 38 into the docking station 14 such that cart 38 is
positioned and oriented with a front of the cart 38 adjacent a
ingress/egress window 102 of the tray removal and positioning
subsystem 18, and an exposed leading edge of each sorting tray 54
extends into the ingress/egress window 102, hereafter referred to
as the cart 38 being in the docked position or being docked.
[0044] The cart receiving assembly 90 further includes a pair of
opposing cart stabilizers 106 that engage the opposing sidewalls 50
to retain the cart 38 in the docked position. In various
embodiments, each cart stabilizer 106 can comprise a pliable roller
that frictionally engages and slightly protrudes into a recess,
groove, raised lip, or channel formed at the leading edge of each
respective sidewall 50 when the cart 38 is fully engaged in the
docked position. Additionally, the cart receiving assembly 90
includes one or more cart locks 108 that are operable to secure the
cart 38 within the docking station 14, i.e., secure the cart 38 in
the docked position. The cart locks 108 can be any device,
mechanism, apparatus or latch structured and operable to firmly
retain the cart 38 within the docking station 14 during operation
of the sorting system 10, e.g., as the trays 54 are being removed
and replaced from the cart 38 by the tray removal and positioning
subsystem 18, as described below. For example, in various
embodiments, the one or more cart locks 108 can comprise solenoids
mounted at distal ends of the guide arms 94 that are electrically
actuated to extend a piston, plunger or rod that physically
contacts the cart 38, e.g., a back side of the cart 38, to securely
maintain and stabilize the cart 38 within the docking station 14.
Or, in other exemplary embodiments, the one or more cart locks 108
can comprise biased pistons, plungers or rods mounted at distal
ends of the guide arms 94 that are manually operated to physically
contact the cart 38 to securely maintain and stabilize the cart 38
within the docking station 14.
[0045] Referring additionally to FIG. 2E, in various embodiments,
the docking station 14 further includes a cart information device
reader 110 that is structured and operable to read a cart
information device 114 affixed to the cart 38, e.g., affixed to a
top surface of the cart 38. The cart information device 114 can
include various information and/or data regarding or pertaining to
the cart 38, the one or more sorting trays 54 stored in the cart 38
and/or the particular small objects stored in the respective
sorting tray(s) 54. For example, in various embodiments, the cart
information device 114 can provide a coded list identifying each of
one or more sorting trays 54 stored in the cart 38. Therefore, once
the cart 38 is docked, the central control system 34 communicates
with and controls the cart information device reader 110 to read
the cart information device 114 and receive the information/data
thereby provided. The cart information/data read and received is
utilized to as data inputs to one or more system control algorithm,
or program, executed by the central control system 34 to control
the operation of the sorting system 10, as described below. The
read cart information/data can be, at least temporarily, compiled
and stored in any desirable format, for example, the cart
information/data can be stored in one or more electronic databases,
spreadsheets and/or look-up tables accessible and readable by the
central control system 34.
[0046] The cart information device 114 can be any machine-readable
identification device, label or tag suitable for containing or
storing information and data, readable or retrievable by the cart
information device reader 110, regarding or pertaining to the cart
38, the one or more sorting trays 54 stored in the cart 38 and/or
the particular small objects stored in the respective sorting
tray(s) 54. For example, in various implementations, the cart
information device 114 can comprise a two-dimensional matrix code
or other machine-readable label, tag or device, such as a radio
frequency identification (RFID) tag or a bar code label, from which
the information/data can be received and interpreted via wireless
communication such as optical signals, e.g., infrared signals, or
magnetic fields. Similarly, the cart information device reader 110
can be any device suitable for reading the cart information device
114, i.e., retrieving the information/data contained in the cart
information device 114, and communicating the retrieved
information/data to the central control system 34. For example, in
various implementations, the cart information device reader 110 can
comprise a device structured and operable to read a two-dimensional
matrix code or other machine-readable label, tag or device, such as
an RFID tag reader or a bar code label reader, operable to read the
information/data stored in the respective cart information device
114 via wireless communication such as optical signals, e.g.,
infrared signals, or magnetic fields.
[0047] Referring now to FIGS. 3A, 3B and 3C, the tray removal and
positioning subsystem 18 is structured and operable to remove the
small object trays 54 from the small object tray cart 38,
controllably position each removed tray 54 such that selected ones
of the small object can be extracted therefrom, and replace each
tray 54 into the cart 38 after the selected small objects have been
extracted. More particularly, the tray removal and positioning
subsystem 18 includes a tray locating assembly 118 that is
structured and operable, as controlled by the central control
system 34, to sequentially remove selected trays 54 from the docked
cart 38, controllably position each removed tray 54 along a
longitudinal axis of the tray locating assembly 118 and reinsert
each removed tray 54 into the docked cart 38 after selected small
objects have been extracted from each respective tray 54.
Additionally, the tray removal and positioning subsystem 18
includes a tray locating assembly lift 122 that is structured and
operable, as controlled by the central control system 34, to
selectively raise and/or lower the tray locating assembly 118.
[0048] Specifically, the tray locating assembly lift 122 is
operable to selectively move the tray locating assembly 118 along a
longitudinal axis of the tray locating assembly lift 122 such that
tray locating assembly 118 is controllably positioned adjacent each
tray 54 to be removed from the cart 38. Furthermore, the tray
locating assembly lift 122 is structured and operable to
selectively raise and/or lower the tray locating assembly 118 in
coordination with the operation of the tray locating assembly such
that selected small objects can be removed from each tray 54 by the
small object extraction subsystem 26, as described below.
[0049] The tray locating assembly lift 122 includes a support
fixture 126 and a Y-axis elevator 130. The support fixture 126 is
movably mounted to the elevator 130 and the tray locating assembly
118 is fixedly mounted to the support fixture 126. The elevator 130
is controllable by the central control system 34 to
bi-directionally move the tray locating assembly 118 along the
longitudinal axis of the elevator 130, i.e., in the .sup.+Y and
.sup.-Y directions. That is, the elevator 130 is operable to raise
and lower the tray locating assembly 118, as controlled by the
central control system 34. The elevator 130 can be any assembly,
system or mechanism structured and operable to controllably move
the tray locating assembly 118 bi-directionally along the
longitudinal axis of the elevator 130. For example, in various
embodiments, the elevator 130 can comprise a pneumatically,
hydraulically or electrically controlled threaded shaft system,
wire or cable pulley system, piston system, conveyor belt system,
linear motor, or any other suitable positioning system structured
and operable to move the tray locating assembly 118
bi-directionally along the longitudinal axis of the elevator 130,
as controlled by the central control system 34.
[0050] In various embodiments, the tray locating assembly 118
includes a shuttle translation stage 134 disposed between a pair of
opposing tray support rails 138 structured to support sorting trays
54 as they are removed from the small object tray cart 38 by the
tray locating assembly 118. The tray locating assembly 118
additionally includes a tray shuttle 142 movably mounted to the
shuttle translation stage 134 and is structure and operable to
engage each selected sorting tray 54 such that each respective
sorting tray 54 can be removed from the cart 38, controllably
position each removed sorting tray 54 on the tray locating assembly
118, and replace each sorting tray 54 into the cart 38.
[0051] The shuttle translation stage 134 is controllable by the
central control system 34 to bi-directionally move the tray shuttle
142 along the longitudinal axis of the shuttle translation stage
134, i.e., in the .sup.+X and .sup.-X directions. Particularly, the
shuttle translation stage 134 is operable, in coordination with
operation of the elevator 130, to selectively remove sorting trays
54 from the tray cart 38, controllably position the removed sorting
trays 54 along the length of the tray support rails 138 such that
selected small objects can be extracted from each removed sorting
tray 54 by the small object extraction subsystem 26, and replace,
or reinsert, the sorting trays 54 into the cart 38. The shuttle
translation stage 134 can be any assembly, system or mechanism
structured and operable to controllably move the tray shuttle 142
bi-directionally along the longitudinal axis of the shuttle
translation stage 134, thereby removing, positioning and replacing
the sorting trays 54. For example, in various embodiments, the
shuttle translation stage 134 can comprise a pneumatically,
hydraulically or electrically controlled threaded shaft system,
wire or cable pulley system, piston system, conveyor belt system, a
linear motor, or any other suitable positioning system (not shown)
that is structured and operable to bi-directionally move the tray
shuttle 142 along the longitudinal axis of the shuttle translation
stage 134, as controlled by the central control system 34.
[0052] As best seen in FIG. 3B, the tray shuttle 142 includes a
tray handling bar 146 disposed at a distal end of the tray shuttle
142, i.e., disposed at the end of the tray shuttle 142 nearest the
docking station 14. The tray handling bar 146 is structure to fit
within the tray handling channels 70 of each sorting tray 54 (shown
in FIG. 2D). As shown in FIG. 2D, the tray handling channels 70
include a window 150, i.e., a gap, space, or opening, that is sized
to accommodate a neck portion 154 of the tray shuttle 142. Hence,
by coordinated operation of the elevator 130 and the shuttle
translation stage 134, as controlled by the central control system
34, the tray handling bar 146 can be positioned within and engage
the tray handling channel 70. Therefore, via the engagement of the
tray handling bar 146 within the tray handling channel 70, the tray
shuttle 142 can be controllably positioned along the shuttle
translation stage 134 to remove a selected sorting tray 54 from the
cart 38, controllably position the removed sorting tray 54 along
the tray support rails 138 as selected small objects are extracted
from the removed sorting tray 54, and replace the removed sorting
tray 54 into the cart 38 after the selected small objects have been
extracted.
[0053] More specifically, to remove a selected sorting tray 54 from
a docked cart 38, the central control system 34 controls the
operation of the elevator 130 and the shuttle translation stage 134
to move the tray shuttle 142 at or near a leading end 154 of the
tray support rails 138 such that the tray handling bar 146 is
adjacent and slightly below the tray handling channel 70 of a
selected sorting tray 54. The shuttle translation stage 134 is then
operated to slightly move the tray shuttle 142 in the .sup.+X
direction such that the tray handling bar 146 is directly below the
tray handling channel 70 of the selected sorting tray 54. The
elevator 130 is then operated to slightly raise the tray shuttle
142 and tray support rails 138 in the .sup.+Y direction such that
the tray handling bar 146 is disposed within and engages the tray
handling channel 70 of the selected sorting tray 54. Subsequently,
the shuttle translation stage 134 is operated to move the tray
shuttle in the .sup.-X direction, whereby the tray handling bar
146, via engagement with the tray handling channel 70, pulls the
selected sorting tray 54 out of the docked tray cart 38 such that
the selected sorting tray 54 is supported on tray support rails
138.
[0054] Additionally, via engagement of the tray handling bar 146
with the tray handling channel 70, the shuttle translation stage
134 can be operated to controllably position the removed sorting
tray 54 anywhere along the length of the tray support rails 138,
and the elevator 130 can be operated to controllably raise and/or
lower removed sorting tray 54 in order to position the removed
sorting tray 54 for extraction of selected small objects, as
described below. Once all the selected small objects have been
extracted from the removed sorting tray 54, the shuttle translation
stage 134 and the elevator 130 can be operated to position the tray
support rails 138 adjacent opposing tray guides 46 of the docked
tray cart 38 and push the removed sorting tray 54 onto the tray
guides 46, thereby replacing the removed sorting tray 54 back into
the docked tray cart 38.
[0055] Referring additionally to FIGS. 2D and 2E, in various
embodiments, the tray locating assembly 118 can include a tray
information device reader 158 that is structured and operable to
read a tray information device 162 affixed to each sorting tray 54.
In various embodiments each tray information device 162 can be
affixed to an exterior edge of the respective tray handling channel
70 and the tray information device reader 158 can be affixed to an
end of the shuttle translation stage 134 near the docking station
14, or any other location on the tray locating assembly 118 near
the docking station 114.
[0056] Each tray information device 162 can include various
information and data regarding or pertaining to the small objects
residing the wells 86 of the respective sorting tray 54. For
example, in various embodiments, each tray information device 162
can provide coded information identifying each small object within
the respective sorting tray 54 and detailing particular attributes
of each small object within the respective sorting tray 54, e.g.,
characteristics and/or traits such as size, shape, color,
composition, quality, weight, genetic traits, etc. Additionally,
each tray information device 162 can provide information
identifying the location, e.g., Cartesian coordinates, of each
respective small object within the respective sorting tray 54, more
particularly, the location of the respective well 86 in which each
small object resides. Therefore, once the cart 38 is docked, the
central control system 34 communicates with and controls the tray
locating assembly 118 and the tray information device reader 158 to
read the tray information device 162 of each sorting tray 54 stored
in the cart 38 and receive the information thereby provided. The
information read and received is utilized as data inputs to the one
or more system control algorithms, or programs, executed by the
central control system 34 to control the operation of the sorting
system 10, e.g., the extraction of selected small objects from
selected ones of the sorting trays 54 stored in the cart 38, as
described below. The tray information/data can be, at least
temporarily, compiled and stored in any desirable format, for
example, the cart information/data can be stored in one or more
electronic databases, spreadsheets and/or look-up tables accessible
and readable by the central control system 34.
[0057] As described above, the cart information device 114 can
include various information and data regarding or pertaining to the
cart 38 and the one or more sorting trays 54 stored in the cart 38.
For example, in various embodiments, the cart information device
114 can include information identifying the particular sorting
trays 54 that are stored in the respective cart 38. In such
embodiments, once the cart 38 is docked, as described above, the
cart information device 114 can be read by the cart information
device reader 110 to obtain the information identifying the
particular sorting trays 54 that are stored in the respective cart
38. Subsequently, the elevator 130 of the tray removal and
positioning subsystem 18 can be operated to raise and/or lower the
shuttle translation stage 134 such that the tray information device
reader 158 can read the tray information device 162 of each sorting
tray 54 stored in the cart 38 to obtain information identifying
each of the sorting trays 54. The tray identification information
acquired from each of the tray information devices 162 can then be
compared, via the central control system 34, with the information
acquired from cart information device 114 to verify that the
respective cart 38 has the correct sorting trays 54 stored
therein.
[0058] Each tray information device 162 can be any machine-readable
identification device, label or tag suitable for containing or
storing information and data, readable or retrievable by the tray
information device reader 158, regarding or pertaining to the
respective sorting tray 54 and the respective small objects
residing therein. For example, in various implementations, each
tray information device 162 can comprise a two-dimensional matrix
code or other machine-readable label, tag or device, such as a
radio frequency identification (RFID) tag or a bar code label, from
which the information/data can be received and interpreted via
wireless communication such as optical signals, e.g., infrared
signals, or magnetic fields. Similarly, the tray information device
reader 158 can be any device suitable for reading the tray
information devices 162, i.e., retrieving the information/data
contained in each tray information device 162, and communicating
the retrieved information/data to the central control system 34.
For example, in various implementations, the tray information
device reader 158 can comprise a device structured and operable to
read a two-dimensional matrix code or other machine-readable label,
tag or device, such as an RFID tag reader or a bar code label
reader, operable to read the information/data stored in each tray
information device 162 via wireless communication such as optical
signals, e.g., infrared signals, or magnetic fields.
[0059] Referring particularly to FIG. 3C, in various embodiments,
the automated tray removal and positioning subsystem 118 includes
an automated tray lid removal assembly 166 that is structured and
operable to remove a lid 170 from each sorting tray 54 removed from
the docked cart 38 and replace the lid 170 prior to replacing the
sorting tray 54 into the docked cart 38. More particularly, in
various embodiments, each sorting tray 54 stored in the cart 38 has
a respective lid 170 removably connected thereto. Each lid 170
operates to retain each of the small objects within the wells 86 of
the respective sorting tray 54. Each lid 170 can be removably
connected to the respective sorting tray 54 using any suitable
connecting or fastening means.
[0060] For example, in various implementations, each sorting tray
54 can include a plurality of L-shaped spring clips 174 attached to
opposing longitudinal sides of the sorting tray 54, and each lid
170 can include a plurality of mating cutouts 178. In such
implementations, each lid 170 can be installed on, or connected to,
the respective sorting tray 54 by positioning the lid 170 onto a
top surface of the respective sorting tray 54 such the cutouts 178
are placed around the tray spring clips 174. The lid 170 can then
be slid across the tray top surface such that perimeter edges of
the lid 170 slide under the spring clips 174, thereby removably
connecting the lid 170 to, or retaining the lid 170 on, the
respective sorting tray 54. To remove the lid 170 from the
respective sorting tray 54 the process is reversed, whereby the lid
170 is slid across the tray top surface until the cutouts 178 align
with the spring clips 174 such that the lid 170 can then be lifted
or removed from the respective sorting tray 54.
[0061] In various embodiments, the lid removal assembly 166
includes a vacuum cup head 182 mounted to a distal end of a linear
actuator 186, e.g., a pneumatic actuator, mounted to system support
structure such that the vacuum cup head 182 is positioned above the
tray support rails 154 of the tray locating assembly 118. The
actuator 186 is operable, as controlled by the central control
system 34, to raise and lower the vacuum cup head 182 in the
.sup.+Y and .sup.-Y directions. The vacuum cup head 182 includes a
plurality of vacuum cups 190 one or more of which are connected to
one or more of the vacuum regulators 37 such that a controlled
vacuum can be provided at selected vacuum cups 190.
[0062] As described above, tray lid removal assembly 166 is
structured and operable to remove the lid 170 from each sorting
tray 54 removed from the docked cart 38 by the tray removal and
positioning subsystem 18 and replace the lid 170 prior to the
sorting tray 54 being replaced into the docked cart 38 by the tray
removal and positioning subsystem 18. More particularly, after a
sorting tray 54 having a lid 170 connected thereto (the tray-lid
assembly 54/170) is removed from the cart 38, the tray locating
assembly 118 moves the tray-lid assembly 54/170 along the tray
support rails 138 to a position directly beneath the vacuum cup
head 182. Additionally, the tray locating assembly lift 122 raises
or lowers the tray locating assembly 118 such that the tray-lid
assembly 54/170 is positioned at a particular height, i.e., a
particular distance from the vacuum cup head 182.
[0063] The actuator 186 is then operated, as controlled by the
central control system 34, to lower the vacuum cup head 182 to a
position wherein the vacuum cups 190 are in contact with the lid
170 of the tray-lid assembly 54/170. A vacuum is then provided at
one or more of the vacuum cups 190 and the actuator is operated to
raise the vacuum cup head 182, thereby removing the lid 170 from
the tray-lid assembly 54/170. In various implementations, wherein
the lid 170 is connected to the sorting tray 54 via the spring
clips 174, as described above, once the vacuum cups 190 are placed
on contact with the lid 170 and the vacuum is applied at the vacuum
cup(s) 170, the vacuum cup head 182 can be slightly raised, or the
tray locating assembly 118 can be slightly lowered, slightly
separate at least a portion of the lid 170 from the sorting tray 54
to break any static electric bond or vacuum formed between the lid
170 and the sorting tray 54. The tray locating assembly 118 is then
operated to move the sorting tray 54 in the .sup.+X or .sup.-X
direction, as the lid 170 is held stationary by the vacuum cup head
182, such that the lid cutouts 178 align with the respective
L-shaped spring clips 174. That is, the sorting tray 54 is moved
such that the perimeter edge of the lid 170 is slid under the
spring clips 174 until the cutouts 178 align with the spring clips
174, thereby disconnecting, or disengaging the lid 170 from the
sorting tray 54. Subsequently, the actuator 186 can be operated to
raise the vacuum cup head 182 while the vacuum continues to be
applied to the vacuum cup(s) 190 such that the lid 170 is lifted
off of and away from the sorting tray 54. The lid 170 is raised to
a parked position that is a sufficient distance above the sorting
tray 54 to allow access by the small object extraction subsystem 26
to the small objects residing in the tray wells 86. The selected
small objects can then be extracted by the small object extraction
subsystem 26 as described below.
[0064] Referring now to FIGS. 4A, 4B, 4C and 4D, the automated
small object extraction subsystem 26 is structured and operable to
extract one or more selected small objects from each sorting tray
54 removed from the cart 38, and deposit each extracted small
object into selected small object receptacles 98 removably disposed
on, or within, the collection assembly 100 of the collection
assembly positioning subsystem 22. The extraction subsystem 26
includes at least one transfer assembly 198 extending between the
tray removal and positioning subsystem 18 and the collection
assembly positioning subsystem 22. In various embodiments, as
illustrated in FIG. 4A, the extraction subsystem 26 can include a
pair of opposing transfer assemblies 198 extending between the tray
removal and positioning subsystem 18 and the collection assembly
positioning subsystem 22 to increase the rate of sorting of the
small objects, as described herein. In the embodiments having more
than one transfer assembly 198, each transfer assembly is
substantially the same in structure and function. Therefore, for
simplicity, only a single transfer assembly 198 will be
described.
[0065] The transfer subassembly 198 includes a nozzle head 202
removably mounted to a nozzle head carriage 206 that is movably
mounted to a carriage transporter 210. The carriage transporter 210
is structured and operable, as controlled by the central control
system 34, to bi-directionally move the nozzle head carriage 206
and, more particularly, the nozzle head 202 along the
longitudinally axis of the carriage transporter 210, i.e., in the
.sup.+Z and .sup.-Z directions, between the tray removal and
positioning subsystem 18 and the collection assembly positioning
subsystem 22.
[0066] The nozzle head carriage 206 includes a base plate 214
extending substantially orthogonally from a back plate 212 that is
mounted to a carriage bracket 222. The carriage bracket 222 is
slidingly mounted to, or within, tracks 226 of the carriage
transporter 210 such that the nozzle head carriage 206 and, more
particularly, the nozzle head 202 can be bi-directionally moved
along the tracks 226 between the tray removal and positioning
subsystem 18 and the collection assembly positioning subsystem 22,
as controlled by the central control system 34. Additionally, the
nozzle head 202 comprises a mounting plate 230 having an array 234
of vacuum nozzles 238 disposed therein, or attached thereto.
Moreover, the vacuum nozzles 238 are geometrically arranged within
the nozzle array 234 such that the spacing between radial center
points of adjacent nozzles 238 corresponds with the spacing between
radial center points of adjacent wells 86 of the respective sorting
tray 54.
[0067] The nozzle head 202 is removably mounted to the nozzle head
carriage 206. More specifically, the nozzle head mounting plate 230
is removably connectable to the carriage base plate 214 using any
fastening means, device, component, assembly or system suitable for
securely and stably connected the nozzle head 202 to the nozzle
head carriage 206 in a fixed position. For example, the nozzle head
mounting plate 230 can be removably connected to the carriage base
plate 214 utilizing magnets, locking pins, biased clamps or
latches, thumb screws, wing nuts and bolts or any other suitable
fastener. Therefore, a first nozzle head 202 having a certain
number of vacuum nozzles 238, e.g., twelve, of a specific size and
spacing, can be easily removed and replaced, i.e., interchanged,
with a second nozzle head 202 having a different number of vacuum
nozzles 238, e.g., twenty-four, of a different specific size and
spacing.
[0068] For example, in various embodiments, the nozzle head
mounting plate 230 can be removably mounted to the carriage base
plate 214, via a magnetic connection. In such embodiments, one or
both of the nozzle head mounting plate 230 and the carriage base
plate 214 can include one or more magnetic coupling inserts 242
disposed in the interfacing surfaces of the mounting and base
plates 230 and 214. The magnetic coupling inserts 242 disposed in
the nozzle head mounting plate 230 are fabricated, i.e., have
material properties, such that they are magnetically attracted to
the magnetic coupling inserts 242 disposed in the carriage base
plate 214 and/or vice versa. Moreover, the magnetic coupling
inserts 242 are located within the interfacing surfaces such that
the magnetic coupling inserts 242 disposed in the nozzle head
mounting plate 230 will magnetically mate, or couple, with the
magnetic coupling inserts 242 disposed in the carriage base plate
214.
[0069] The magnetic coupling inserts 242 can by any insert having
magnetic properties suitable to magnetically couple the nozzle head
mounting plate 230 to the carriage base plate 214. For example, in
various embodiments, the magnetic coupling inserts 242 disposed in
the nozzle head mounting plate 230 can comprise magnets of a first
polarity and the magnetic coupling inserts 242 disposed in the
carriage base plate 214 can comprise magnets of the opposite
polarity such that an attractive force is exerted between the
opposing magnetic coupling inserts 242 that is utilized to
magnetically couple the nozzle head mounting plate 230 to the
carriage base plate 214. Alternatively, the magnetic coupling
inserts 242 disposed in the nozzle head mounting plate 230 can
comprise magnets and the magnetic coupling inserts 242 disposed in
the carriage base plate 214 can comprise a ferrous material such
that an attractive force is exerted between the magnet inserts 242
and the ferrous material inserts 242 that is utilized to
magnetically couple the nozzle head mounting plate 230 to the
carriage base plate 214. Or, the magnetic coupling inserts 242
disposed in the nozzle head mounting plate 230 can be a ferrous
material and the magnetic coupling inserts 242 disposed in the
carriage base plate 214 can comprise magnets such that an
attractive force is exerted between the magnet inserts 242 and the
ferrous material inserts 242 that is utilized to magnetically
couple the nozzle head mounting plate 230 to the carriage base
plate 214.
[0070] Additionally, in various embodiments, to securely and stably
connect the nozzle head 202 to the nozzle head carriage 206 in a
fixed position, the carriage base plate 214 and/or the nozzle head
mounting plate 230 can include one or more locating pins 246 that
securely mate with locating pin receiving wells 250 formed in
respective opposing carriage base plate 214 and/or the nozzle head
mounting plate 230. More particularly, when the nozzle head
mounting plate 230 is mounted to the carriage base plate 214, as
described above, the locating pins 246 securely mate with the
receiving wells 250 to maintain the mounting plate 230 and the
carriage base plate 214 in fixed position and orientation with
respect to each other.
[0071] The carriage transporter 210 can be any assembly, system or
mechanism structured and operable to controllably move the nozzle
head and carriage 202 and 206 bi-directionally along the
longitudinal axis of the carriage transporter 210. For example, the
carriage transporter 210 can comprise a pneumatically,
hydraulically or electrically controlled threaded shaft system,
wire or cable pulley system, piston system, conveyor belt system,
linear motor, or any other suitable positioning system structured
and operable to move the nozzle head and carriage 202 and 206 along
the length of the carriage transporter 210, as controlled by the
central control system 34. Particularly, in various embodiments,
the carriage transporter 210 can comprise a linear motor structured
and operable to produce a controllable linear force exerted on the
nozzle head carriage bracket 222 to controllably move the nozzle
head and carriage 202 and 206 between the tray removal and
positioning subsystem 18 and the collection assembly positioning
subsystem 22.
[0072] Referring particularly to FIGS. 4B and 4C, each of the
vacuum nozzles 238 of the nozzle array 234 are communicatively
connected to one of the regulators 37 in the pneumatic supply
assembly 35. As controlled by the central control system 34, each
nozzle regulator 37 provides vacuum signals to each of the
respective vacuum nozzles 238, via a corresponding vacuum line 254,
e.g., a flexible vacuum line, to activate the respective nozzles
238, as described below. Although each vacuum nozzle 238 is
communicatively coupled to a respective nozzle regulator 37 via a
corresponding vacuum line 254, for simplicity and clarity only a
single vacuum line 254 is shown in FIGS. 4B and 4C. The nozzle
regulators 37 are vacuum pressure regulators that monitor,
condition and/or modulate vacuum signals communicated to each of
the nozzles 238 via the vacuum lines 254. Generally, the nozzle
regulators 37 include switches, valves, and sensors to control and
regulate the vacuum pressure for each respective nozzle 238.
[0073] Generally, each vacuum nozzle 238 includes a tubular body
having an internal passage defined therein. Each vacuum line 254 is
removably coupled to a proximal end of the respective vacuum nozzle
238. In various embodiments, the proximal end of each vacuum nozzle
238 can include a quick coupling fixture 258 that is structured and
operable to allow the respective vacuum line 254 to be easily
connected to and removed from the proximal end of the respective
vacuum nozzle 238. Accordingly, as controlled by the central
control system 34, the regulators 37 regulate vacuum pressure
signals communicated, via the vacuum lines 254, to a tip 262 of
each respective vacuum nozzle 238. More particularly, a vacuum can
be controllably and selectively provided to the tips 262 of
selected vacuum nozzles 238 to extract, i.e., remove, one or more
selected small objects from the removed sorting tray 54, as
described further below. Once the small object(s) have been
extracted, the vacuum is maintained at the respective nozzle tips
262 such that the extracted small object(s) are retained on the
respective tips 262 while the nozzle head 202 is moved, via the
nozzle head carriage transporter 210, from the tray removal and
positioning subsystem 18 to the collection assembly positioning
subsystem 22. The extracted small objects are then deposited into
selected small object receptacles 98, as also described further
below.
[0074] In various embodiments, each nozzle tip 262 can be
customized to optimize handling of each small object as it is
extracted from the sorting tray 54 and deposited in the selected
receptacle 98. For example, in various embodiments, each nozzle tip
262 can be structured or formed to accommodate the shape of the
wells 86 of the sorting tray 54. For example, if the wells 86 have
a shallow, rounded, concave shape, each nozzle tip 262 can be
structured or formed to have wider rounded convex shape such that
each nozzle tip 262 operates more efficiently when extracting an
object from the wells 86. Alternatively, if the wells 86 have a
deeper, cylindrical, flat bottom shape, each nozzle tip 262 can be
structured or formed to have narrow, cylindrical shape with a flat
distal end such that each nozzle tip 262 operates more efficiently
when extracting an object from the wells 34. Additionally, in
various embodiments, each vacuum nozzle tip 262 includes a
screen-like device having a plurality of openings spaced apart such
that the small objects can be extracted without damaging the
object. Furthermore, in various embodiments, each nozzle tip 262
can be interchangeable to meet the handling preferences or
requirements of various different small objects.
[0075] Referring now to FIG. 4A, the automated collection assembly
positioning subsystem 22 is structured and operable to selectively
position the collection assembly 100 such that the selected one or
more small object extracted from the removed sorting tray 54 can be
deposited into the selected one or more of seed receptacles 98. The
collection assembly positioning subsystem 22 includes a collection
assembly translation stage 266 and the collection assembly 100. The
collection assembly 100 is movably mounted to the collection
assembly translation stage 266 and is structure and operable to
removably retain a multi-receptacle receiving fixture 270 that
includes the plurality of small object receptacles 98. The
collection assembly 100 additionally includes a multi-funnel small
object disposition fixture 274 that includes a plurality of funnels
278 structured to receive the small objects extracted from the
removed sorting tray 54 and funnel extracted small objects into the
one or more selected small object receptacles 98.
[0076] The collection assembly translation stage 266 is
controllable by the central control system 34 to bi-directionally
move the collection assembly 100, receptacle fixture 270 and
receptacles 98 along the longitudinal axis of the collection
assembly translation stage 266, i.e., in the .sup.+X and .sup.-X
directions. Particularly, the collection assembly translation stage
266 is operable to position the selected ones of the funnels 278 of
the multi-funnel small object disposition fixture 274 directly
beneath the nozzle head 202, more particularly, directly beneath
the nozzle array 234, positioned at a disposition end 280 of the
carriage transporter 210 after the selected small objects have been
extracted from the removed sorting tray 54, as described below. In
the various embodiments wherein the small object extraction
subsystem 26 includes a plurality of transfer assemblies 198, i.e.,
a plurality of nozzle head carriage transporters 210, the
collection assembly translation stage 266 is operable to position
the selected funnels 278 directly beneath the nozzle head 202 of
each transfer assembly 198 as the respective nozzle head 202 is
transported to the respective disposition end 280 of the respective
carriage transporter 210.
[0077] For example, in embodiments wherein the small object
extraction subsystem 26 includes a pair of opposing transfer
assemblies 198, i.e., a pair of opposing nozzle head carriage
transporters 210, the central control system 34 can control
operation of the carriage transporters 210 such that as one
carriage transporter 210 positions the respective nozzle head 202
at the respective disposition end 280 to deposit extracted small
objects in the receptacles 98, the other carriage transporter 210
is operated to position the respective nozzle head 202 at an
extraction end 282 (shown in FIG. 3B) of the respective carriage
transporter 210 to extract small objects from the removed sorting
tray 54. Hence, as each nozzle head 202 is transported to the
disposition end 280 of the respective carriage transporter 210, the
collection assembly translation stage 266 is operated to position
the selected ones of the funnels 278 directly beneath the
respective nozzle head 202, more particularly beneath the
respective nozzle array 234, at the disposition end 280 of the
respective carriage transporter 210. As described above, in the
embodiments having more than one transfer assembly 198, each
transfer assembly is substantially the same in structure and
function. Therefore, for simplicity, cooperative operation of tray
removal and positioning subsystem 18, the collection assembly
positioning subsystem 22 and the small object extraction subsystem
26 will be described herein with reference to only a single
transfer assembly 198.
[0078] The collection assembly translation stage 266 can be any
assembly, system or mechanism structured and operable to
controllably move the collection assembly 100, receptacle fixture
270 and receptacles 98 bi-directionally along the longitudinal axis
of the collection assembly translation stage 266. For example, the
collection assembly translation stage 266 can comprise a
pneumatically, hydraulically or electrically controlled threaded
shaft system, wire or cable pulley system, piston system, conveyor
belt system, linear motor, or any other suitable positioning system
structured and operable to move the collection assembly 100,
receptacle fixture 270 and receptacles 98 along the length of
collection assembly translation stage 266, as controlled by the
central control system 34. Particularly, in various embodiments,
the collection assembly translation stage 266 can comprise a linear
motor structured and operable to produce a controllable linear
force exerted on the collection assembly 100 to controllably
position the selected ones of the collection assembly funnels 278
beneath the nozzle head 202 position at the disposition end 280 of
the carriage transporter 210, whereby the one or more extracted
small objects can be deposited into the selected ones of the
receptacles 98.
[0079] Referring now to FIGS. 3A, 3B, 3C and 4A, once a selected
sorting tray 54 is removed from the cart 38 by the tray removal and
positioning subsystem 18, as described above, the central control
system 34 executes the one or more system control algorithms to
coordinated the operation of the tray removal and positioning
subsystem 18 and the small object extraction subsystem 26 to
extract selected small objects from the removed sorting tray 54.
More particularly, the central control system 34 utilizes selection
data input to the central control system 34 prior to initiation of
the operation of the sorting system 10 and the sorting tray
identification data and small object identification data acquired
by the cart information device reader 110 and the tray information
device reader 158 to sequentially remove particular sorting trays
54 from the cart 38 and extract particular small objects from each
removed sorting tray 54. Still more specifically, the selection
data stipulates which small objects stored in the cart 38 are to be
extracted and deposited, i.e., sorted, into the small object
receptacles 98. Then, utilizing the sorting tray information/data
and small object identification data acquired by the cart
information device reader 110 and the tray information device
reader 158, as described above, the particular sorting trays 54
storing the stipulated small objects to be sorted into the
receptacles 98 are sequentially removed from the cart 38 and the
stipulated small objects are extracted.
[0080] To extract the selected small objects from each removed
sorting tray 54, i.e., the small objects stipulated to be extracted
by the selection data input to the central control system 34, the
central control system 34 controls the operation of the tray
removal and positioning subsystem 18 and the small object
extraction subsystem 26 as follows. The carriage transporter 210 is
operated to transport the nozzle head 202 to or near the extraction
end 282 of the carriage transporter 210. At, or about, the same
time, the tray locating assembly 118 and the tray locating assembly
lift 122 are operated to position the small objects stipulated for
extraction, i.e., the selected small objects, at or near a location
beneath the carriage transporter extraction end 282.
[0081] More specifically, utilizing the known location of each
small objects within the removed sorting tray 34, as provided by
the small object identification data acquired by the tray
information device reader 158, the following movements of the tray
removal and positioning subsystem 18 and the small object
extraction subsystem 26 are coordinated to position one or more of
the small objects stipulated for extraction, i.e., one or more of
the selected small objects, directly beneath and in close proximity
to the nozzle tips 262 of the nozzle array 234 positioned at, or
near, the carriage transporter extraction end 282.
[0082] The removed sorting tray 34 is moved along the tray support
rails 138 in the .sup.+X and/or .sup.-X direction to position one
or more of the selected small objects in alignment, in the .sup.+Z
and .sup.-Z direction, with the nozzle head 202. The nozzle head
202 is then moved in the .sup.+Z and/or .sup.-Z direction, as
needed, to locate one or more selected small objects directly
beneath and in close proximity to the nozzle tips 262 of the nozzle
array 234. That is, the tip 262 of each of nozzles 238 in the
nozzle array 234 is directly above a corresponding one of the
sorting tray wells 86 and in close proximity to the respective
small object residing in each of the corresponding wells 86, one,
some or all of which are selected small objects.
[0083] Alternatively, the nozzle head 202 can be moved in the
.sup.+Z and/or .sup.-Z direction to position one or more of the
selected small objects in alignment, in the .sup.+X and .sup.-X
direction, with the nozzle head 202. The removed sorting tray 34 is
then moved along the tray support rails 138 in the .sup.+X and/or
.sup.-X direction, as needed, to position one or more selected
small objects directly beneath and in close proximity to the nozzle
tips 262 of the nozzle array 234. Hence, the tip 262 of each of
nozzle 238 in the nozzle array 234 is directly above a
corresponding one of the sorting tray wells 86 and in close
proximity to the respective small object residing in each of the
corresponding wells 86, one, some or all of which are selected
small objects.
[0084] In various embodiments, once the one or more small objects
stipulated for extraction are positioned directly beneath and in
close proximity to the nozzle tips 262 of the nozzle array 234, the
tray locating assembly lift elevator 130 can be operated to
slightly raise the removed sorting tray 54 such that the tip 262 of
each nozzle 238 lightly contacts the small object residing in each
of the corresponding wells 86.
[0085] The central control system 34 then commands selected
regulators 37 to communicate a vacuum pressure to the tip 262 the
nozzles 238 corresponding to the one or more small objects
stipulated for extraction. Hence, one, some or all of the nozzles
238 can be activated by the central control system 34, i.e., one,
some or all of the nozzles 238 can be provided with a vacuum
pressure at the respective tip 262, depending on the number of
corresponding small objects that are to be extracted. Although a
single nozzle 238 can be activated to extract a single small
object, extraction of the one or more small objects will be
described herein in the plurality.
[0086] Utilizing the vacuum pressure, the activated nozzles 238
extract the corresponding small objects from the removed sorting
tray wells 86. That is, the provided vacuum draws, or sucks, the
corresponding small objects into contact with the tip 262 of the
activated nozzles 238 such that the corresponding small objects are
free from the respective wells 86 and slightly above a top surface
of the removed sorting tray 54. The regulators 37 are operable such
that the vacuum pressure provided at the tip 262 of each nozzle 238
is modulated to exert sufficient force to extract the respective
small object without damaging the respective small object. The
extracted small objects are retained, or held, in contact with the
respective nozzle tips 262 until the small objects are deposited
into the selected receptacles 98, as described below.
[0087] In the embodiments wherein the removed sorting tray 54 is
raised slightly to lightly contact the small objects with the
nozzle tips 262 prior to activation of the selected nozzles 238,
after the selected nozzles 238 are activated, the removed sorting
tray 54 is lowered slightly such that the corresponding small
objects are extracted from the removed sorting tray 54. That is,
the removed sorting tray 54 is lowered slightly such that the
corresponding small objects are free from the respective wells 86
and slightly able a top surface of the removed sorting tray 54.
[0088] Referring additionally to FIG. 5, after the selected small
objects have been extracted, the carriage transporter 210 is
operated to transport the nozzle head 202, and the extracted small
objects retained on the respective nozzle tips 262, to a small
object extraction verification position between the extraction end
282 and the disposition end 280 of the carriage transporter 210.
More specifically, the nozzle head 202 and extracted small objects
are moved to a position directly above the small object
verification assembly 30 that is located between the tray removal
and positioning subsystem 18 and collection assembly positioning
subsystem 22. The small object extraction verification assembly 30
is structured and operable to verify that the small object
extraction subsystem 26 actually extracted each of the selected
seeds from the seed tray.
[0089] The small object extraction verification assembly 30 can be
any assembly, system, apparatus or device structured and operable,
as controlled by the central control system 34, to verify that each
activated vacuum nozzle 238 is, in fact, retaining the
corresponding small object, thereby verifying that the selected
small objects were actually extracted from the removed sorting tray
54. For example, the small object extraction verification assembly
30 can comprise any X-ray based, magnetic based, sonic based, light
based or laser based imaging device, or any other device suitable
for verifying that each activated vacuum nozzle 238 in fact retains
a small object as the nozzle head 202 is transported from the tray
removal and positioning subsystem 18 to the collection assembly
positioning subsystem 22.
[0090] In various embodiments, the small object extraction
verification assembly 30 includes one or more digital imaging
devices 286 positioned to capture digital image data of the nozzle
tips 262 of the nozzle array 234 as the nozzle head 202 is moved to
the small object extraction verification position. Additionally, in
various implementations, the small object extraction verification
assembly 30 can include one or more light sources 290 positioned to
project light on the nozzle tips 262 of the nozzle array 234 as the
nozzle head 202 is moved to the small object extraction
verification position.
[0091] The digital imaging device(s) 286 is/are communicatively
linked to central control system 34. Hence, as the nozzle head 202
is moved to the small object extraction verification position, the
digital imaging device(s) 286 capture digital image data of tips
262 of nozzles 238 and communicate the captured data to the central
control system 34. The central controls system 34 then executes a
verification algorithm, or a verification subroutine of the one or
more system control algorithms, to analyze the received image data
and determine whether a small object is in fact retained on the
tips 262 of the selected activated nozzles 238. For example,
utilizing known data identifying the location, i.e., Cartesian
coordinates, of each nozzle tip 262 within nozzle array 234, the
central control system 34 can analyze the captured image data to
determine whether the location of each activated nozzle tip 262
includes data indicative of small object.
[0092] In various embodiments, if the image data at the location of
any of the activated nozzles tips 262 indicates that a small object
was `missed, i.e., is not retained on the respective tip 262, the
sorting system 10 will deposit the selected small objects that were
extracted into the selected receptacles 98, as described below.
Then, subsequently, the sorting system 10 will reattempt to extract
the `missed` small object. Reattempting to extract any `missed`
small object can be repeated any desirable number of times, e.g.,
twice. After the desired number of reattempts, the sorting system
will cease attempting to extract the particular small object.
[0093] Referring now to FIG. 4A, once selected small objects have
been extracted from the respective removed sorting tray 54 and the
extraction verified, as described above, the central control system
34 executes the one or more system control algorithms to
coordinated the operation of the small object extraction subsystem
26 and the collection assembly positioning subsystem 22 to
selectively deposit the extracted small objects into one or more of
the small object receptacles 98. More particularly, the central
control system 34 utilizes receptacle data, input to the central
control system 34 prior to initiation of the operation of the
sorting system 10, the sorting tray information/data and the small
object identification data acquired by the cart information device
reader 110 and the tray information device reader 158 to deposit
each of the extracted small objects into selected one or more
receptacles 98. Specifically, the extracted small objects are
deposited into the selected one or more receptacles 98 such that
small objects having the same or similar attributes, e.g.,
characteristics and/or traits such as size, shape, color,
composition, quality, weight, genetic traits, etc., are deposited
into the same receptacle 98.
[0094] In various embodiments, each receptacle 98 includes a
receptacle identification tag 294 containing the receptacle data.
The receptacle data is used for identifying the respective
receptacle 98 and cataloging the selected small objects deposited
into the particular receptacle 98. More particularly, in various
embodiments, the receptacle identification tags 294 are used to
compile the receptacle data identifying the location, e.g.,
Cartesian coordinates, of each specific receptacle 98 within the
multi-receptacle receiving fixture 270. Each location within the
multi-receptacle receiving fixture 270 corresponds to the location,
e.g., Cartesian coordinates, of a respective funnel 278 of the
multi-funnel small object disposition fixture 274 such that when
the multi-receptacle receiving fixture 270 is placed within the
collection assembly 100, a dispensing end of each funnel 278 aligns
with an open top end of a corresponding receptacle 98. Therefore,
to deposit each extracted small object into a selected receptacle
98, the central control system 34 coordinates the operation of the
small object extraction subsystem 26 and the collection assembly
positioning subsystem 22 to deposit each extracted small object in
the particular funnel 278 corresponding to the respective selected
receptacle 98.
[0095] The multi-receptacle receiving fixture 270 can be any
fixture structured to be removable retained within the collection
assembly 100 and to provide or receive a plurality of receptacles
98 having any desired form or structure. The multi-receptacle
receiving fixture 270 can be any fixture structured to retain a
plurality of the collection receptacles 98. Additionally, the
collection receptacles 98 can be any type of collection devices,
apparatus or structures suitable for receiving extracted small
objects. For example, the receptacles 98 can comprise envelopes,
containers, tubes, cups, boxes or any other vessel suitable for
receiving and retaining the extracted small objects.
[0096] For example, as shown in FIG. 4A, in various embodiments,
the multi-receptacle receiving fixture 270 can be structured to
retain a plurality of envelope receptacles 98. In such embodiments,
the multi-receptacle receiving fixture 270 can include a base 298
having a plurality of slot 302 formed therein and a top plate 306
that provides a plurality of open tubes 310. Each open tube 310 is
disposed within the top plate 306 such that each open tube is
aligned with a bottom opening of a respective one of the funnels
278. The top plate 306 is connected to and spaced apart from the
base 298 via a standoff 314. Each envelope receptacle 98 is placed
in and retained by the multi-receptacle receiving fixture 270 by
placing one of a respective one of the open tubes 310 inside a top
opening of the envelope receptacle 98 and a bottom edge of each
envelope receptacle 98 within a corresponding one of the base slots
302. The multi-receptacle receiving fixture 270 can then be placed
within the collection assembly 100 such that the bottom opening of
each funnel 278 aligns with a respective one of the open tubes 310.
Accordingly, when a selected small object is released into one of
the funnels 278, as described above, the small object will travel
through the funnel and the open tube 310 such that the small object
is deposited into the selected envelope receptacle 278.
[0097] Referring to FIG. 4E, in various other embodiments, wherein
the small objects to be sorted are agricultural products such as
seeds, the multi-receptacle receiving fixture 270 can comprise an
alignment platform 314 structured to be removably retained within
the collection assembly 100 and to removable retain a
multi-reservoir planter-ready tray 318. In such embodiments, the
receptacles 98 can comprise a plurality of plant-ready cups or
reservoirs 322 included in, formed in, or disposed in the
multi-reservoir indexing tray 318. The plant-ready receptacles 98
can contain soil or other organic compound suitable and ready for
planting seeding. Therefore, each extracted seed can be deposited
into a respective funnel 98 whereby each seed is deposited, or
planted, directly into a selected one of the plant-ready
receptacles 98. In such embodiments, the multi-funnel small object
disposition fixture 274 can be structured to provide a number of
funnels 278 equal to the number of plant-ready receptacles 98 such
that when the multi-receptacle receiving fixture 270 is placed
within the collection assembly 100, the dispensing end of each
funnel 278 will be directly above and in close proximity to a
respective one of the plant-ready receptacles 98. Alternatively,
each of the plurality of funnels 278 can be structured and operable
to direct extracted seeds to two or more plant-ready receptacles
98.
[0098] In various embodiments, the 98 receptacles can include one
or more discard cans 322 structured to receive selected extracted
objects. Hence, some or all of the small objects within a
respective sorting tray 54 can be sorted, whereby some of the small
objects are sorted into the receptacles 98 for further use and
others are sorted into the discard cans 322 to be disposed of.
[0099] Generally, prior to initiating operation of the sorting
system 10, each receptacle tag 294 is read and each receptacle 294
is assigned a location within the multi-receptacle receiving
fixture 270. The identification information for each receptacle 98
and the corresponding location of the receptacles 98 within the
multi-receptacle receiving fixture 270 are stored in the central
control system 34 as receptacle data used during execution of the
one or more system control algorithms.
[0100] Each receptacle tags 294 can be any machine-readable
identification device, label or tag suitable for containing or
storing information and data, readable or retrievable by a
receptacle tag reader (not shown) communicatively connected to the
central control system 34, regarding or pertaining to each
respective receptacle 98. For example, in various implementations,
each receptacle tag 294 can comprise a two-dimensional matrix code
or other machine-readable label, tag or device, such as a radio
frequency identification (RFID) tag or a bar code label, from which
the information/data can be received and interpreted via wireless
communication such as optical signals, e.g., infrared signals, or
magnetic fields. Similarly, the receptacle tag reader can be any
device suitable for reading the receptacle tags 294 and
communicating the receptacle data to the central control system 34.
For example, in various implementations, the receptacle tag reader
can comprise a device structured and operable to read a
two-dimensional matrix code or other machine-readable label, tag or
device, such as an RFID tag reader or a bar code label reader,
operable to read the receptacle data stored in the respective
receptacle tag 294 via wireless communication such as optical
signals, e.g., infrared signals, or magnetic fields.
[0101] To deposit the extracted small objects into the receptacles
98 the central control system 34 controls and coordinates the
operation of the small object extraction subsystem 26 and the
collection assembly positioning subsystem 22 as follows. The
carriage transporter 210 is operated to transport the nozzle head
202 carrying the extracted small objects to, or near, the
disposition end 280 of the carriage transporter 210. At, or about,
the same time, the collection assembly translation stage 266 is
operated to position the funnel 278 corresponding to a selected one
of the receptacles 98 at, or near, a location beneath the carriage
transporter disposition end 280. The vacuum provided to the nozzles
238 retaining the small objects to be deposited into the selected
receptacle 98 is then terminated such the small object(s) is/are
released and fall(s) into the funnel 278, and subsequently into the
selected receptacle 98.
[0102] More specifically, utilizing the known location of each
funnel 278 within the collection assembly 100 and the receptacle
data of each corresponding receptacle 98, the following movements
of the small object extraction subsystem 26 and the collection
assembly positioning subsystem 22 are coordinated to position a
selected funnel 98 directly beneath and in close proximity to the
nozzle tips 262 of the nozzle array 234 positioned at, or near, the
carriage transporter extraction end 282. As used herein, the
selected funnel 98 will be understood to indicate the funnel 98
corresponding to a selected one of the receptacles into which one
or more of the extracted small objects are to be deposited.
[0103] The collection assembly 100 is moved along the collection
assembly translation stage 266 in the .sup.+X and/or .sup.-X
direction to position the selected funnel 98 in alignment, in the
.sup.+Z and .sup.-Z direction, with the nozzle head 202. The nozzle
head 202 is then moved in the .sup.+Z and/or .sup.-Z direction, as
needed, to locate nozzle tips 262 of the nozzle array 234 directly
above and in close proximity to a top opening of the selected
funnel 278. In various embodiments, the top opening of each funnel
278 can be sized to be slightly larger than the outer dimensions of
the nozzle array 234 such that the nozzle tip 262 of each nozzle
238 in the array 234 is positioned directly above and in close
proximity to the selected funnel 278 top opening.
[0104] Alternatively, the nozzle head 202 can be moved in the
.sup.+Z and/or .sup.-Z direction to position the nozzle tips 262 of
the nozzle array 234 in alignment, in the .sup.+X and .sup.-X
direction, with the selected funnel 98. The collection assembly 100
is then moved along the collection assembly translation stage 266
in the .sup.+X and/or .sup.-X direction, as needed, to position the
top opening of the selected funnel 278 directly beneath and in
close proximity to the nozzle tips 262 of the nozzle array 234.
[0105] Once the nozzle array 234 is positioned directly above the
selected funnel 278, the central control system 34 commands
selected ones of the activated nozzles 238 to deactivate, i.e.,
terminate the vacuum pressure supplied to selected activated
nozzles 238, thereby releasing selected small object(s) into the
top end of the selected funnel 278. The selected funnel 278 guides
the released small object(s) into the selected receptacle 98. As
described above, the extracted small objects are deposited into the
selected receptacles 98 such that small objects having the same or
similar attributes, e.g., characteristics and/or traits such as
size, shape, color, composition, quality, weight, genetic traits,
etc., are deposited into the same receptacle 98.
[0106] If not all the extracted small objects are not deposited
into the same receptacle 98, the nozzle head 202 and collection
assembly 100 are moved, as described above to position the top
opening of a subsequent selected funnel 278 directly beneath and in
close proximity to the nozzle tips 262 of the nozzle array 234.
Then other selected nozzles 238 are deactivated, i.e., the vacuum
pressure is terminated, such that one or more subsequent selected
small objects are released and deposited into a subsequent selected
receptacle 98 based on the attributes of the respective small
objects. This process is repeated until all the extracted small
objects have been deposited into the respective selected
receptacles 98. Subsequently, the nozzle head 202 is moved back to
the tray removal and positioning subsystem 18 and, if the selection
data stipulated that subsequent small objects are to be extracted
from the removed sorting tray 54, the subsequent selected small
objects are extracted and deposited into the selected receptacles
98 in the same manner as described above.
[0107] Once all the selected small objects have been extracted and
deposited, as stipulated by the selection data, the tray locating
assembly 118 and the tray locating assembly lift 122 are operated,
as described above, to place the removed sorting tray 54 back into
the sorting tray cart 38. Thereafter, if needed, based on the
selection data, the sorting tray information/data and the small
object identification data, a subsequent sorting tray 54 is removed
from the cart 38 and the selected small objects are extracted and
deposited into the selected receptacles 98, as described above.
This process is repeated until the small object sorting system 10
has extracted and deposited, i.e., sorted, all the selected small
objects as stipulated by the selection data.
[0108] Referring to FIG. 6, in various embodiments, the central
control system 34 is a computer based system that generally
includes at least one processor 326 suitable to execute all
functions of central control system 34 to automatically, or
robotically, control the operation of the sorting system 10, as
described herein. The central control system 34 additionally
includes at least one electronic storage device 340 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. Furthermore, the
central control system 34 includes a display 334 for displaying
such things as information, data and/or graphical representations,
and at least one user interface device 338, such as a keyboard,
mouse, stylus, and/or an interactive touch-screen on the display
334. In various embodiments the central control system 34 can
further include a removable media reader 342 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 342 can be an I/O
port of the central control system 34 utilized to read external or
peripheral memory devices such as flash drives or external hard
drives.
[0109] In various embodiments, the central control system 34, i.e.,
the processor 154 can be communicatively connectable to a remote
server network 346, e.g., a local area network (LAN), via a wired
or wireless link. Accordingly, the central control system 34 can
communicate with the remote server network 346 to upload and/or
download data, information, algorithms, software programs, and/or
receive operational commands. Additionally, in various embodiments,
the central control system 34 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.
[0110] In various embodiments, the central control system 34 can
include one or more system control algorithms, or programs 350,
stored on the storage device 330 and executed by processor 326. The
one or more system control algorithms utilize the small object
selection data and the receptacle data input to the central control
system 34 prior to initiation of the operation of the sorting
system 10, the sorting tray identification data acquired by the
cart information device reader 110, the small object identification
data acquired by the tray information device reader 158, and other
inputs from various components and sensors of the various systems,
subsystems, assemblies and subassemblies of the sorting system 10
to automatically operate the sorting system 10 as described
herein.
[0111] 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.
* * * * *