Transport system
The present disclosure relates to a method and apparatus for controlling the transportation of a product from a first transporter to a second transporter. Further, a feed transport system and method of use is provided.
The present invention relates to transporters, such as conveyor systems, and in particular to transporters used in the food industry.
Many types of products are transported by transporters, such as conveyor systems. For instance, in the food industry prepared food items, such as pizzas, entrees, and desserts, are assembled from various component pieces, including foodstuffs and packaging, which are transported by one or more transporters. Further, the finished product and/or the component pieces are often transported on or by multiple transporters, such as by a first transporter and then by a second transporter.
The creation of the finished product from the component pieces often requires that the component pieces be brought together at certain times. As such, it is desirable to control the spacing and/or positioning of the component pieces on a given transporter to ensure adequate processing of the component pieces to form the product.
Further, some component pieces are provided in bulk. As such, it is desirable to accept a bulk amount of a given component piece and to subsequently arrange the individual component pieces such that the individual component pieces may be transported in a somewhat ordered manner, such as a single layer of the individual component pieces on a transporter.
In one exemplary embodiment, a transport control system is provided that is configured to control the spacing and/or orientation of the individual component pieces of a product which are to be transported from a first transporter to a second transporter. In another exemplary embodiment, a transport system is provided that is configured to accept individual component pieces of a product in bulk and to arrange the individual component pieces in a somewhat ordered manner, such that the individual component pieces may be presented to a transporter in a somewhat ordered manner. In one example, the individual component pieces are arranged such that the individual component pieces are in a single layer.
In a further embodiment, a transport system for placing a plurality of randomly positioned product on a transporter in a single layer is provided. The transport system includes a first transporter having a first end and a second end and a transport member configured to transport the product from the first end to the second end, a hopper, a drive system coupled to the first transporter, and a control system connected to the drive system. The hopper forming a repository proximate the first end of the first transporter. The repository is adapted to receive a randomly positioned product. The drive system is configured to drive the transport member at a transport speed such that at least a portion of the randomly positioned product is moved from the repository towards the second end of the first transporter. The control system is configured to control the transport speed. The control system includes a first sensor positioned to monitor the presence of a first one of the product in an output region proximate to the second end of the transport member and a controller connected to first sensor. The controller is configured to set the transport speed generally equal to a baseline speed when the first one of the product is detected in the output region and to deviate the transport speed from the baseline speed when the first one of the product is not detected in the output region. In one variation the transport system further includes a product rake configured to block a second one of the product stacked on top of the first one of the product from being transported to the output region.
In a first exemplary method, a method of transporting a plurality of randomly positioned product from a hopper to a first region of a transporter, such that the plurality of randomly positioned product is placed on the transporter in a single layer is provided. The method includes the steps of transporting a portion of the plurality of product on a feed transporter from the hopper towards the transporter, blocking a first one of the portion of the product as it is being transported by the feed transporter such that a single layer of product remains on the feed transporter, the first one of the product being stacked upon a second one of the product, monitoring the first region of the transporter to determine if a third one of the product is currently present in the first region, and moving the second one of the product from the feed transporter to the first region of the transporter if the third one of the product is not currently detected in the first region.
In another exemplary method, a method of controlling the placement of at least one of a plurality of product from a first transporter moving at a transport speed and having an output region to a second transporter moving at a baseline speed and having an input region is provided. The method includes the steps of setting the transport speed generally equal to the baseline speed in the absence of an event, monitoring at least one of the output region and the input region for the occurrence of an event, wherein an event corresponds to one of the detection of the presence of or absence of a first one of the product in one of the output region of the first transporter and the input region of the second transporter, and deviating the transport speed from the baseline speed upon a detection of an event.
In yet a further exemplary embodiment, a transport control system for controlling the placement of at least one of a plurality of product from a first transporter to a second transporter, the first transporter having an output region and a first drive system to drive the first transporter at a transport speed and the second transporter having an input region and a second drive system to drive the second transporter at a baseline speed is provided. The transport control system includes a first sensor configured to detect the presence of the product and is positioned to detect the presence of the product within the output region of the first transporter, a second sensor configured to detect the presence of the product and is positioned to detect the presence of the product within the input region of the second transporter, and a controller is connected to the first sensor and the second sensor, the controller is configured to control the transport speed of the first transporter based at least on one of a first input signal from the first sensor and a second input signal from the second sensor, wherein the controller increases the transport speed above the baseline speed of the second transporter when the first input signal indicates that a first one of the product is not present in the output region of the first transporter.
In yet another exemplary embodiment, a transport system for placing a plurality of randomly positioned product onto a transporter is provided. The transport system including a first transport system configured to receive the randomly positioned product and to organize the randomly positioned product into a single layer, the first transport system having a first end and a second end; a first product mover configured to move a first portion of the product from the first transport system to the transporter, the first product mover positioned between the first end and the second end of the first transport system; a second transport system configured to receive a second portion of the product from the first transport system not moved by the first product mover, the second transport system positioned adjacent the second end of the first transport system; and a second product mover configured to move at least a portion of the second portion of the product from the second transport system to the transporter.
In still a further exemplary method, a plurality of randomly positioned product are moved to a transporter, such that each individual product is positioned in a respective tray transported on the transporter by a method including the steps of receiving a plurality of randomly positioned product; arranging the product into a single layer; transporting the product; moving a first portion of the product to the trays on the transporter; collecting a second portion of the product; arranging the second portion of the product into a single layer; transporting the second portion of the product; and moving the second portion of the product to the trays on the transporter.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring to
Transport control system 10 includes a first sensor 12 configured to detect the presence of product 15 to be transported on first transporter 14, a second sensor 16 configured to detect the presence of product 15 to be transported on second transporter 18, and a controller 20 connected to first sensor 12 and second sensor 16. Controller 20 is connected to first sensor 12 and second sensor 16 through either one or more wired connections, such as wired connections 22 and 24, through one or more wireless connections (not shown), or through one or more wired and one or more wireless connections.
First transporter 14 includes a drive system 26, such as a motor, which drives first transporter 14 such that the product, such as products 15A and 15B, is transported or otherwise moved along a path 28, shown as a linear direction, generally at a given speed. In one example, first transporter 14 is a conveyor system and includes one or more belts, rollers, tracks, chains or other suitable means for supporting and transporting product 15. As such, first transporter 14 transports product 15 generally from a first end 30 towards a second end 32.
Second transporter 18 includes a drive system 34, such as a motor, which drives second transporter 18 such that the product, such as product 15C and 15D, is transported or otherwise moved along a path 36, shown as a linear direction, generally at a given speed. In one example, transporter 18 is a conveyor system and includes one or more belts, rollers, tracks, chains or other suitable means for supporting and transporting product 15. As such, second transporter 18 transports product 15 generally from a first end 38 towards a second end 40. In an alternative embodiment, the first transporter 14 and the second transporter 18 are each driven by a common drive system.
Paths 28 and 36 are shown in
Further, paths 28 and 36 may be parallel, but oriented in opposite directions, for instance second transporter 18 may return product 15 received from first transporter 14 back towards first end 30 of first transporter 14. Additionally, although paths 28 and 36 are shown generally to be linear paths, each can be comprised of path components moving in various directions. For example, path 36 may be comprised of a linear path component followed by a curved component followed by an inclined linear component.
Drive systems 26 and 34 of first transporter 14 and second transporter 18, respectively, are controlled by a controller 42. Controller 42 at least controls the speed at which first transporter 14 and second transporter 18 are driven by respective drive systems 26 and 34 and in turn the speed at which first transporter 14 and second transporter 18 transport product 15. In one example, controller 42 includes at least one of software or firmware configured to control at least the speed of first transporter 14 and second transporter 18.
Controller 42 may also control other parameters of first transporter 14 or second transporter 18, such as the speed of a product rake (for example product rake 260 of in
An example product placer is product placer or mover 136, described below in connection with
Controller 20 of transport control system 10, receives a sensing signal from first sensor 12 over connection 22 indicating the presence or absence of product 15 within a region 44 being monitored by first sensor 12 and a sensing signal from second sensor 16 over connection 24 indicating the presence or absence of the product being transported within a region 46 being monitored by second sensor 16. Regions 44 and 46 may include generally a line to be monitored, generally a plane to be monitored, or generally a three-dimensional volume to be monitored. The sensing signals can be one of one or more analog voltage signals, one or more analog current signals, and/or one or more digital signals.
In one embodiment, first sensor 12 and second sensor 16 each includes an emitter positioned on a first lateral side of the respective transporter 14, 18 and a detector or receiver positioned on the other lateral side of the respective transporter 14, 18. The presence of product 15 between the emitter and detector pair of either first sensor 12 and second sensor 16, prevents the respective detector from detecting the signal from the emitter indicating the presence of product 15. In another embodiment, at least one of first sensor 12 and second sensor 16 includes multiple sensors configured to detect the presence of product 15 in one or more regions. In a further embodiment, the first sensor and the second sensor are cameras or machine vision systems.
Controller 20 generates a control signal which is provided to at least one of drive system 26, drive system 34, and controller 42 based at least in part on one or more sensing signals received from first sensor 12 and/or second sensor 16. The control signal can be one of one or more analog voltage signals, one or more analog current signals, and/or one or more digital signals. Controller 20 includes at least one of software and firmware programmed or configured to generate the control signal based at least in part on one or more sensing signals received from first sensor 12 and/or second sensor 16.
In the illustrated embodiment, controller 20 is connected to controller 42 over a wired connection 48. In another embodiment, controller 20 is connected to controller 42 through a wireless connection or a combination of a wired connection and a wireless connection. In a further embodiment, controller 20 is connected to at least one of drive system 26 and drive system 34. In still a further embodiment, controller 20 and controller 42 are incorporated into a single controller.
The control signal generated by controller 20 is used in setting the speed at which at least one of drive system 26 and drive system 34 drives the respective transporter 14, 18. The control signal can be further used to control additional parameters of first transporter 14, second transporter 18, and/or components associated with one of first transporter 14 or second transporter 18. In one example, the speed a respective transporter 14, 18 is driven is independent of the speed of the other respective transporter 14, 18. In another example, the speed of one of transporters 14, 18 is based at least in part on the speed of the other of transporters 14, 18.
Referring to
Control routine 60 is configured to prevent the transition or transport of product 15 from first transporter 14 to second transporter 18 if there is not an open location to receive product 15. As such, control routine 60 prevents product from being placed on top of existing product and/or otherwise contacting existing product. As explained below, control routine 60 is further configured to alter the transport speed to increase the likelihood that product 15 is positioned within output or staging region 44 of first transporter 14 ready to be transported to second transporter 18.
As represented by block 62, a first control signal is generated by controller 20 to drive first transporter 14 at the baseline speed of second transporter 18. Controller 20 may either directly control the transport speed by controlling drive system 26 or provide an indication of the transport speed to controller 42 which in turn controls drive system 26. The baseline speed of second transporter 18 is the default transport speed assigned to first transporter 14 in the absence of an event to trigger a deviation from the baseline speed, such as one of an increase in transport speed above the baseline speed, a reduction in transport speed below the baseline speed, or a transport speed equal to zero.
The baseline speed of second transporter 18 in one example is a constant speed. In another example, the baseline speed of second transporter 18 is a non-constant speed. In yet another example, the baseline speed of second transporter 18 is a constant speed in the absence of an event to trigger one of an increase in speed above the baseline speed, a reduction in speed below the baseline speed, or a speed equal to zero.
Controller 20 monitors whether first sensor 12 detects the presence of product 15 in output or staging region 44 as represented by block 64. The absence of product 15 detected by first sensor 12 within output region 44 is a first event which results in controller 20 generating a control signal to increase the transport speed above the baseline speed, as represented by block 66. Once product 15 is detected by first sensor 12 within output region 44, controller 20 generates a control signal to return the transport speed to the baseline speed, as represented by block 68.
Controller 20 further monitors whether second sensor 16 detects the presence of product 15 in region 46, an input region of transporter 18, as represented by block 70. The presence of product 15 detected by second sensor 16 within input region 46 is a second event which results in controller 20 generating a control signal to reduce the transport speed below the baseline speed to a reduced transport speed, as represented by block 72. If product is not detected in input region 46, then controller 20 returns or maintains the transport speed to the baseline speed, as represented by the return connection 71 to block 62.
The reduced transport speed in one example is zero. In another example, the reduced transport speed is a function of the baseline speed and a general knowledge of the size of product 15. For example, by knowing the baseline speed and the general size of product 15, controller 20 may calculate the time (t) required for product 15 to exit region 46 and hence calculate a reduced transport speed which will result in product 15 in output region 44 being transitioned to the input region 46 at the calculated time (t).
As stated above, the baseline speed of second transporter 18 may be governed by one or more inputs, may be constant, or may vary over time in response to one or more inputs or may operate at a given speed profile. Referring to
Referring to
Referring to
At a time (t4) the transport speed of first transporter 14 is reduced to speed (υ2), the baseline speed, in response to product 15 being detected in output region 44. As such, at time (t4) both of first transporter 14 and second transporter 18 are stopped or paused (υ2=0). At a time (t5) the transport speed of first transporter 14 is raised to a speed (υ3) because the baseline speed of the second transporter 18 is raised to speed (υ3). At time (t6) the transport speed of first transporter 14 is reduced to speed (υ1) because the baseline speed of second transporter 18 is lowered to speed (υ1). At a time (t7) the transport speed of first transporter 14 is lowered to a fifth speed (υ5) in response to an event, the detection of the presence of product 15 in output region 44 by first detector 12 and in input region 46 by second detector 16. At a time (t8) the transport speed of first transporter 14 is returned to the baseline speed due to the absence of product 15 in input region 46 of second transporter 18.
Referring to
Transporter 110 transports product 102 along a path 112 for further processing. Transporter 110 is driven by a drive system 114, such as a motor. Drive system 114 is controlled, directly or indirectly, by a controller 116. In one example, transporter 110 is a conveyor system and includes one or more belts, rollers, tracks, chains, or other suitable means for supporting and transporting product 102. In one embodiment, controller 20 and controller 116 are combined into a controller.
The transitioning and hence positioning of product 102 on transporter 110 is controlled by transport control system 10 as described in more detail below. In one example, product 102 is positioned on transporter 110 as a single layer of product. Exemplary products include frozen meat portions which are to be packaged as part of a frozen entree. The spacing or density of the single layer of product on transporter 110 is controlled by one or more parameters including the ratio of the transport speed of 106 and the transport speed of transporter 110, the direction of path 108 (degree of incline, if any), and the speed of a product rake, if included (see
As previously described, transport control system 10 includes controller 20, first sensor 12 and second sensor 16. Controller 20, either directly or indirectly, based at least in part on the sensing signals from first sensor 12 and second sensor 16, controls the speed at which drive system 105 drives transporter 106, hereinafter the feed transport speed. Controller 20 may further control additional parameters of feed system 100 and/or parameters of transporter 110. In alternative embodiments, controller 116 of the transporter, based at least in part on the sensing signals from first sensor 12 over connection 22, and second sensor 16 over connection 24, controls drive system 105 and hence the feed transport speed.
As discussed above, transport control system 10 controls the transition of product, such as product 102, to be transported from a first transporter, such as transporter 106, to a second transporter, such as transporter 110. Transport control system 10 is used to control the positioning and spacing of product 102.
Returning to
In one embodiment, the feed transport speed of transporter 106 is determined by controller 20 independent of the speed of transporter 110. As such, a baseline speed of the feed transport speed and adjustments from the baseline speed are independent of the speed of transporter 110. In a preferred embodiment, the feed transport speed of transporter 106 is determined at least in part based on the speed of transporter 110. As such, the speed of transporter 110 or the speed of transporter 110 multiplied by a weight factor, such as 70% or 110%, is considered to be a baseline speed for the feed transport speed of transporter 106. The baseline speed is one of a constant speed, a variable speed, or a constant speed in the absence of an event.
In a preferred embodiment, controller 20 executes control routine 60 of
Referring to
An example product mover 136 is a robot configured to pick-up or otherwise handle product 102, transport product 102 to transporter 132, and in some examples orient product 102. In a preferred example, product mover 136 is Model No. SIG XR22 Delta Robot available from SIG Pack Systems AG located at CH-8222 Beringen, Switzerland. Additionally, a suitable product mover and associated controller is disclosed in U.S. Pat. No. 4,976,582, issued Dec. 11, 1990, the disclosure of which is expressly incorporated by reference. A further suitable product mover and associated controller is disclosed in U.S. Pat. No. 6,543,987, issued Apr. 8, 2003 and assigned to SIG Pack Systems AG, the disclosure of which is expressly incorporated by reference.
The movements of product mover 136 are controlled by a controller, such as controller 116. An exemplary controller is SIG XMC available from SIG Pack Systems AG. Product mover 136 is able to locate product 102 on transporter 110 through the use of a sensor 140 configured to monitor a region 142 of transporter 110. Sensor 140 is connected to controller 116. In one example, sensor 140 is a machine vision system, such as SIG XMV Vision System, available from SIG Pack Systems AG. As is known in the art, based on the output of sensor 140, the position of product mover 136 is adjusted within region 142 to pick up or otherwise handle product 102.
Further, based on the number of products 102 in region 142 or the presence or absence of product 102 in region 142, controller 116 may adjust the baseline speed of transporter 110. For instance, if no product is detected in region 142 by sensor 140, controller 116 may increase the speed of the baseline speed over a default baseline speed. Conversely, if multiple products 102 are detected within region 142 by sensor 140, controller 116 may decrease the speed of the baseline speed of transporter 110 or pause transporter 110. As explained above and in detail with respect to
As discussed below in connection with
Referring to
Feed system 200 is a portable unit that may be moved from location to location on wheels 210. At least one of wheels 210 includes a brake 212 to lock the location of feed system 200 once feed system 200 has been properly located. As shown in
Transporter 204 of feed transport system 200 is a conveyor system and includes a belt 214 moving in the direction of arrow 216, shown in
In one example, belt 214 is a cleated belt having a plurality of cleats, such as representative cleats 226 shown in
Returning to
Referring to
As shown in
In one embodiment, the direction 216 (shown in
Referring to
As shown in
Referring to
Referring to
Second portion 280 is shown in
Referring to FIGS. 11A-C, for cleanability and sanitary reasons, it is preferred that rake members 268 maintain an orientation as each member 268 rotates in direction 276 that minimizes the likelihood that portions of product 150 become lodged in rake assembly 262. In the illustrated example, rake members 268 are maintained generally perpendicular to direction 216, see FIGS. 11A-C. In another example, rake members 268 are generally maintained in a vertical orientation.
Referring to
Referring to
Since links 286 are fixably coupled to the respective rake member 268, which is supported by a respective bushing 289 so that rake members 268 are rotatable relative to first plate 264 and the length of links 286 are constant, links 286 maintain the orientation of rake members 268 relative to transporter 204. The required length of links 286 and hence the orientation of rake member 268 is controlled by the offset between the centers of fixed plate 282 and the center of rake assembly 262 (drive shaft 270), as well as, the direction of the offset.
By maintaining the orientation of rake members 268 as shown in
Referring to
Referring to
Referring to
In one embodiment, the positioning of product rake 260 and/or the length of rake members 268 is adjustable to permit the configuration of product rake for various size products.
In alternative embodiments, additional means may be used to aid in ensuring that the product is in a single layer at the first end of the feed transporter. For instance, the product rake may be replaced with a fixed aperture. Further, the feed transporter may be vibrated by a vibration means to settle the product.
Referring to
As shown in
If product 150 is not positioned along a line 316 between emitter 312 and detector 314, detector 314 receives the signal emitted by emitter 312 and provides a corresponding sensing signal to controller 302. However, if product 150 is positioned along line 316 between emitter 312 and detector 314, detector 314 no longer receives the signal emitted by emitter 312 and provides a corresponding sensing signal to controller 302. In alternative embodiments, other types of sensors may be used, such as machine vision systems.
Second sensor 306 is generally similar to first sensor 304. Second sensor 306 includes an emitter 320 and a detector 322. Similarly to first sensor 304, emitter 320 emits a signal that is detected by detector 322. Detector 322 provides a sensing signal to controller 302 indicating the presence or absence of product 150. As shown in
If product 150 is not positioned along a line 324 between emitter 320 and detector 322, detector 322 receives the signal emitted by emitter 320 and provides a corresponding sensing signal to controller 302. However, if product 150 is positioned along line 324 between emitter 320 and detector 322, detector 322 no longer receives the signal emitted by emitter 320 and provides a corresponding sensing signal to controller 302. In alternative embodiments, other types of sensors may be used, such as machine vision systems.
In a preferred embodiment, transport control system 300 receives or determines the baseline speed of transporter 252 and controls drive system 206 to set the speed of transporter 204, the feed transport speed. In a preferred example, controller 302 executes control routine 62 provided in
Further, controller 302 is connected to drive system 272 and controls the speed product rake 260 rotates in direction 276 (see
Further, by adjusting parameters of feed system 200 the density of product 150 placed on transporter 252 may be varied. Example parameters include a weight factor between the speed of transporter 204 and transporter 252, such as 70% or 110%, a ratio of the speed of transporter 204 and transporter 252, the angle of incline of transporter 204, and/or the rotation speed of product rake 260.
As such, with feed transport system 200 a plurality of randomly oriented products 150 may be dumped or otherwise placed in a holder 204 and still be presented to a conveyor or transporter in an ordered manner. The incline of transport 204 and/or the use of a product rake 260 ensure that a single layer of product is transported to the output region of transporter 204. Transport control system 300 ensures that product 150, if available, is ready to be transitioned to transporter 252 and that product 150 is transitioned to transporter 252 in a single layer.
Referring back to
Referring to
Excess product 102 not moved by product mover 136A continues along path 108 to a second end 119A of transporter 11A. A second feed system 100B or 200 is positioned approximate to second end 119A of first transporter 110A such that the excess product 102 is placed or deposited into a holder 104B of second feed system 100B. Second feed system 100B is configured to provide product 102 to a second transporter 110B such that product 102 may be picked up or otherwise handled by a second product mover 136B. Feed system 100B, transporter 110B, and product mover 136B are collectively shown as 103B. Second product mover 136B detects the presence of a tray 160 within region 143 through a sensor 141. Further, product mover 136B is configured to place product 102 only in a tray 160 which does not already contain product 102 within compartment 166. In one embodiment, a second sensor 145 monitors a region 146 generally between product movers 136B and 136B such that the baseline speed of second transporter 110B can be adjusted based upon the number of empty trays 160 exiting product mover 136A.
In one embodiment, the speed of second transporter 110B is varied to adjust for the number of empty trays 160 moving towards product mover 136B. In one example, the speed of second transporter 110B is further adjusted to insure that all of product 102 transported by transporter 110B is moved by product mover 136B. Therefore, in this example, no excess product 102 is transported beyond product mover 136B.
Further, the density of product 102 positioned on transporter 110B is lower than the density of product 102 positioned on transporter 110A. In another embodiment, the speed of second transporter 110B is varied such that all of the product transported by second transporter 110B is similar to the speed of transporter 110A such that product mover 136B moves at closer to its max capacity and there is a potential for excess product 102. It is within the scope of the present invention to cascade a third feed system (not shown) adjacent a second end 119B of transporter 110B along with a third transporter (not shown) and a third product mover (not shown)
Referring to
While the invention is susceptible to various modifications and alternative forms, exemplary embodiments thereof have been shown by way of example in the drawings and will herein be described in detail. It should be understood, however, that there is no intent to limit the invention to the particular forms disclosed, but on the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.
Claims
1. A transport system for placing a plurality of randomly positioned product on a transporter in a single layer, the transport system comprising:
- a first transporter having a first end and a second end and a transport member configured to transport the product from the first end to the second end;
- a hopper, the hopper forming a repository proximate the first end of the first transporter, the repository adapted to receive the randomly positioned product;
- a drive system coupled to the first transporter and configured to drive the transport member at a transport speed such that at least a portion of the randomly positioned product is moved from the repository towards the second end of the first transporter; and
- a control system connected to the drive system, the control system configured to control the transport speed, the control system comprising: a first sensor positioned to monitor the presence of a first one of the product in an output region proximate to the second end of the transport member; and a controller connected to first sensor, the controller configured to set the transport speed generally equal to a baseline speed when the first one of the product is detected in the output region and to deviate the transport speed from the baseline speed when the first one of the product is not detected in the output region.
2. The transport system of claim 1, further comprising a product rake configured to block a second one of the product stacked on top of the first one of the product from being transported to the output region.
3. The transport system of claim 1, wherein the second end of the first transporter is elevated relative to the first end of the first transporter.
4. The transport system of claim 2, wherein the second end of the first transporter is elevated relative to the first end of the first transporter.
5. The transport system of claim 1, wherein the controller increases the transport speed from the baseline speed when the first one of the product is not detected in the output region.
6. The transport system of claim 5, wherein the control system further includes a second sensor positioned to monitor the presence of the first one of the product in an input region of the transporter.
7. The transport system of claim 6, wherein the controller decreases the transport speed from the baseline speed when a second one of the product is detected in the output region of the first transporter and the first one of the product is detected in the input region of the transporter.
8. The transport system of claim 1, wherein the baseline speed is determined based on at least one input from the transporter.
9. The transport system of claim 8, wherein the baseline speed is generally equal to a speed of the transporter.
10. The transport system of claim 2, wherein the controller increases the transport speed from the baseline speed when the first one of the product is not detected in the output region.
11. The transport system of claim 2, wherein the control system further includes a second sensor positioned to monitor the presence of the first one of the product in an input region of the transporter.
12. The transport system of claim 11, wherein the controller decreases the transport speed from the baseline speed when a second one of the product is detected in the output region of the transporter and the first one of the product is detected in the input region of the transporter.
13. The transport system of claim 2, wherein the baseline speed is determined based on at least one input from the transporter.
14. The transport system of claim 13, wherein the baseline speed is generally equal to a speed of the transporter.
15. A method of transporting a plurality of randomly positioned product from a hopper to a first region of a transporter, such that the plurality of randomly positioned product is placed on the transporter in a single layer, the method comprising the steps of:
- transporting a portion of the plurality of product on a feed transporter from the hopper towards the transporter;
- blocking a first one of the portion of the product as it is being transported by the feed transporter such that a single layer of product remains on the feed transporter, the first one of the product being stacked upon a second one of the product;
- monitoring the first region of the transporter to determine if a third one of the product is currently present in the first region; and
- moving the second one of the product from the feed transporter to the first region of the transporter if the third one of the product is not currently detected in the first region.
16. The method of claim 15, wherein the portion of the plurality of product is transported by the feed transporter at a transport speed based at least in part on a baseline speed of the transporter.
17. The method of claim 16, wherein the step of transporting the portion of the product on the feed transporter includes the step of transporting the portion of the product along an inclined portion of the feed transporter.
18. The method of claim 16, wherein the transport speed is decreased relative to the baseline speed when the third one of the product is detected in the first region of the transporter.
19. The method of claim 16, further comprising the step of monitoring an output region of the feed transporter to determine if the second one of the product is currently present in the output region.
20. The method of claim 19, wherein the transport speed is increased relative to the baseline speed when the second one of the product is not detected in the output region of the feed transporter.
21. A method of controlling the placement of at least one of a plurality of product from a first transporter moving at a transport speed and having an output region to a second transporter moving at a baseline speed and having an input region, the method comprising the steps of:
- setting the transport speed generally equal to the baseline speed in the absence of an event;
- monitoring at least one of the output region and the input region for the occurrence of an event, wherein an event corresponds to one of the detection of the presence of or absence of a first one of the product in one of the output region of the first transporter and the input region of the second transporter; and
- deviating the transport speed from the baseline speed upon a detection of an event.
22. The method of claim 21, wherein a first event corresponds to the detection of the absence of the first one of the product from the output region of the first transporter.
23. The method of claim 22, wherein the transport speed is increased from the baseline speed in response to the detection of the first event.
24. The method of claim 21, wherein a second event corresponds to the detection of the presence of the first one of the product in the output region of the first transporter and the detection of a second one of the product in the input region of the second transporter.
25. The method of claim 24, wherein the transport speed is decreased from the baseline speed in response to the detection of the second event.
26. A transport control system for controlling the placement of at least one of a plurality of product from a first transporter to a second transporter, the first transporter having an output region and a first drive system to drive the first transporter at a transport speed and the second transporter having an input region and a second drive system to drive the second transporter at a baseline speed, the transport control system comprising:
- a first sensor configured to detect the presence of the product and positioned to detect the presence of the product within the output region of the first transporter;
- a second sensor configured to detect the presence of the product and positioned to detect the presence of the product within the input region of the second transporter; and
- a controller connected to the first sensor and the second sensor, the controller configured to control the transport speed of the first transporter based at least on one of a first input signal from the first sensor and a second input signal from the second sensor, wherein the controller increases the transport speed above the baseline speed of the second transporter when the first input signal indicates that a first one of the product is not present in the output region of the first transporter.
27. The transport control system of claim 26, wherein the controller decreases the transport speed below the baseline speed of the second transporter when the first input signal indicates that the first one of the product is present in the output region of the first transporter and the second input signal indicates that a second one of the product is present in the input region of the second transporter.
28. The transport control system of claim 26, wherein the first sensor includes an emitter and a detector configured to detect a signal emitted by the emitter.
29. The transport control system of claim 28, wherein when the first one of the product is within the output region of the first transporter, the signal emitted from the emitter is blocked by the first one of the product from reaching the detector.
30. A transport system for placing a plurality of randomly positioned product onto a transporter, the transport system comprising:
- a first transport system configured to receive the randomly positioned product and to organize the randomly positioned product into a single layer, the first transport system having a first end and a second end;
- a first product mover configured to move a first portion of the product from the first transport system to the transporter, the first product mover positioned between the first end and the second end of the first transport system;
- a second transport system configured to receive a second portion of the product from the first transport system not moved by the first product mover, the second transport system positioned adjacent the second end of the first transport system; and
- a second product mover configured to move at least a portion of the second portion of the product from the second transport system to the transporter.
31. The apparatus of claim 30, wherein the first transport system and the second transport system each include a hopper to receive the product.
32. The apparatus of claim 31, wherein the first transport system and the second transport system each further include a product rake configured to block a first instance of the product from being transported to the respective product mover while on top of a second instance of the product.
33. A method for transporting a plurality of randomly positioned product to a transporter, such that each individual product is positioned in a respective tray transported on the transporter, the method comprising the steps of:
- receiving a plurality of randomly positioned product;
- arranging the product into a single layer;
- transporting the product;
- moving a first portion of the product to the trays on the transporter;
- collecting a second portion of the product;
- arranging the second portion of the product into a single layer;
- transporting the second portion of the product; and
- moving the second portion of the product to the trays on the transporter.
34. The method of claim 33, wherein the step of transporting the product includes the step of transporting the product along an inclined path.
35. The method of claim 33, wherein the second portion of the product is moved to the trays on the transporter at a position spaced apart from where the first portion of the product is moved to the trays on the transporter.
Type: Application
Filed: Oct 3, 2003
Publication Date: Apr 7, 2005
Inventors: Glen Raque (Louisville, KY), Jerry Barnes (Crestwood, KY), Wail Elkhatib (Louisville, KY), Robert Raque (Louisville, KY), Michael Weidman (Crestwood, KY)
Application Number: 10/678,708