A system for automated layering and filling of multiple grains and assembly in a confined region and a method thereof

Abstract

Embodiments relate to a system and a method to facilitate automated control for filling, assembly and integration of Charge Module, CM, with all the safety and operational interlocks, especially dispensing layers of pallets in a vertically aligned manner in quick succession to build a stack of layers of pallets, wherein the number of grains dispensed in each layer can be decided at the design stage or controlled through a flapper during operation.

Description

[0001] A SYSTEM FOR AUTOMATED LAYERING AND FILLING OF MULTIPLE GRAINS AND ASSEMBLY IN A CONFINED REGION AND A METHOD THEREOF

[0002] TECHNICAL FIELD

[0003] The present invention relates to a system and a method thereof for automated filling, and assembly of a Charge Module (CM). In particular, the present invention relates to a system and a process to facilitate automated control for filling, assembly and integration of Charge Modules with all the safety and operational interlocks, especially dispensing layers of pallets in a vertically aligned manner in quick succession to build a stack of layers of pallets and placement of stacked layers in confined region, wherein the number of grains dispensed in each layer can be decided at the design stage or controlled through a flapper during operation.

[0004] BACKGROUND OF THE INVENTION

[0005] A Charge Module (CM) consists of three components, viz. Main-Module, Cover Disk and Inner Tube; they fit with each other during the assembly process. In addition to that, the predefined weight of grains as per requirement needs to be filled in an annular space of the Main-Module. To accommodate required mass of grains in the constrained space of Charge Module, the grains are required to be filled layer by layer in a vertically aligned manner.

[0006] The existing and conventional process of filling was based on the manual process of alignment of grains in layers and subsequent filling into the annular region of Charge Module, which was time-consuming and required direct human contact.

[0007] In this regard, reference is made to some of the existing patents which belongs to the field of packaging system such as US Patent: 1972657, US Patent: 864256, European patent 0149822, European patent 0619231A1, European patent 1977974A1, UK patent GB2448816.

[0008] Hence, automated filling needs to be carried out to make the system more reliable in terms of repeatability making the filling process faster and to avoid direct human contact. In this regard, there was a need to develop a method and a system for meeting filling pattern and weight requirements, along with automated layering of the pallets and automated stacking of layers one over another without disturbing the integrity of the formed layers.

[0009] More specifically, in the charge module, grains are arranged in layered fashion. In each layer, there are approximately 110 / 120 nos (nos. is only indicative) of grains aligned vertically. The arrangement of vertically aligned grains in six layers is essential to have close packing of grains in minimum possible volume.

[0010] In conventional method, the arrangement of these grains in each layer is carried out manually. In order to meet the faster production / assembly requirement of these modules, it is essential that the alignment process in each layer be carried out through machine automation.

[0011] Hence, there is a need of a process / mechanism / technique which is not only quick but also reliable in terms of making the layer of desired shape (circular, annular etc.). Currently, no process or mechanism is known to dispense vertically aligned grain layer after layer in quick succession. With multiple layers stacked one over another while keeping the geometrical integrity of individual layers also. In that regard, there is a need to provide a system and a method thereof capable of dispensing vertically aligned grains with layer-by-layer fashion. The system then can be utilized for vertically aligned grains to be dispensed one after another layer. After dispensing vertically aligned grains of each layer on a plate, a gathering mechanism is implemented to make those closer to form a shape of circle, annular or region of desired shape. These gathered vertically aligned pallets of a single layer should then be placed on a plate and then into an annular region (for this particular case). These processes of vertical alignment, dispensing and placement of aligned single layer of pallets is required to be repeated to make stacks of required numbers of layers in the module. In addition to automated filling and assembly; automated retrieval of filled and assembled modules also needs to be carried out. SUMMARY OF THE INVENTION

[0012] The following presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not an extensive overview of the present invention. It is not intended to identify the key / critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some concept of the invention in a simplified form as a prelude to a more detailed description of the invention presented later.

[0013] The main object of the invention is overcome the drawbacks of the prior arts.

[0014] An object of the present invention is to provide a method and system for automated filling of pallets, alignment, layering, stacking, assembly and retrieval of integrated Charge Module; to overcome the challenges of manual assembly, human intervention; and to save time and manpower for end users.

[0015] An object of the present invention is to provide a method and a system with a mechanism by which pallets can be dispensed layer by layer. The layer-by-layer dispensing of the grains is utilized for stacking grains for packaging, filling or assembly in an annular, circular or any type of cross-sectional region. The number of grains to be dispensed in each layer can be decided during the design stage (if numbers are fixed) or can also be determined dynamically during the running of the system using a stopper with the electronic control system.

[0016] Yet another object of the present invention is a method and a system that can be utilized for automated filling of pallets layer by layer as per the required weight of the module to be filled; and subsequent assembly with other components of Charge Module, and final retrieval of an Assembled Charge Module.

[0017] Yet another object of the present invention is a method and a system for dispensing of layers of pallets in a vertically aligned manner in a quick succession. The number of grains dispensed in each layer shall be decided at the design stage or can also be controlled through a stopper during operation.

[0018] Further an object of present invention is a method and a system to dispense layer after layer of vertically aligned pallets to build the stack of layers of pallets, and the vertically aligned grains need to be brought closer to form the desired shape to make it arranged in a compact manner, and stacking multiple layers one over another at the required location, while keeping the geometrical integrity of individual layers.

[0019] Yet another object is to ensure the fitment of required weight of pallets in the constrained space of Charge Module, and filling the grains layer by layer in a vertically aligned manner.

[0020] According to first aspect of present invention there is provided a system for automated alignment, dispensing, layering, gathering and filling of pallets, assembly with a Charge Module, and subsequent recovery of integrated and filled charge modules, without human intervention, said system comprising: a plurality of tracks originating from a vibratory bowl feeder (2), said tracks being communicably coupled to a vertical grain dispenser (1) with controlled dispensing unit (13), to allow grains to be dropped into a plurality of holes of a rotational grain aligner assembly (11) having a multi -perforated disc assembly for formation of layers of vertically aligned grains in an annular fashion, said plurality of holes of the rotational grain aligner assembly being arranged in concentric circles, with the center axis as the rotational axis, said grain aligner assembly (11) is adapted to rotate about its axis to facilitate dropping of the grains from the dispenser (1) into the holes of the aligner assembly (11) during the rotation; multiple stations for a grain holding table (6) and a grain positioner assembly (24); a control unit operably coupled to the dispensing unit to stop the dropping of grains from the corresponding tracks of the grain dispenser (1) during the rotation of aligner disc assembly (11) to control the numbers of grains to be placed in any layer during operation; a user terminal / computer communicably coupled to the vibratory bowl feeder (2), the vertical grain dispenser (1) with controlled dispensing unit (13), the rotational grain aligner assembly (11), the grain holding table (6) and a grain positioner assembly (24), via a communication interface (21), said user terminal is configured for operation and control of said system, for motion control and data acquisition, through a plurality of encoders, a plurality of sensors, a plurality of limit switches and accordingly activate various actuators such as motors, linear slides, and solenoid valves for user desired functioning of the system.

[0021] According to second aspect of present invention, there is provided method for filling and assembly of Charge Module (CM) to automate the operations of alignment, dispensing, layering, gathering and filling of pallets, assembly and subsequent retrieval of integrated and filled Charge Module (CM), without human intervention, by a system for automated alignment, dispensing, layering, gathering and filling of pallets, said method comprising: sensing positions of all the sub-systems through a plurality of encoders, a plurality of sensors, a plurality of limit switches and accordingly activate various actuators such as motors, linear slides, and solenoid valves as per required sequence of steps of the system; ensuring the event-driven safety interlocks by determining the current state of the system through various encoders, sensors, limit switches, and ensuring the issue of command for the next stage only if all the operations of the current step are completed; facilitating a user to monitor the state of the system in a graphical user interface and perform the manual override operation, if needed; feeding pallets to a vibratory bowl feeder (2); dispensing the grains through a plurality of tracks originating from the vibratory bowl feeder (2), said tracks being fed into a vertical grain dispenser (1) with controlled dispensing unit (13); allowing grains to be dropped into a plurality of holes of a rotational grain aligner assembly (11) having a multi-perforated disc assembly, said plurality of holes of the rotational grain aligner assembly being arranged in concentric circles, with the center axis as the rotational axis; rotating the grain aligner assembly (11) about its axis to facilitate dropping of the grains from the dispenser (1) into the holes of the aligner (11) during the rotation; providing multiple stations for a grain holding table (6) and a grain positioner assembly (24) to facilitate moving of the grain holding table for filling and assembly of Charge Module in an automated way; controlling, by a control unit operably coupled to the dispensing unit, the start and stop of the dropping of grains from the corresponding tracks of the grain dispenser (1) during the rotation of aligner disc assembly (11) to control the numbers of grains to be placed in any layer during operation and formation of layers of vertically aligned grains in an annular fashion; and controlling, by a user terminal / computer communicably coupled to the vibratory bowl feeder (2), the vertical grain dispenser (1) with controlled dispensing unit (13), the rotational grain aligner assembly (11), the grain holding table (6) and a grain positioner assembly (24), via a communication interface (21).

[0022] Other aspects, advantages, and salient features of the invention will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses exemplary embodiments of the invention.

[0023] BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

[0024] The above and other aspects, features and advantages of the embodiments of the present disclosure will be more apparent in the following description taken in conjunction with the accompanying drawings, in which:

[0025] Figure 1 illustrates a schematic of the components of a Charge Module (CM), namely the assembly of the components - a Main-Module, a Cover Disk and an Inner Tube.

[0026] Figure 2 illustrates a Cover Disk and an Inner Tube of Charge Module (CM).

[0027] Figure 3 illustrates a Main-Module of the Charge Module (CM).

[0028] Figures 4, 4A-F illustrate a schematic of a system for automated layering and filling of multiple grains and assembly in a confined region, according to one of the implementations of present invention.

[0029] Figure 5 illustrates a flow chart for a method for automated layering and filling of multiple grains and assembly in a confined region, according to one of the implementations of present invention.

[0030] Persons skilled in the art will appreciate that elements in the figures are illustrated for simplicity and clarity and may have not been drawn to scale. For example, the dimensions of some of the elements in the figure may be exaggerated relative to other elements to help to improve understanding of various exemplary embodiments of the present disclosure. Throughout the drawings, it should be noted that like reference numbers are used to depict the same or similar elements, features, and structures.

[0031] DETAILED DESCRIPTION OF THE INVENTION

[0032] The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of exemplary implementations of the invention. It includes various specific details to assist in that understanding but these are to be regarded as merely exemplary.

[0033] Features that are described and / or illustrated with respect to one implementation may be used in the same way or in a similar way in one or more other implementations and / or in combination with or instead of the features of the other implementations.

[0034] The present invention relates to a system for automated alignment, dispensing, layering, gathering and filling of pallets, assembly with a Charge Module, CM, and subsequent recovery of integrated and filled Charge modules, without human intervention, said system comprising: a plurality of tracks originating from a vibratory bowl feeder (2), said tracks being communicably coupled to a vertical grain dispenser (1) with controlled dispensing unit (13), to allow grains to be dropped into a plurality of holes of a rotational grain aligner assembly (11) having a multi-perforated disc assembly for formation of layers of vertically aligned grains in an annular fashion, said plurality of holes of the rotational grain aligner assembly being arranged in concentric circles, with the center axis as the rotational axis, said grain aligner assembly (11) is adapted to rotate about its axis to facilitate dropping of the grains from the dispenser (1) into the holes of the aligner assembly (11) during the rotation; multiple stations for a grain holding table (6) and a grain positioner assembly (24); a control unit operably coupled to the dispensing unit to stop the dropping of grains from the corresponding tracks of the grain dispenser (1) during the rotation of aligner disc assembly (11) to control the numbers of grains to be placed in any layer during operation; a user terminal / computer communicably coupled to the vibratory bowl feeder (2), the vertical grain dispenser (1) with controlled dispensing unit (13), the rotational grain aligner assembly (11), the grain holding table (6) and a grain positioner assembly (24), via a communication interface (21), said user terminal is configured for operation and control of said system, for motion control and data acquisition, through a plurality of encoders, a plurality of sensors, a plurality of limit switches and accordingly activate various actuators such as motors, linear slides, and solenoid valves for user desired functioning of the system.

[0035] CM consists of three components, viz. Main-Module, Cover Disk and Inner Tube; they fit with each other during the assembly process, and the components are illustrated in Figs. 1-3. In addition to that, the predefined weight of grains as per requirement needs to be filled in an annular space of the Main-Module. To accommodate required mass of grains in the constrained space of Charge Module, the grains are required to be filled layer by layer in a vertically aligned manner.

[0036] As shown in Fig. 4, an embodiment of the present invention illustrates a system developed for dispensing and stacking of vertically aligned grains for assembly of Charge Module for close packing / superior volume loading. The system for dispensing of pallets is automated for filling and assembly of Charge Module. The system mainly consists of major sub-systems, Grain Dispenser (1) with controlled dispensing unit (13), Grain Aligner (i.e. Multi-perforated Disc assembly) (11), Grain Positioner Assembly (24), Grain Holding Table (6), Dummy Covering Disc (4), Main Module Locator Disc (16), Semi-Assembled Unit Lifting and Tilting System (10), Communication Interface (21) and Locking System (23), Main Module Positioning and Locator (16) System. The required systems are driven through a plurality of motors to make the process fully automated. The controller controls the movement of different units according to the received command from a user terminal / computer.

[0037] As illustrated in Fig. 4(C), the mechanism collects the aligned grains on a split plate (19) and the gathering arrangement comprising a gather plate pair (12), which gathers the vertically aligned grains (15) to give a particular shape. In this example, an annular region is required to be filled. Hence the gathering arrangement (12) and dispensing unit (1) is designed in that fashion, whereas any kind of shape can be filled with this technology. This process uses the gravitational potential energy for free falling of the grains, which means no force is given to the grain to move from top to bottom. In the process, the vertically aligned single layer of grains is collected on a split plate. The grains are then gathered with the help of gathering arrangement after lowering down to the placing position.

[0038] Another mechanism controls the numbers of grains to be fed to the multiperforated disc (11) at the exit point using a moving pin mechanism to control the weight of the total grains fed or number of grains fed for the assembly.

[0039] Grain dispenser (1) has five number tracks for alignment of the grains in the vertical manner for layering of grains subsequent stacking of layers. The tracks of grain dispenser (1) dispense the vertically aligned grains into the holes of Grain Aligner (11), Centre of each of five exit holes of grain dispenser (1) is aligned with the corresponding five PCDs of the holes of Grain Aligner (11) with respect to axis of rotation of Grain Aligner (11).

[0040] In other words, exit hole of Grain dispenser (1) is at the distance equal to the radius of rotation of hole(s) from axis of rotation of grain aligner (11). This condition is met for each of the five holes in grain dispenser (1). Vertical separation between the grain dispenser (1) and the grain aligner (11) is optimized based on diameter and length of the grains to be dispensed and the relative angular speed for holes of grain aligner (1).

[0041] The dimensions of tracks of the grain dispenser (1) are optimized based on the average diameter and length of grains to be dispensed, and the required tolerance in their dimensions. The vertical separation (gap) between grain dispenser (1) and multiperforated-disk (rotating disk) (11) is decided based on length and diameter of the grain to be dispensed along with the required speed of dispensing (r.p.m of rotating disk).

[0042] This particular embodiment uses grain dispenser (1) with five holes however number of holes can be selected based on the required number of grains to be distanced in each layer. Moreover, if lesser numbers of grains are required to be dispensed in each layer, then few holes in the grain dispenser can be temporarily blocked to meet the requirement. Fig. 4(E) illustrates the side view and isometric view of grain dispenser.

[0043] The details of the system will be better explained with the help of drawing in as illustrated in Fig. 4, Fig. 4(A), Fig. 4(B), Fig. 4(C) and Fig. 4(D) by explaining each of the process steps in the next part.

[0044] The invention mainly consists a mechanism for alignment, dispensing, layering, gathering and filling of grains (cylindrical pallets) inside Charge Module without human intervention, and automation sensing and actuation for reliable and automated filling and assembly of Charge modules. Automated pallets filling is performed using a Feeder / Dispensing Tubes in Grain Dispenser (1), multiperforated rotating disk (11), layering, splitting mechanism (19) and gathering the layered grains inside the cylindrical containers and finally transferring multiple dispended layers of grain from Cylindrical Enclosure to the Main-Module (5). Electronic components such as industrial computer (30), Stepper Motor Drives, Eimit Switches, Solenoid Valves, and Motion Control Card (32) are used to automate the system with required operational and safety interlocks. An industrial computer (30) is configured to Control and Operate filling and assembly System as per the required sequence of operation as illustrated in Fig. 4.

[0045] The detailed description of the various components / sub-systems of the filling and assembly system are given.

[0046] ■ Elevator

[0047] This unit is an industrial elevator to lift the bunch of pallets from a hopper and drop in to the vibratory bowl feeder.

[0048] ■ Vibratory Bowl Feeder

[0049] This vibratory bowl feeder is an industrial vibratory bowl feeder with necessary modifications to hold required number of pallets and feeds through 5 tracks with varying speed of feeding through different 5 tracks.

[0050] ■ Grain Dispenser (1) with controlled dispensing unit (13) [grain dispenser is shown as a part of Fig. 4] ■ Multi-perforated Disc Assembly (11) i. Multi-perforated disc with rotating arrangement ii. Angle measurement unit

[0051] ■ Grain Positioned Assembly (24) i. Vertical Linear Slide (18) ii. Pair of Sliding Gather Plates (12) iii. Pair of Sliding Split Plates (19)

[0052] ■ Grain Holding Table (6) i. Grain Holding Base (with Load Cell) ii. Grain Holder Pipe (7) iii. Module Lifter (8)

[0053] ■ Main Module Locator Disc (16) i. Mechanism for placement and removal of Main Module Locator Disc (14)

[0054] ■ Dummy Covering Disc

[0055] ■ Lifting and Tilting Mechanism (10) for Semi-Assembled Unit (20) i. Locking unit (23) ii. To & Fro movement slide (34) iii. Rotating unit and Linear Slide for translation

[0056] ■ Main Module Positioning and Locator System (16) i. Positioning of Main Module ii. Locating of Main Module

[0057] As illustrated in Fig. 4, at station 2, home position of the grain holding table (6), the dummy covering disc (4) will be placed on to the Lifting System / Module Lifter (8), and subsequently, the inner tube (3) is also placed on to the dummy covering disc (4). The grain holding table (6) will be moved from station 2 to station 1.

[0058] Sorted grains for their length and diameter had to be put in the hopper of the elevator. The elevator will feed the sorted grains into the vibratory bowl feeder. The vibratory bowl feeder with five tracks takes the grains to the dispenser (1). The numbers of tracks in the vibratory bowl feeder are decided based on the number of grains required to be dispensed in a single layer and also the required dimension of the grain positioner assembly (24). The grain aligner (11) will then rotate about its axis which allows the grains from the dispenser (1) to drop into the holes of the aligner (11) during the rotation. The holes in the aligner are arranged in number of concentric circles with the rotation axis as the center. The control units placed on the dispensing unit can stop the dropping of grains from the corresponding tracks of the dispenser as per the requirement. This process of stopping of grains from the dispenser during the rotation of aligner disc (11) can practically control the numbers of grains to be placed in any layer during the operation. The precise number of grains those can be dispensed on a single layer can be electronically controlled through tracking of angular position of the aligner disc (11) through an encoder and operation of the stopper on the dispenser (1). The rotation of the aligner disc (11) will be done when the split plate pair (19) is placed just below the aligner disc (11) in closed condition. Single layer of the grains is dispensed by rotating the aligner disc (11) by 360° and also by operating the stopper in the dispenser (1) for controlling number of grains on the layer. Fig. 4(C) illustrates the single layer of grains dispensed on split plate pair (19).

[0059] Once single layer of grains is dispensed, the split plate pair (19) in this closed condition is brought down by moving the vertical linear slide (18) of the grain positioner assembly (24). The grain positioner assembly (24) will be brought down till that point so that the split plate (19) will be a few mm away from the top surface of the grain holder pipe (7). At this position, the gather plate pair (12) is being closed to make it a circle around the inner tube (3). The split plate pair (19) is then opened till end so as to allow the gathered grains in an annular region around the inner tube (3) to get dropped inside the grain holder pipe (7). Then the grain positioner assembly (24) is moved upwards, and simultaneously the grain holder pipe (7) is also moved upwards. The grain holder pipe (7) is moved upwards till the complete length of one grain is covered. The split plate pair (19) is closed, and the gather plate pair (12) is opened till both extreme ends. At this condition, the grain positioner assembly (24) is again moved upwards till the closed split plate pair (19) is placed few mm below the grain aligner disc (11). The procedure of grains alignment and placement onto the grain holder pipe (7) is continued till the desired number of layers of grains is built inside the grain holder pipe (7). Stacking of layers of vertically aligned grains inside grain holding pipe is illustrated in detail in Fig. 4(D) [Detail View-II]. The Separation Disk, as desired in between the layers can be placed between buildings of layers.

[0060] Once desired number of layers of grains are built inside the grain holder pipe (7), the grain holding table (6) is moved out of station 1, and moved to the station 3. At station 3, the main module locator disc (16) is placed onto the top of the grain holder pipe (7) with the help of the mechanism (14) for placement and removal of Main-Module Locator Disc (16). Fig. 4(D) [Detail View-II] illustrates Placement of Main Module locator disc (16) on the grain holding pipe at station-3.

[0061] The grain holding table (6) is then moved to another station. At this station, the main module (5) in inverted condition along with an optional polyester bag inside is placed on the Main Module Locator Disc (16). A weight is placed onto the main module base from the top, and then the grain holder pipe (7) is lowered down slowly to push the aligned grains into the main module (5) in the available annular region. The grain holder pipe is lowered down till the main body (5) top collar is separated from the Main Module Locator Disc (16). The applied weight is then removed from the top base of the main module. Then the grain holding table (6) is moved to station 5.

[0062] At station 5, the module lifter (8) is then allowed to lift the semi-assembled unit (20) by the required height. Fig. 4(D) [Detail View-IV] illustrates the lifting of semi-assembled unit by module lifter at station-5. At this elevated position of the semi-assembled unit, the to & fro slide (34) is operated to bring the locking unit of the lifting and tilting system (10) onto the top and bottom of the semi-assembled unit (20). The locking unit (23) of the lifting and tilting system (10) is operated to hold and lift the semi-assembled unit (20), as illustrated in Fig. 4(D) [Detail View-V]. The module lifter (8) is brought down, and the linear slide for translation is operated to move the semi-assembled unit (20) away from station 5. During movement, the rotator of the Lifting and tilting system (10) is rotated 180° about its axis to make the main-module (5) on straight top condition, as illustrated in Fig. 4(D) [Detail View- VI]. The linear slide for translation takes the semiassembled unit (20) to station 6.

[0063] At station 6, the locking unit (23) of the lifting and tilting system (10) is operated to open and place the semi-assembled unit onto the table of station 6. At this station, the dummy covering disc (4) is taken out, and the actual covering disc is placed inside. The pressing unit then press the covering disc and locks it to the main body (5). Parallelly, different axes of the Semi-Assembled Unit Lifting and Tilting System (10) are operated to bring those to home condition.

[0064] Bring the grain holder pipe (7) to home position and move the grain holding table (6) to station 3. At station 3, the Main Module Locator Disc (16) is to be removed from the top of the grain holder pipe (7) by the help of Mechanism (14), for placement and removal of Main Body Locator Disc (16). After this the grain holding table (6) is moved to station 2 and wait for the command instruction for the next cycle for assembly of the next Charge module (CM).

[0065] According to an embodiment, the method to control the process for filling, assembly, and integrating Charge Module (CM) with all the safety and operational interlocks are implemented using computer / embedded controller and various sensors, actuators, limit switches, motors, fixtures, and hardware assemblies, as illustrated in the figures and subsequent drawings.

[0066] In accordance with the present invention, a process is developed for dispensing and stacking of vertically aligned pallets for assembly of Charge Module for close packing / superior volume loading of Charge Module. The process of dispensing of pallets is automated for automatic filling and assembly of Charge Module using the user terminal / Computer.

[0067] The detailed implementation of the methods is further explained by various steps in the flow chart in Fig. 5. As illustrated in Fig. 4, the computer (30) senses the positions of all the sub-systems through various encoders, Sensors, Limit Switches, etc. Accordingly, it issues commands to multiple actuators such as motors, linear slides, solenoid valves etc. as per required sequence of steps by the process. Automated program / computer (31) also ensures the event-driven safety interlocks by determining the system's current state through various encoders, Sensors, Limit Switches; and ensures the issue of command (33) for the next stage only if all the operations of the current step are completed. The process facilitates all the safety and operational interlocks to ensure the system will continue its operation only if the minimum pre conditions are met. A graphical user interface enables the user to monitor the state of the system and perform the manual override operation. If needed, emergency switch can be used to stop the operation of the system in case of an emergency.

[0068] Placement of Separation Disk between the layers is perfumed if required by sequence of operations. As illustrated in flow chart / Sequence in Figure-5, the computer (30) is configured to perform the processes through various motors / actuators; based on the state of the system sensed by various sensors and proxy switches. The computer (30) is configured to perform various operations as per the required sequence of operations. The same is described by various steps and illustrated in the Flow chart in Fig. 5.

[0069] Step-1

[0070] Computer is configured to bring all the sub systems at Home Condition to start the process for new module.

[0071] Step-2

[0072] Computer is configured issue command / indication for Placement of dummy covering disc (4) on to the grain holding pipe (base) at station-2.

[0073] Step-3

[0074] Computer is configured issue command / indication for placement of inner tube (3) on to the dummy covering disc (4) at station-2.

[0075] Step-4

[0076] Computer is configured to move the grain holding table (6) from station 2 to station 1.

[0077] Step-5

[0078] Computer is configured to rotate the grain aligner (11) about its axis which allows the grains from dispenser (1) to drop into the holes of the aligner during the rotation. The holes in the aligner are arranged in five concentric circles with the rotation axis as the center.

[0079] The control units (13) placed on the dispensing unit (1) can stop the dropping of grains from the corresponding tracks of dispenser (1) as per the requirement. This process of stopping of grains from the dispenser during the rotation of aligner disc (11) can practically control the numbers of grains to be placed in any layer during the operation. Electronic controller controls the precise number of grains those can be dispensed on a single layer through tracking of angular position of the aligner disc through an encoder and operation of the stopper on the dispenser (1). Computer (30) is configured to: control the rotation of the aligner disc (11) when the split plate pair (19) is placed just below the aligner disc (11); rotate the aligner disc by 360 degree and also by operating the stopper in the dispenser (1) for dispensing of controlled number of grains on the single layer.

[0080] Step-6

[0081] Computer is configured to bring down split plate pair (19) in this closed condition, by moving the vertical linear slide of the grain positioner assembly (24) , till that point so that the split plate will be few mm away from the top surface of the grain holder pipe(7).

[0082] Step-7

[0083] Computer is configured to close the gather plate pair (12) to make it a circle of vertically aligned grains around the inner tube (3).

[0084] Step-8

[0085] Computer is configured to open the split plate pair (19) till end so as to allow the gathered grains in an annular region around the inner tube to get dropped inside the grain holder pipe (7).

[0086] Step-9 and Step-10

[0087] Computer is configured to simultaneously move grain positioned assembly (24) & grain holder pipe (7) upwards till the complete length of the grains is covered to support the complete grain. Step-11 (home position)

[0088] The computer is configured to close the split plate pair (19) and open the gather plate pair (12) both extreme ends. Computer is further configured to move grain positioned assembly (24) upwards till the closed split plate pair (19) is placed just below the grain aligner disc (11).

[0089] Step-12

[0090] The computer is configured to issue command / indication for placement of Separation Disk between the layers as per requirement.

[0091] Step-13

[0092] The computer configured to perform to keep the check on number of layers of grains and continue the operation from step -5 to step- 12 (grains alignment and placement) till numbers of layers built inside the grain holder pipe (7) are one less than the required.

[0093] Step-14

[0094] Computer is configured to issue commands to collect vertically aligned single layer of grains on the sliding Split Plate (19) as per the required numbers of grains as per total weight.

[0095] Step-15

[0096] Computer is configured to follow step-5 to step-11.

[0097] Step-16

[0098] Computer is configured to move the grain holding table out of the station 1, to the station 3.

[0099] Step-17

[0100] At station 3, Computer is configured to issue commands / indication for placement of main body locator discs (16) on to the top of the grain holder pipe (7) with the help of the mechanism (14) for placement and removal of Main- Module Locator Disc (16)

[0101] Step-18

[0102] Computer is configured to move the grain holding table (6) to another station. Step-19

[0103] Computer is configured to issue commands / indication for placement of Main- Module (5) in inverted condition with polyester bag inside it on the Main Body Locator Disc (16).

[0104] Step-20

[0105] Computer is configured to issue commands / indication for placement of weight on Main-Module (5) base from top. Computer (30) is further configured to slowly lower down the grain holder pipe (7) to push the aligned grains in to the Main- Module (5) in the available annular region, till the main module top collar is separated from the Main Module Locator Disc (16). Computer is further configured to issue commands / indication for removal of applied weight from the top base of the Main-Module (5).

[0106] Step-21

[0107] Computer is configured to move the grain holding table (6) to station 5.

[0108] Step-22

[0109] Computer is configured to lift the semi assembled unit by the required height; by means of a module lifter (8).

[0110] Step-23

[0111] Computer is configured to operate to & fro slide to bring the locking unit (23) on to the top and bottom of the semi-assembled unit and to operate the locking unit (23) to hold and lift the semi-assembled unit. Computer is further configured to operate the linear slide for translation to move the semi-assembled unit away from station 5, and simultaneously rotate the rotator by 180 deg. about its axis to make the Main-module (5) on straight top condition, and finally taking the semiassembled unit down to station 6. The computer is further configured to operate the locking unit (23) to open and place the semi-assembled unit on to the table of station 6

[0112] Step-24

[0113] Computer is configured to issue commands / indication for taking out the dummy covering disc (4). Step-25

[0114] Computer is configured to issue commands / indication for Folding the polyester bag.

[0115] Step-26

[0116] Computer is configured to issue commands / indication for placement of actual covering disc inside, and operate the pressing unit to then press the closing disc and lock it to the main module (5).

[0117] Step-27

[0118] Computer is configured to issue commands / indication for removal of assembled unit from station 6.

[0119] Step-28

[0120] Computer is configured to bring the grain holder pipe (7) to home position and move the grain holding table (6) to station 3. Computer is further configured to issue command / indication for removal of Main Module Locator Disc (16) using Mechanism for removal of Main-module Locator Disc.

[0121] Step-29

[0122] Computer is configured to move the grain holding pipe / table (6) to station 2, and wait for the command for next cycle from the user.

[0123] The above-mentioned process is further utilized for removal of dummy cover-disk (4) and fixing of actual cover-disk in the filled Main-module (5).

[0124] Some of the non-limiting advantages of system for automated alignment, dispensing, layering, gathering and filling of grains (pallets), assembly with CM, and subsequent recovery of integrated and filled CM module, and the corresponding method thereof are:

[0125] 1. Automated filling, alignment, layering, stacking, assembly and retrieval of integrated Charge Module (CM); to overcome the challenges of manual assembly, human intervention; and to save time and manpower for end users.

[0126] 2. Dispensing of layers of pallets in a vertically aligned manner in a quick succession. 3. Automated filling of (grains) pallets, assembly of Charge Module (CM) and final retrieval of integrated Charge Module (CM); to save time, energy and manpower requirement and to improve reliability and safety. Although a system for automated filling of grains (pallets), assembly of Charge Module, and final retrieval of integrated Charge Module to save time, energy and manpower requirement and to improve reliability and safety and a method thereof have been described in language specific to structural features, it is to be understood that the embodiments disclosed in the above section are not necessarily limited to the specific methods or devices described herein. Rather, the specific features are disclosed as examples of implementations of a system for automated filling of grains (pallets), assembly of Charge Module, and final retrieval of integrated CM and a method thereof. Table 1 : Labels for identification of each subsystem related to Conceptual diagram

[0127] * (12), (18) and (19) are collectively referred as Grain Positioner Assembly (24)

Claims

CLAIMS:

1. A system for automated alignment, dispensing, layering, gathering and filling of pallets, assembly with a Charge Module, CM, and subsequent recovery of integrated and filled charge modules, without human intervention, said system comprising: a plurality of tracks originating from a vibratory bowl feeder (2), said tracks being communicably coupled to a vertical grain dispenser (1) with controlled dispensing unit (13), to allow grains to be dropped into a plurality of holes of a rotational grain aligner assembly (11) having a multi-perforated disc assembly for formation of layers of vertically aligned grains in a constrained region, said plurality of holes of the rotational grain aligner assembly being arranged in concentric circles, with the center axis as the rotational axis, said grain aligner assembly (11) is adapted to rotate about its axis to facilitate dropping of the grains from the dispenser (1) into the holes of the aligner assembly (11) during the rotation; multiple stations for a grain holding table (6) and a grain positioner assembly (24); a control unit operably coupled to the dispensing unit to stop the dropping of grains from the corresponding tracks of the grain dispenser (1) during the rotation of aligner disc assembly (11) to control the numbers of grains to be placed in any layer during operation; a user terminal / computer communicably coupled to the vibratory bowl feeder (2), the vertical grain dispenser (1) with controlled dispensing unit (13), the rotational grain aligner assembly (11), the grain holding table (6) and a grain positioner assembly (24), via a communication interface (21), said user terminal is configured for operation and control of said system, for motion control and dataacquisition, through a plurality of encoders, a plurality of sensors, a plurality of limit switches and accordingly activate various actuators such as motors, linear slides, and solenoid valves for user desired functioning of the system.

2. The system as claimed in claim 1, wherein the multi-perforated disc assembly (11) comprises a multi-perforated disc with a rotating arrangement, and an angle measurement unit; wherein the grain positioner assembly (24) comprises a vertical linear slide (18), a pair of sliding gather plates (12), and a pair of sliding split plates (19); wherein the grain holding table (6) comprises a grain holding base (with load cell), a grain holder pipe (7), and a module lifter (8), wherein the system further comprises: a main module locator disc (16) with a mechanism for placement and removal of main module locator disc (14); a lifting and tilting mechanism (10) for a semi-assembled unit (20) comprising a locking unit (23), a To and fro movement slide (34), and a rotating unit and linear slide for translation; wherein the main module positioning and locator system (16) comprises a positioning of main module, and a locating of main module.

3. The system as claimed in claim 1, wherein the multiple stations comprise a home position (station 2) of the grain holding table (6), and a dummy covering disc (4) is operably placed on to the grain holding pipe (7), and subsequently, an inner tube (3) is operably placed on to the dummy covering disc (4), and the grain holding table (6) is moved from station 2 to station 1.

4. The system as claimed in claim 1, wherein the vibratory bowl feeder (2) is operably coupled to an elevator adapted to lift a bunch of pallets from a hopper and drop in to the vibratory bowl feeder,wherein the vibratory bowl feeder is adapted to hold required number of pallets and feed through the plurality of tracks with varying speed of feeding through different tracks, wherein the numbers of tracks in the vibratory bowl feeder are based on the number of grains required to be dispensed in a single layer and also the required dimension of the grain positioner assembly (24) and the number of holes in the aligner assembly are varied by permanently blocking some of the holes by means of a special adaptor, based number of grains required to be dispensed in a single layer, wherein the control unit is configured to electronically control a precise number of grains to be dispensed on a single layer, through tracking of angular position of the aligner disc (11) through an encoder and operation of the stopper on the dispenser (1), wherein the pair of split plates (19) is operably placed below the aligner disc assembly (11) in closed condition, to enable rotation of the aligner disc assembly (11) by 360° to dispense a single layer of the grains, and a stopper in the dispenser (1) is adapted for controlling number of grains on the layer.

5. The system as claimed in claim 1, wherein once single layer of grains is dispensed, the vertical linear slide (18) of the grain positioner assembly (24) is adapted to bring down the pair of split plates (19) in this closed condition, till a point that the pair of split plates (19) is a few millimeters away from the top surface of the grain holder pipe (7), and the pair of sliding gather plates (12) of the grain positioned assembly (24) is adapted to be closed to make a circle around the inner tube (3).

6. The system as claimed in claim 1, wherein the pair of split plates (19) is opened till end so as to allow the gathered grains in an annular region around the inner tube (3) to get dropped inside the grain holder pipe (7),wherein the grain positioner assembly (24) is adapted to move upwards, and simultaneously with the grain holder pipe (7) till the complete length of one grain is covered, wherein the pair of split plates (19) is closed, and the pair of sliding gather plates (12) is opened till both extreme ends, and the grain positioner assembly (24) is again moved upwards till the closed pair of split plates (19) is placed few millimeters below the grain aligner disc assembly (11), wherein grains alignment and placement onto the grain holder pipe (7) is continued till the desired number of layers of grains is built inside the grain holder pipe (7), wherein a separation disk, is operably placed between the buildings of layers.

7. The system as claimed in claim 1, wherein the grain holding table (6) is configured to be moved out of station 1 to station 3, once desired number of layers of grains are built inside the grain holder pipe (7), wherein at station 3, the main module locator disc (16) is placed onto the top of the grain holder pipe (7) with the help of a mechanism (14) for placement and removal of main-module locator disc (16), wherein when the grain holding table (6) is moved to another station, the main module (5) is in inverted condition along with a polyester bag placed on the main module locator disc (16), a weight is placed onto the main module base from the top, and then the grain holder pipe (7) is lowered down slowly to push the aligned grains into the main module (5) in the available annular region, the grain holder pipe is lowered down till the main module (5) top collar is separated from the main module locator disc (16), and the applied weight is then removed from the top base of the main module and the grain holding table (6) is moved to station 5, wherein the grain holding table (6) is at station 5, a module lifter (8) is adapted to lift the semi-assembled unit (20) by a required height, and at this elevated position of the semi-assembled unit, a To and fro slide (34) is operated to bring the locking unit of the lifting and tilting system (10) ontothe top and bottom of the semi-assembled unit (20), the locking unit (23) of the lifting and tilting system (10) is adapted to hold and lift the semiassembled unit (20), wherein the module lifter (8) is brought down, and the linear slide for translation is operated to move the semi-assembled unit (20) away from station 5, and during movement, the rotator of the Lifting and tilting system (10) is rotated 180° about its axis to make the main-module (5) on straight top condition and the linear slide for translation takes the semiassembled unit (20) to station 6.

8. The system as claimed in claim 1, wherein at station 6, the locking unit (23) of the lifting and tilting system (10) is adapted to open and place the semi-assembled unit onto the table of station 6, and at this station, the dummy covering disc (4) is taken out, and the actual covering disc is placed inside, wherein a pressing unit is adapted to press the covering disc and lock it to the main module (5), and parallelly, different axes of the semi-assembled unit lifting and tilting system (10) are operated to bring those to home condition; and bring the grain holder pipe (7) to home position and move the grain holding table (6) to station 3, wherein at station 3, the main module locator disc (16) is removed from the top of the grain holder pipe (7) by the help of a mechanism (14), for placement and removal of main body locator disc (16), and the grain holding table (6) is moved to station 2 for the next cycle for assembly of the next Charge module (CM), wherein numbers of grains to be dispensed in every layer are dynamically controlled based on the required weight of filled main module, wherein the controlled dispensing unit stops the dropping of grains from the corresponding tracks of dispenser during rotation to practically control the numbers of grains to be formed in a layer during the operation,wherein an Electronic Unit is adapted for controlling number of grains to be dispensed on each layer; through tracking of angular position of the aligner disc through an encoder, and operation of the stopper on the dispenser, and for fine control over the final weight of the main module, by sensing the real time the weight of module being filled through a load cell and precisely controlling number of grains to be dispensed on the last layer to achieve the required target weight of the module, wherein the system is configured to fill any numbers of layers in the main module as per requirement.

9. A method for filling and assembly of Charge Module (CM) to automate the operations of alignment, dispensing, layering, gathering and filling of pallets, assembly and subsequent retrieval of integrated and filled Charge Module (CM), without human intervention, by a system for automated alignment, dispensing, layering, gathering and filling of pallets, said method comprising: sensing positions of all the sub-systems through a plurality of encoders, a plurality of sensors, a plurality of limit switches and accordingly activate various actuators such as motors, linear slides, and solenoid valves as per required sequence of steps of the system; ensuring the event-driven safety interlocks by determining the current state of the system through various encoders, sensors, limit switches, and ensuring the issue of command for the next stage only if all the operations of the current step are completed; facilitating a user to monitor the state of the system in a graphical user interface and perform the manual override operation, if needed; feeding pallets to a vibratory bowl feeder (2);dispensing the grains through a plurality of tracks originating from the vibratory bowl feeder (2), said tracks being fed into a vertical grain dispenser (1) with controlled dispensing unit (13); allowing grains to be dropped into a plurality of holes of a rotational grain aligner assembly (11) having a multi -perforated disc assembly, said plurality of holes of the rotational grain aligner assembly being arranged in concentric circles, with the center axis as the rotational axis; rotating the grain aligner assembly (11) about its axis to facilitate dropping of the grains from the dispenser (1) into the holes of the aligner (11) during the rotation; providing multiple stations for a grain holding table (6) and a grain positioner assembly (24) to facilitate moving of the grain holding table for filling and assembly of Charge Module (CM) in an automated way; controlling, by a control unit operably coupled to the dispensing unit, the start and stop of the dropping of grains from the corresponding tracks of the grain dispenser (1) during the rotation of aligner disc assembly (11) to control the numbers of grains to be placed in any layer during operation and formation of layers of vertically aligned grains in an annular fashion; and controlling, by a user terminal / computer communicably coupled to the vibratory bowl feeder (2), the vertical grain dispenser (1) with controlled dispensing unit (13), the rotational grain aligner assembly (11), the grain holding table (6) and a grain positioner assembly (24), via a communication interface (21).

10. The method as claimed in claim 1, wherein the multi-perforated disc assembly (11) comprises a multi-perforated disc with a rotating arrangement, and an angle measurement unit; wherein the grain positioner assembly (24) comprises a vertical linear slide (18), a pair of sliding gatherplates (12), and a pair of sliding split plates (19); wherein the grain holding table (6) comprises a grain holding base (with load cell), a grain holder pipe (7), and a module lifter (8), wherein the system comprises: a main module locator disc (16) with a mechanism for placement and removal of main module locator disc (14); a lifting and tilting mechanism (10) for a semi-assembled unit (20) comprising a locking unit (23), a To and fro movement slide (34), and a rotating unit and linear slide for translation; wherein the main module positioning and locator system (16) comprises a positioning of main module, and a locating of main module.

11. The method as claimed in claim 9, wherein the method comprises: placing a dummy covering disc on to a grain holding pipe (base) at a home position (station 2), positioning of an inner tube on to the dummy covering disc at station-2, moving the grain holding table from station 2 to a station 1, rotating the grain aligner disk about its axis; to allow the grains from dispenser to drop into the holes of the aligner, controlling the precise number of grains those can be dispensed on a single layer by tracking of the angular position of the aligner disc through an encoder and operation of the stopper on the dispenser, allowing the rotation of the aligner disc only when the split plate pair is placed just below the aligner disc, bringing down the pair of sliding split plates in this closed condition, by moving the vertical linear slide of the grain positioned assembly till that point so that the split plate is just above the top surface of the grain holder pipe, closing the pair of sliding gather plates to make it a circle of vertically aligned grains around the Inner tube, opening the pair of sliding split plates till the end; to allow the gathered grains in an annular region around the Inner tube to get dropped inside the grain holder pipe, simultaneously moving the grain positioner assembly and the grain holder pipe upwards till the complete length of the grains is covered, closing the pair of sliding split plates and opening the pair of sliding gather plates till both extreme ends,moving grain positioned assembly upwards till the closed pair of sliding split plates is placed just below the grain aligner disc assembly, placing separation discs between the layers as per requirement, checking the number of layers of grain and continuing the operation of grains alignment and placement till numbers of layers built inside the grain holder pipe are one less than the required automatically, collecting a vertically aligned single layer of grains on the pair of sliding split plates based on required numbers as per the required weight, continuing the operation of gathering and placement for the last layer of grain.

12. The method as claimed in claim 9, wherein the method comprises: moving the grain holding table from station 1 to station 3, and placing main- module locator discs onto the top of the grain holder pipe; moving the grain holding table to another station, and placing of main- module in inverted condition with polyester bag inside it on the Main Body Locator Disc, placing of weight (force) on main-module base from the top, and slowly lowering down the grain holder pipe to push the aligned grains into the main module in the available annular region till the main module top collar is separated from the Main module Locator Disc, and removing applied weight (force) from the top base of the main- module; moving the grain holding table to station 5, to lift the semi assembled unit by the required height by means of a module lifter, operating the To and fro slide to bring the locking unit around the top and bottom of the semiassembled unit, holding and lifting the semi-assembled unit by the locking unit, operating the linear slide for translation; to move the semi-assembled unit away from station 5, and simultaneously rotate the rotator by 180 degrees about its axis to make the main module on straight top condition, for taking the semi-assembled unit down to station 6; opening and placing the semi-assembled unit on to the table of station 6, by the locking unit; taking out the dummy covering disc, folding thepolyester bag, placing of actual covering disc inside, operating the pressing unit to then press the covering disc and lock it to the main module, removing of assembled unit from station 6, bringing the grain holder pipe to home position (station-2) for the next cycle for assembly of the next Charge module (CM).

13. The method as claimed in claim 9, wherein the plurality of vertical tracks are selected based on number of grains in a single layer and the required dimensions of grain positioner assembly, wherein the dimensions of tracks of the grain dispenser is optimized based on the average diameter and length of grains to be dispensed, and the required tolerance in their dimensions, wherein the vertical separation (gap) between the grain dispenser and multi perforated-disk (rotating disk) is decided based of length and diameter of the grain to be dispensed along with the speed of dispensing (r.p.m of the rotating disk), wherein the shape of grain positioner assembly is based on the required shape of arrangement of grains in a single layer, wherein the dispenser is used for vertical alignment of grains and to enable the dropping of grains into the holes of the rotating grain aligner, wherein the number of holes in the aligner assembly are varied by permanently blocking some of the holes by means of a special adaptor, based number of grains required to be dispensed in single layer.

14. The method as claimed in claim 9, wherein the forming multiple layers of grains stacked one over another comprises: dynamically controlling numbers of grains to be dispensed in every layer, based on the required weight of filled main module, stopping the dropping of grains from the corresponding tracks of dispenser during rotation to practically control the numbers of grains to be formed in a layer during the operation, by the controlled dispensing unit,controlling number of grains to be dispensed on each layer, by an Electronic Unit through tracking of angular position of the aligner disc through an encoder, and operation of the stopper on the dispenser, and controlling the final weight of the main module, by sensing the real time the weight of module being filled through a load cell and precisely controlling number of grains to be dispensed on the last layer to achieve the required target weight of the module.

Images