System and method for feeding raw materials to an automated handling system

Abstract

A system 100 for feeding one or more components to an Automated Handling System (AHS) 118 is provided. The system includes a first step feeder 102, first step feeder block 104, first step feeder lifting cylinder 106, a second step feeder lifting cylinder 110 and a pusher cylinder 116. The first step feeder block automatically transfers the one or more components linearly to a second step feeder 108 by automatically lifting the one or more components from a first step feeder 102 by performing a cylinder forward stroke using a first step feeder lifting cylinder 106 associated with the first step feeder block.The second step feeder lifting cylinder automatically transfers a component from the second step feeder to a V block 114 by performing a cylinder forward stroke.The pusher cylinder is positioned in any of a first side or a second side of the V block, transfers the component from the V block to the AHS in any of a first direction or a second direction, when a tooling of the AHS is at a component pick position. FIG. 1

Description

BACKGROUNDTechnical Field

[0001] The embodiments herein generally relatetostep feeding of raw materials to amachine tending automated system, more particularly to a system and a method for feedingcomponents to an automated handling system.Description of the Related Art

[0002] Invarious manufacturing industries, particularly those involvingmetalworking, it is essential to have efficient and automated systems for handling rawmaterials.The demand for increased productivity, reduced manual labor, and higherprecision has led to the development of advanced technologies in machine tending tohandle raw materials. Machine tending refers to the process of loading and unloadingworkpieces / raw materials to and from machines, ensuring a seamless production flow.

[0003] Traditionally, machine tending involved manual labor or basic automationsystems to feed raw materials. However, with advancements in robotics and automation,there is a need for a more versatile and adaptable system that can handle a variety of rawmaterial shapes and sizes. This challenges associated with loading raw materials,particularly those with cylindrical and regular polygon shapes, into machine tendingsystems, ensuring both efficiency and flexibility in production processes.

[0004] Existing machine tending systems often face limitations in handling diverseraw material shapes efficiently. The need for frequent changeovers and complex setupshinder the productivity of the system. Additionally, bulk loading processes are often time-consuming, leading to reduced overall productivity of the machine tending system.

[0005] The existing systems use pallets, step feeders, conveyors to transfer rawmaterials / components.The existing systems also use robot or customized system to scan forcomponent edge and pick from a custom designed pallet.

[0006] However, there remains a need for a system and a method for feedingcomponents of different shapes to an automated handling system.SUMMARY

[0007] In view of a foregoing,anembodiment herein provides a system for feedingone or more components to an Automated Handling System (AHS). The system includes aFirst Step Feederincluding an Input Chuteand a First Block, a First Step Feeder Slab, aComponent Holding Plate, a First Step Feeder Lifting Cylinder, a Second StepFeederincluding a Second Block, a Second Slab, a Component Holding Plate, one or moreStoppers, a Second Step Feeder Lifting Cylinder, a V Block and a Pusher Cylinder. Thefirst step feeder block automatically transfers the one or more components linearly to thesecond step feeder by automatically lifting the one or more components from the first stepfeeder by performing a cylinder forward stroke using the first step feeder lifting cylinderassociated with the first block.The second step feeder lifting cylinder automaticallytransfers a component from the second step feeder to the V block by performing a cylinderforward strokeusing the Second Step Feeder Lifting Cylinder associated with theSecondStep Feeder.The pusher cylinder is positioned in any of a first side or a second sideof the V block, transfers the component from the V block to the AHS in any of a firstdirection or a second direction, when a tooling of the AHS is at a component pick position.

[0008] In some embodiments, the pusher cylinder is positioned in any of a left sideor a right side of the V block to transfer the component to the AHS.

[0009] In some embodiments, the pusher cylinder is configured to transfer thecomponent in any of a left direction or a right direction to enable the AHS to pick thecomponent.

[0010] In some embodiments, the first step feeder accommodates N number ofcomponents that needs to be delivered to the second step feeder.The first step feederincluding the first step feeder slab accommodates the one or more components for liftingand transferring to the second step feeder.

[0011] In some embodiments, the second step feeder includes a stopper that avoidsoverflowing of components while transferring the one or more components from the firststep feeder to the second step feeder and avoids lifting of more than one component to theV block, and a second slab that accommodates the one or more components that arelinearly arranged for lifting a component to the V block.

[0012] In some embodiments, the first step feeder block includes a componentholding plate that blocks the one or more components resting at the first step feeder slab ofthe first step feeder.

[0013] In some embodiments, the second step feeder include fixed platespositioned on both sides of the second step feederto hold the equipment for the movableplates, and the movable plates are adjusted according to the length of the components.

[0014] In some embodiments, the V block delivers the one or more components tothe AHS, andused as a buffer station for keeping the one or more components that areflippedfrom any of first side machine operations to second side machine operations.

[0015] In some embodiments, the system includes an output gravity chute thatreceives a finished product from the AHS.

[0016] In an aspect, an embodiment herein provides a method for feeding one ormore components to the Automated Handling System (AHS).The method includes (i)automatically transferring one or more components linearly to a second step feeder byautomatically lifting the plurality of components from a first step feeder using a first stepfeeder blockby performing a cylinder forward stroke using a first step feeder liftingcylinder associated with the first step feeder block, (ii) automatically transferring acomponent from the second step feeder to a V block using a second step feeder liftingcylinderby performing a cylinder forward stroke, and (iii) transferring the component fromthe V block to the AHS using a pusher cylinderin any of a first direction or a seconddirection when a tooling of the AHS is at a component pick position.

[0017] The system and method eliminate the designing of pallets, by transferringthe one or more components using gravity and step feeding. The system and methodreduce usage of additional mechanical systems thereby reducing energy consumption. Thesystem eliminates the need for scanning the edges of the component so it directly servescomponent to the AHS thereby eliminating the scanning sequence.

[0018] These and other aspects of the embodiments herein will be betterappreciated and understood when considered in conjunction with the following descriptionand the accompanying drawings. It should be understood, however, that the followingdescriptions, while indicating preferred embodiments and numerous specific detailsthereof, are given by way of illustration and not of limitation. Many changes andmodifications may be made within the scope of the embodiments herein without departingfrom the spirit thereof, and the embodiments herein include all such modifications.BRIEF DESCRIPTION OF THE DRAWINGS

[0019] The embodiments herein will be better understood from the followingdetailed description with reference to the drawings, in which:

[0020] FIG. 1 illustrates a block diagram of a system for feeding one or morecomponents to an Automated Handling System (AHS) according to the embodimentsherein;

[0021] FIG. 2A illustrates an exemplary perspective view of the system of FIG. 1with a pusher cylinder in a first direction according to some embodiments herein ;

[0022] FIG. 2B illustrates an exemplary side view of the system of FIG. 1 with thepusher cylinder in the first direction according to some embodiments herein;

[0023] FIGS. 2C and 2D illustrate exemplary views of the system of FIG. 1 withthe pusher cylinder in a second direction according to some embodiments herein;

[0024] FIG. 3 is a flowchart that illustrates a process of feeding the one or morecomponents with first side to the Automated Handling System (AHS) using the system ofFIG. 1 according to some embodiments herein;

[0025] FIGS. 4A-4C are flowcharts that illustrate a process of feeding the one ormore components with first side and second side to the Automated Handling System (AHS)using the system of FIG. 1 according to some embodiments herein;

[0026] FIGS. 5A-5Cillustrate exemplary views of a first step feederof the system ofFIG. 2A that holds the one or more components in cylindrical shapes with differentdimensions according to some embodiments herein;

[0027] FIGS. 6A-6B illustrate exemplary views of a first step feeder of the systemof FIG. 2A that holds the one or more components in hexagon shapes with differentdimensions according to some embodiments herein;

[0028] FIGS. 7A-7Hillustrate exemplary views of the system of FIG. 1 for feedingone or more components from a first step feeder to a second step feeder andfrom the secondstep feederto a V block according to some embodiments herein;

[0029] FIGS. 8A and 8Billustrate exemplary views of a pusher cylinder thatdelivers the componentto the AHS with the pusher cylinder in a first direction according tosome embodiments herein;

[0030] FIGS. 8C and 8Dillustrate exemplary views of a pusher cylinder thatdelivers the componentto the AHS with the pusher cylinder in a second direction accordingto some embodiments herein;

[0031] FIGS. 9A-9D illustrate exemplary views of the system of FIG. 1 for andflipping of the component from a first side to a second side by AHS and feeding the one ormore components to the AHS with a pusher cylinder according to some embodimentsherein; and

[0032] FIG. 10 is a flow diagram that illustratesa method for feeding the one ormore components to the Automated Handling System (AHS) according to someembodiments herein.DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0033] The embodiments herein and the various features and advantageous detailsthereof are explained more fully with reference to the non-limiting embodiments that areillustrated in the accompanying drawings and detailed in the following description.Descriptions of well-known components and processing techniques are omitted so as to notunnecessarily obscure the embodiments herein. The examples used herein are intendedmerely to facilitate an understanding of ways in which the embodiments herein may bepracticed and to further enable those of skill in the art to practice the embodiments herein.Accordingly, the examples should not be construed as limiting the scope of theembodiments herein.

[0034] As mentioned, there remains a needfor a system and a method for feedingone or more components to an automated handling system.Referring now to the drawings,and more particularly, FIG. 1 through FIG.10, where similar reference characters denotecorresponding features consistently throughout the figures, preferred embodiments areshown.

[0035] FIG. 1 illustrates a block diagram of a system 100 for feeding one or morecomponents to an Automated Handling System (AHS) 118 according to someembodiments herein. The system 100 includes a first step feeder 102, a first step feederblock 104, a first step feeder lifting cylinder 106, a second step feeder 108, a second stepfeeder lifting cylinder 110, a second step feeder block 112, a V block 114, a pushercylinder 116, an output gravity chute 120, and the AHS 118. The first step feeder 102receives one or more components in a bulk quantity loaded by an Operator. The one ormore components may be a solid or a hollow raw material. In some embodiments, a shapeof the one or more components can be any of a cylindrical shape, a polygonal shape, ahexagonal shape, or a square shape. In some embodiments, the shape of the one or morecomponents can be in any of a regular shape or an irregular shape. In some embodiments,the first step feeder 102 can be a gravity chute to store the one or more components.

[0036] The first step feeder block 104 is used to lift and transfer the one or morecomponents from the first step feeder 102 to the second step feeder 108. In someembodiments, the first step feeder lifting cylinder 106 transfers the one or morecomponents placed over the first step feeder block 104. The one or more components areenabled by the first step feeder lifting cylinder 106 with a forward or downwardstroke.When in operation, the first step feeder block 104 automatically transfers the one or morecomponents linearly to the second step feeder 108 by automatically lifting the one or morecomponents from the first step feeder 102 by performing a forward stroke using the firststep feeder lifting cylinder 106 associated with the first step feeder block 104. The firststep feeder lifting cylinder 106 may perform any of a forward stroke or a downwardstroke. In some embodiments, the first step feeder block 102 transfers the one or morecomponents to the second step feeder 108 with the forward stroke of the first step feederlifting cylinder 106. Due to an angle of repose in the first step feeder 102,theone or morecomponents at the rear position moves to the front position of the first step feeder 102when the first step feeder lifting cylinder106 reverses during the downward stroke. Insome embodiments, the second step feeder 108 enables the second step feeder block 112to place at least one component.

[0037] The second step feeder lifting cylinder 110 automatically transfers the atleast one component from the second step feeder block 112 to the V block 114 byperforming a forward stroke. Each forward stroke of the second step feeder 108 enablesthe second step feeder 108 to provide one component to the V block 114. The V block114is configured to hold the component for pick and place operations by the AHS 118.The pusher cylinder 116 is positioned in any of a first side or a second side of the V block114, transfers the component from the V block 114 to the AHS 118 in any of a firstdirection or a second direction, when a tooling of the AHS 118 is at a component pickposition. The pusher cylinder 116 is positioned in any of a left side or a right side of the Vblock 114 to transfer the component to the AHS 118. In some embodiments, the pushercylinder 116 is configured to transfer the component in any of a left direction or a rightdirection to enable the AHS 118 to pick the component. The system 100 checks whethertooling of the AHS 118 at a position to pick the component. In some embodiments, theAHS 118 picks the component and delivers it to a machine that performs a first machiningoperation on a first side of the component and a second machining operation on a secondside of the component. The output gravity chute 120is configured to hold or transfer oneor more finished productsplaced by the AHS 118.

[0038] FIG. 2A illustrates an exemplary perspective view of the system 100 ofFIG. 1 with the pusher cylinder 116 in a first direction according to some embodimentsherein. The system 100 includes the first step feeder 102, the first step feeder block 104,the first step feeder lifting cylinder 106, the second step feeder 108, the second step feederlifting cylinder 110, the V block 114, the pusher cylinder 116, and the output gravity chute120. The first step feeder 102 receives the one or more components in bulk quantityloaded by an operator. The first step feeder 102 accommodates N number of componentsthat needs to be delivered to the second step feeder 108. In some embodiments, theforward stroke of the first step feeder lifting cylinder 106 is 200 millimeters (mm) and thesecond step feeder lifting cylinder 110 is about 50 millimeters (mm),whichboth may varybased on the requirement.

[0039] In some embodiments, the system 100 includes one or more mechanicalstoppers that adjusts the delivery length of the pusher cylinder 116 from the V block 114tothe AHS 118 based on specific requirements.While using other equipment is like linearactuator(s), servo motor with ball screw or other required accessories available in themarket, instead of pusher cylinder 116 with the one or more mechanical stopper(s), thelength of delivery can be achieved without the one or more mechanical stoppers. In someembodiments, the number of components loaded to the input gravity chute / first step feeder102 at a time is 115 to 457. In another embodiment, the number of components loaded tothe input gravity chute / first step feeder 102 at a time is 74 to 372. In some embodiments,the first step feeder 102 provides 01 (one) to 11 (eleven) components to the second stepfeeder 108 during each cylinder forward stroke of the first step feeder lifting cylinder 106.The numbers components can vary based on design and is not restricted to the abovementioned quantities.

[0040] In some embodiments, after completing the first machining operation, theAHS 118 picks the component from the first machine, the AHS 118 turns the tooling andplaces the component with the second side on the V block 114. The pusher cylinder 116delivers the component with the second side to the AHS 118 for further machiningoperations. In some embodiments, the AHS 118 may be a Single Axis or Multi AxesGantry (or Gantries), or Robot(s).In some embodiments, the components may be a solid ora hollow raw material with cylindrical or regular polygonal shapes.

[0041] In a working example,with concept of Angle of Repose μs = tanΦs, Coefficient of Static Friction for Metal on Metal (μs) is about 0.15 to 0.6 which results Φs =8.5° to 30°. Hence, at an angle greater than or equal to 30°,steel components may slide onits own weight.Thus, the system 100 is designed for 30° inclination and surface may beoiled to make the components slide easily.

[0042] In some embodiments, the system 100 further includes fixed plates on boththe sides of the second step feeder 108 to hold the equipments for the movable plates. Insome embodiments, the system 100 further includes movable plates to adjust a length ofthe component. In some embodiments, the system 100 includes a box for mountingsolenoid valves and wiring accessories.

[0043] The system 100 transfers the one or more components using gravity andstep feeding. Hence the system 100 reduces the usage of additional mechanical systemsthereby reducing energy consumption. The system 100 does not scan for edges and candirectly serve to component to the AHS 118 thereby eliminating the scanning sequenceand its time by the robot or customized system.The system 100 can accommodate differentshapes of the one or more components (e.g., cylindrical, and hexagonal or any regularpolygonwith different dimensions).

[0044] The system 100 feeds the one or more components in two stepsto reducethe manual intervention during Automatic Material Handling Work Cell Operation,whichincreases the throughput of the system and eliminates use of Geared Motor systemsavailable in the market. The V block 114of the system 100 is used for both delivering theone or more components to the AHS 118 andused as a buffer station for keeping the oneor more components that are flipped from any of first side machine operations to secondside machine operations.

[0045] FIG. 2B illustrates an exemplary side view of the system 100 of FIG. 1with the pusher cylinder 116 in the first direction according to some embodimentsherein.The system 100 includes an input gravity chute / first step feeder 102, a second stepfeeder 108, a V block 114, the first step feeder lifting cylinder106 and the output gravitychute 120.The functionalities of the above components are described in FIG. 2A. Thesystem 100 further includes a component holding plate 204, and a First Step Feeder Slab206.The first step feeder block 104 is used to lift and transfer component from the firststep feeder 102 to the second step feeder 108 during the forward stroke of the First StepFeeder Lifting Cylinder 106. The component holding plate 204 is used to block thecomponents resting at the back of the block so that the first step feeder lifting cylinder106may not get stuck during thereverse stroke. The First Step Feeder Slab 206 is used to holdthe component in such a manner that only one column of components is present at theblock during lifting.Thefirst step feeder lifting cylinder106 is used to deliver componentfrom the first step feeder 102 to the second step feeder108.The component holding plate204 holds the one or more components which are adjacent to the components that aredelivered to the second step feeder 108.The component holding plate 204 avoids blockingof first step feeder lifting cylinder106 during each cylinder return stroke. The First StepFeeder Slab 206 is attached to the input gravity chute / first step feeder102 that is used tohold the component in such a manner that only one column of components is present at theblock during lifting.

[0046] FIGS. 2C and 2D illustrate exemplary views of the system 100 of FIG. 1with the pusher cylinder 116 in a second direction according to some embodiments herein.The functions and explanations of the system 100 are explained above.

[0047] FIG. 3 is a flowchart that illustrates a process of feeding the one or morecomponents with first side to the Automated Handling System (AHS) 118 using thesystem 100 of FIG. 1 according to some embodiments herein. At a step 302, the first stepfeeder 102 of the system 100 receives the one or more components in bulk quantity loadedby an Operator. At a step 304, the system 100 checks whether the first step feeder 102 isempty or not. If the first step feeder 102 is empty, it goes to the step 302. At a step 306, ifthe first step feeder 102 is not empty, the first step feeder 102 provides one or morecomponents to a second step feeder 108 of the system 100 during the forward stroke of theFirst Step Feeder Lifting Cylinder 106. Due to the property of angle of repose, the one ormore components automatically align themselves at the top of the first step feeder block104 while the first step feeder lifting cylinder 106 comes down during the return / reversestroke.At a step 308, the second step feeder 108 provides one component to a V block114of the system 100 during the Second Step Feeder Lifting Cylinder 110forward strokeof the second step feeder 108. The V block 114is configured to hold the component ofboth cylindrical or any regular polygon,for pick and place operations by the AutomatedHandling System (AHS) 118. At a step 310,the system 100 checks whether tooling of theAHS 118 isat a position to pick the component or not. If the tooling of the AHS 118 is notin the pick position of the component,it goes to the step 310. At a step 312,if the tooling ofthe AHS 118 is in the pick position of the component,apusher cylinder 116 of the system100 delivers the componentwith first side to the AHS 118.The pusher cylinder 116 iscommunicatively connected to the AHS 118. At a step 314, the system 100 checkswhether the V block 114is empty or not. If the V block 114is not empty, repeat the step310. At a step 316,if the V block 114is empty, the system 100 checks whether thesecondstep feeder 108 is empty or not. If the second step feeder 108 is not empty, it goes to thestep 308. If the second step feeder 108 is empty, it goes to the step 304.

[0048] In some embodiments, the AHS 118 picks the component and delivers it toa machine that performs machining operation(s) on the first side of the component. Insome embodiments, the AHS 118 places a finished product in an output gravity chute 120of the system.

[0049] FIGS. 4A-4C are flowcharts that illustrate a process of feeding the one ormore componentswith first side and second side to the Automated Handling System(AHS) 118 using the system 100 of FIG. 1 according to some embodiments herein.At astep 402, an input gravity chute / first step feeder 102 of the system 100 receives one ormore components in bulk quantity loaded by an Operator. At a step 404, the system 100checks whether the first step feeder 102 is empty or not. If the first step feeder 102 isempty, it goes to the step 402. At a step 406, if the first step feeder 102 is not empty, thefirst step feeder 102 provides one or more components to a second step feeder 108 of thesystem 100 during the forward stroke of the First Step Feeder Lifting Cylinder 106. Due tothe property of angle of repose the components automatically align themselves at the topof the block 202 while the cylinder comes down during the return / reverse stroke. At a step408,the second step feeder 108 provides one componentto a V block 114of the system 100during the forward stroke of the Second Step Feeder Cylinder110. The V block 114isconfigured to hold the componentof both cylindrical and regular polygon shapes for pickand place operations by the AHS 118. At a step 410,the system 100 checks whethertooling of the AHS 118 at a position to pick the componentwith first side or not. At a step412, if the tooling of the AHS 118 is not in the pick position of the componentwith firstside,the system 100 checks whether the componentin the V block 114is available for afirst machining operation, and to be picked byAHS 118.If the componentin the V block114is available for the first machining operation of the AHS 118, repeat the step 410. Ifthe componentin the V block 114is not available for the first machining operation of theAHS 118, it goes to a step 418. At a step 414, if the tooling of the AHS 118 is in the pickposition of the componentwith first side,apusher cylinder 116 of the system 100 deliversthe componentwith first side to the AHS 118. The pusher cylinder 116 is communicativelyconnected to the AHS 118.The AHS 118 picks the component and delivers it to a machinethat perform themachining operation(s) on the first side of the component.

[0050] At a step 416,after completing the machining operation on the first side, theAHS 118 turns the tooling and places the componentwith second side on the V block 114and goes to a step 420. At the step 418,if the componentin the V block 114is not availablefor the first machining operation of the AHS 118, the system 100 checks whether thecomponentin the V block 114is available for a second machining operation of the AHS118. If the componentin the V block 114is not available for the second machiningoperation, the system 100 alerts the operator about an error occurrence. At the step 420, ifthe componentin the V block 114is available for the second machining operation, the AHS118 turns the tooling at a position to pick the componentwith second side.At a step 422,thesystem 100 checks whether the tooling of the AHS 118 at the position to pick thecomponentwith second side or not. If the tooling of the AHS 118 is not in the pick positionof components with second side, repeat the step 420. At a step 424, if the tooling of theAHS 118 is in the pick position of components with second side, the pusher cylinder 116delivers the componentwith second side to the AHS 118.

[0051] At a step 426, the system 100 checks whether the V block 114is empty ornot. At a step 428, if the V block 114is not empty, the system 100 checks whether thecomponentin the V block 114is available for the second machining operation of the AHS118. If the V block 114is empty, it goes to a step 432.If the componentin the V block114is available for the second machining operation of the AHS 118, it goes to a step 420.At a step 430,if the componentin the V block 114is not available for the second machiningoperation of the AHS 118, the system 100 checks whether the componentin the V block114is available for the first machining operation of the AHS 118. If the componentin the Vblock 114is not available for the first machining operation of the AHS 118, the system 100alerts the operator about the error occurrence. If the componentin the V block 114isavailable for the first machining operation of the AHS 118, it goes to the step 410. At astep 432, the system 100 checks whether the second step feeder 108 is empty or not. If thesecond step feeder 108 is not empty, it goes to the step 408. If the second step feeder 108is empty, it goes to the step 404.

[0052] FIGS. 5A-5C illustrate exemplary views of the first step feeder102 of thesystem 100 of FIG. 2A that holds the one or more componentsin cylindrical shapes withdifferent dimensions according to some embodiments herein. FIG. 5A shows the inputgravity chute / first step feeder 102 that holds up to 78 numbers of components withΦ32millimeter (mm)shafts (i.e., the raw material) in cylindrical / circle shape. FIG. 5Bshows the input gravity chute / first step feeder 102 that holds 362 numbers of componentswith Φ16mm shafts in cylindrical / circle shape. FIG. 5C shows the input gravity chute / firststep feeder 102 that holds up to 306 numbers of components withΦ17.2mm shaftsincylindrical / circle shape.

[0053] FIGS. 6A-6B illustrate exemplary views of the first step feeder102 of thesystem 100 of FIG. 2A that holds the one or more components in hexagon shapes withdifferent dimensions according to some embodiments herein. FIG. 6A shows the inputgravity chute / first step feeder 102 that holds 146 numbers of components with across flat24mm hex nuts (i.e., the raw material) in hexagon shape. FIG. 6B shows the input gravitychute / first step feeder 102 that holds 107numbers of components with across flat 27mmhex nuts in hexagon shape.

[0054] FIGS. 7A-7H illustrate exemplary views of a system 100 of FIG. 1 forfeeding the one or more components from the First Step Feeder 102 to the Second StepFeeder 108, and from the Second Step Feeder 108 to the V block 114 according to someembodiments herein.The system 100 includes an input gravity chute / first step feeder 102,a second step feeder 108, a V block 114, a pusher cylinder 116and an output gravity chute120. The input gravity chute / first step feeder 102 holds the one or more components inbulk quantity loaded by an Operator as shown in FIGS. 7A-7C show the first step feeder102 that provides one or more componentsto the second step feeder 108 in each forwardstroke of theFirst Step Feeder Lifting Cylinder 106.The first step feeder block 104 isattached to the first step feeder Lifting Cylinder 106 to transfer the componentsto thesecond step feeder 108. The component holding plate 204 holds the components which areadjacent components that are delivered to the second step feeder 108. The componentholding plate 204 avoids blocking of the first step feeder lifting cylinder 106during eachcylinder return stroke. The First Step Feeder Slab 206 is attached to the input gravitychute / first step feeder block 104 to hold the component in such a manner that only onecolumn of components is present at the block during lifting.

[0055] FIGS. 7D and 7Eshow the second step feeder 108 that provides onecomponentto the V block 114each Second Step Feeder Lifting cylinder 110 forward strokeof the second step feeder 108 enables. The second step feeder 108 further includes astopper 702, a second slab 704 and a second step feeder lifting cylinder 110. The stopper702 is used to avoid overflowing of component one over the other while transferring fromthe first step feeder 102 to the second step feeder 108 and used to avoid lifting of twocomponents to the V block 114. The second slab 704 is attached to the second step feeder108 that is used to hold the component in such a manner that only one component ispresent at the block during lifting.The second step feeder lifting cylinder 110 is used to liftone component from the second step feeder 108 and deliver it to the V block 114. The Vblock 114is configured to hold the componentsfor different shapes (e.g., cylindrical, andhexagonal) for pick and place operations for the Automated Handling System (AHS) 118.The system 100 checks whether tooling of the AHS 118 at a position to pick thecomponent. The pusher cylinder 116 is communicatively connected to the AHS 118.

[0056] FIG. 7F shows the component delivered to the V block 114 from thesecond step feeder block 112. FIG. 7G shows the second step feeder lifting cylinder110returning to the original position with a backward stroke, and the next component willbe placed over the second step feeder block 112 due to gravity. In some embodiments, theV block 114 can be in a shape rangingfrom, but not limited to90 degrees to 120 degrees.The shape of the V block 114 may be modified based on the shape of the component.Components in cylindrical shape may be adaptable to the V block 114 in any shaperanging from 90 degrees to 120 degrees.FIG. 7H shows the component of hexagonal shapein the V block 114 that is delivered from the second step feeder block 112 by the secondstep feeder lifting cylinder 110. Components in hexagonal shape may be adaptable to theV block 114 in a shape with 120 degrees.

[0057] FIGS. 8A and 8Billustrate exemplary views of the pusher cylinder 116thatdelivers the componentto the AHS 118 with the pusher cylinder 116in the first directionaccording to some embodiments herein. In some embodiments, the pusher cylinder116delivers the componentto the AHS 118 on one or more sides (i.e., a first side or asecond side). In some embodiments, the pusher cylinder 116 delivers the first side of thecomponentto the AHS 118. In some embodiments, the AHS 118 picks the component anddelivers it to a machine thatperforms a first machining operation on the first side of thecomponentand a second machining operation on the second side of the component. insome embodiments, the output gravity chute 120 holds and transfers a finished product(s)placedby the AHS 118.

[0058] FIGS. 8C and 8Dillustrate exemplary views of the pusher cylinder 116 thatdelivers the componentto the AHS 118 with the pusher cylinder 116 in the seconddirection according to some embodiments herein. The functions and explanations areexplained above.

[0059] The delivery of the Component by the Pusher Cylinder 116 to the AHS 118provides a specified delivery length 802 of the Component,which is same and repeatableirrespective of the length of the component from the previous operationssuch as Cutting,Sawing, Machining, and the like.In some embodiments, the specified delivery length 802is a specified distance of rod. The delivery of the component with the specified deliverylength 802 enables the AHS 118 to place the component in the machine with positionrepeatability irrespective of the component length.

[0060] FIGS. 9A-9D illustrate exemplary views of the system 100 of FIG. 1 forfeeding the componenttothe Automated Handling System (AHS) 118 with the pushercylinder 116 and flipping of the component from the first side to the second side accordingto some embodiments herein. FIG. 9A shows the AHS 118 that picks the component froma machine that performs a first operation, flips and and delivers it to the V block 114.After taking the finished component from the first machine (first side is shown ascheckered side of the round component in FIG. 9A), the AHS 118 turns the tooling 910and picksthe componentwith second side (second side is shown as uncheckered side of theround component in FIG. 9B)fromthe V block 114for the second machining operation ofthe AHS 118. FIGS. 9Band 9C show the AHS 118 that turns the tooling 910 at a positionto pick the componentwith second side for the second machining operation of the AHS118. FIG. 9D shows the pusher cylinder 116that delivers the componentwith second sideto the AHS 118.

[0061] FIG. 10 is a flow diagram that illustrates a method for feeding one or morecomponents to the Automated Handling System (AHS) 118 according to someembodiments herein.At a step 1002, the one or more components are automaticallytransferred to the second step feeder 108 linearly using a first step feeder block 104, byautomatically lifting the one or more components from the first step feeder by performinga forward stroke using the first step feeder lifting cylinder 106 associated with the firststep feeder block 104. At a step 1004, the component from the second step feeder 108 isautomatically transferred to the V block 114 using a second step feeder lifting cylinder110 by performing a forward stroke.At a step 1006, the component from the V block 114istransferred to the AHS 118 in any of a first direction or a second direction when a toolingof the AHS 118 is at a component pick position using the pusher cylinder 116.

[0062] The foregoing description of the specific embodiments will so fully revealthe general nature of the embodiments herein that others can, by applying currentknowledge, readily modify and / or adapt for various applications such specificembodiments without departing from the generic concept, and, therefore, such adaptationsand modifications should and are intended to be comprehended within the meaning andrange of equivalents of the disclosed embodiments. It is to be understood that thephraseology or terminology employed herein is for the purpose of description and not oflimitation.Therefore, while the embodiments herein have been described in terms ofpreferred embodiments, those skilled in the art will recognize that the embodiments hereincan be practiced with modification within the scope of the appended claims.

Claims

1. A system (100) for feeding plurality of components to an Automated Handling System (AHS) (118), wherein the system (100) comprises: characterized in that, a first step feeder block (104) that automatically transfers the plurality of components linearly to a second step feeder (108) by automatically lifting the plurality of components from a first step feeder (102) by performing a forward stroke using a first step feeder lifting cylinder (106) associated with the first step feeder block (104); a second step feeder lifting cylinder (110) that automatically transfers a component from the second step feeder (108) to a V block (114) by performing a forward stroke; and a pusher cylinder (116) that is positioned in any of a first side or a second side of the V block (114), transfers the component from the V block (114) to the AHS (118)in any of a first direction or a second direction, when a tooling of the AHS (118) is at a component pick position.

2. The system (100) as claimed in claim 1, wherein the pusher cylinder (116) is positioned in any of a left side or a right side of the V block (114) to transfer the component to the AHS (118).

3. The system (100) as claimed in claim 1, wherein the pusher cylinder (116) is configured to transfer the component in any of a left direction or a right direction to enable the AHS (118) to pick the component.

4. The system (100) as claimed in claim 1, wherein the pusher cylinder (116)delivers the component to the AHS (118)with a specified delivery length (802)of the component that is same and repeatable irrespective of the length of the component from previous operations.

5. The system (100) as claimed in claim 1, wherein the first step feeder (102) accommodates N number of components that needs to be delivered to the second step feeder (108), wherein first step feeder (102) comprises a first step feeder slab (206) that accommodates the plurality of components for lifting and transferring to the second step feeder (108).

6. The system (100) as claimed in claim 1, wherein the second step feeder (108) comprises a stopper (702) that avoids overflowing of components while transferring the plurality of components from the first step feeder (102) to the second step feeder (108) and avoids lifting of more than one component to the V block (114), and a second slab (704) that accommodates the plurality of components that are linearly arranged for lifting a component to the V block (114).

7. The system (100) as claimed in claim 1, wherein the first step feeder block (104) comprises a component holding plate (204) that blocks the plurality of components resting at the first step feeder slab (206) of the first step feeder (102).

8. The system (100) as claimed in claim 1, wherein the second step feeder (108) comprise fixed plates that placed on both the sides of the second step feeder (108) to provide the component to the V block (114), and movable plates that adjust the length of the components.

9. The system (100) as claimed in claim 1, wherein the V block (114) delivers the plurality of components to the AHS (118), and used as a buffer station for keeping the one or more components that are flipped from any of first side machine operations to the second side machine operations.

10. A method for feeding plurality of components to the Automated Handling System (AHS) (118), wherein the method comprises: automatically transferring, using a first step feeder block (104), a plurality of components linearly to a second step feeder (108) by automatically lifting the plurality of components from a first step feeder (102) by performing a forward stroke using a first step feeder lifting cylinder (106) associated with the first step feeder block (104); automatically transferring, using a second step feeder lifting cylinder (110), a component from the second step feeder (108) to a V block (114) by performing a forward stroke; transferring, using a pusher cylinder (116), the component from the V block (114) to the AHS (118) in any of a first direction or a second direction when a tooling of the AHS (118) is at a component pick position.