Singularizing and Orienting Objects for Delivery

Abstract

To provide a system for singulation, sorting, and orientation of an object, and for placing a selected object into an ordered array.SOLUTION: An object 52 in a flow through a duct 51 makes a singulation and an orientation by being rotated at least somewhat so that all the orientations are aligned. In one arrangement, a slot 58 is provided in a singulation duct 51, a trunk part drops thereto and a head remains in the singulation duct 51. In another arrangement, a buffer device and a conveyance member 66 for conveying an oriented object from the buffer device to an operation position are provided. In another arrangement, a first path changes the orientation with respect to a second path. The object 52 is fed from the singulation duct 51 into a feed duct having an outlet opening which is on a rotating shaft of the singulation duct 51.SELECTED DRAWING: Figure 1A

Description

[Technical Field]

[0001] The present invention is a system for singulating, sorting, and orienting objects and placing selected objects into an ordered array. The present invention is primarily directed to singulating and orienting objects for automated assembly. In an exemplary application, the objects may be fasteners, such as screws fed into an automated screwdriver. Other types of objects may also be used. [Background technology]

[0002] Automated fastening machines are widely used in manufacturing to assemble products. Several methods are used in the prior art to singulate and orient fasteners before transporting them to a machine that installs them on the parts being assembled. Bowl feeders operate by vibrating a spiral ramp. The vibration energizes a random collection of fasteners in a central storage location, causing the fasteners to change orientation. The vibration frequency is typically between 60 Hz and 400 Hz and is tuned to resonate with the fasteners to singulate them. Fasteners with a preferred orientation (those with their long axes substantially aligned with the local tilt axis) are propelled along the spiral ramp, while those with unpreferred orientations fall back into the central storage location. In another variation, a group of fasteners is fed onto a vibrating ramp with a step feeder. In another variation, the fasteners are fed onto an intermittently vibrating plate with an orientation feature. After a period of vibration, the fastener orientation is detected by machine vision, and the preferred-orientation fasteners are extracted by an automated picker. These devices produce significant acoustic noise that must be attenuated. The prior art methods described above can deliver 2-3 parts per second. A primary object of the present invention is to increase the number of parts per second that can be delivered to an automated fastener device to increase production speed. Another object of the present invention is to reduce the size of the singulation device. Another object of the present invention is to reduce the cost of the singulation device. Another object of the present invention is to reduce the noise of the singulation device. Summary of the Invention

[0003] The present invention is a system for singulating, sorting, and orienting objects and placing selected objects in an ordered array. In the context of the present invention, the term object refers to any item requiring orientation relative to a substrate or another object. An object referred to as "antiparallel" to another object means that the antiparallel object is oriented 180 degrees relative to the reference object. The term ordered array implies that there is a constant average displacement between the centers of mass of the objects in the array. The orientation of an object can be specified by a set of orientation vectors related to at least one spatially varying property of the object. For convenience, the center of mass of the object will be interpreted as the origin of the orientation vectors in the following discussion. Different properties may have different sets of associated orientation vectors. Orientation is often specified by the shape of the object, but it may also be specified by internal properties of the object that are unrelated to shape, such as material properties or changes in the wiring of an electrical circuit. The term orientation herein generally refers to a set of one or more selected orientation vectors. The selected set may include orientation vectors related to different object properties. For example, one orientation vector may specify the direction of a surface normal, and another orientation vector may specify the direction from the center of gravity to an electrical contact. The term orientation axis is used interchangeably with the term orientation vector herein. In one important set of embodiments, the orientation vector corresponds to the longitudinal axis of the object. The term longitudinal axis is used throughout for descriptive purposes and is not intended to limit the invention to orientation along the longitudinal axis alone. Within the spirit and intent of the present invention, the term longitudinal axis has the same meaning as the selected orientation axis. An object could be, for example, a molded plastic base that is bonded to a circuit on a silicon substrate. An object could be a fastener, such as a screw or rivet, used to join two or more parts of a manufactured item together. An object could be a tulip bulb that requires orientation prior to placement in a soil substrate.

[0004] According to a first aspect of the present invention, there is provided a method for supplying objects in a stream from a bulk supply of objects, each object having an orientation axis and the objects being shaped to have first and second different orientations about the orientation axis, the method comprising: supplying the bulk supply of objects; conveying the objects from the supply into a singulation duct; forming the objects into a stream of objects to be singulated one after the other by passing the objects along the singulation duct and rotating the singulation duct about an axis of rotation such that centrifugal force generated by the rotation drives the objects along the singulation duct and acts to press the objects against a wall of the singulation duct so that the objects slide along the wall; and orienting the objects in the stream by nesting the objects in the stream and rotating at least some of the objects so that all of the objects in the stream have aligned orientations.

[0005] The axis of orientation is typically the longitudinal direction of the body involved, although this is not necessarily the case as objects of other shapes may be oriented by the methods herein.

[0006] Preferably, the method includes the step of rotating the longitudinal axes of at least some of the objects about the horizontal axis so that, after orientation, all objects at a position in the stream have longitudinal axes and their orientations aligned.

[0007] That is, beyond simply aligning the object along an axis of orientation along which orientation occurs during movement along the duct, another component is additionally provided that acts on the aligned object to rotate the axis of orientation. In this way, an object such as a screw or other fastener can be positioned with the head forward, or the head backward, or the axis of the screw transverse to the direction of flow movement.

[0008] In accordance with another important aspect of the present invention, an object buffer apparatus and transport member are provided for transporting singulated and oriented objects from the object buffer apparatus to a manipulation tool.

[0009] According to another aspect of the invention, it is provided that an action on an oriented object is performed on each object at the same orientation.

[0010] Where definitions herein refer to channels or ducts, the rotating body may include as few as one singulated duct, or may involve multiple ducts operating on the same object to increase productivity, or multiple ducts operating on different types of objects, such as different size fasteners.

[0011] According to another aspect of the present invention, there is provided a sensor for detecting an orientation of an object in a stream, wherein the object is directed to first and second paths in response to detecting the first and second orientations, and wherein the first path is arranged to change the orientation of an object therein relative to the second path such that the object is combined with a common stream from the first and second paths that is of the same orientation.

[0012] In one example, a first path is arranged to feed objects into the common stream in a first direction, and a second path is arranged to feed objects into the common stream in a second direction opposite the first direction, which inverts the orientation of objects in the second path relative to the first path, ensuring that all objects in the common stream have the same orientation.

[0013] In another example, the second path includes a component for reversing the orientation of an object thereon. This can be a twist for reversing the orientation of an object thereon. This can be a movable component operable to bring an object thereon into a reverse orientation for reversing the orientation of the object thereon.

[0014] In one arrangement, the orienting of the object is performed while the object is in the singulation duct.

[0015] That is, orientation may be achieved by an abutment structure that engages the object while in the singulation duct and acts to rotate the object, or its axis of orientation, about a lateral axis.

[0016] In one example, the orientation acts to rotate the object so that all longitudinal axes are transverse to the direction of movement along the singulation duct. This is particularly effective for fasteners, where fasteners are fed into a magazine or buffer moving toward a tool such as a screwdriver with the screw axis transverse to the direction of movement.

[0017] In one example, the object has a head and a body, with its longitudinal axis longitudinal to the body. However, the arrangements described herein can be used with other shapes of objects and other structures that require a particular orientation. Preferably, the screw or fastener is positioned so that the head and body are aligned perpendicular to the direction of movement. However, orientations may also be used to provide the fastener with the tip at one end and the head at the other end along the direction of movement.

[0018] For example, orientation may be achieved by providing a slot in the singulation duct into which the body fits, while the head remains threaded through the singulation duct. In this way, the slot acts to orient the object so that its longitudinal axis is transverse to the singulation duct.

[0019] In another arrangement, the orientation is located beyond the end of the singulation duct so that the duct affects only singulation, and the orientation is performed while the object remains in the singulation flow but downstream of the duct.

[0020] In one example, the objects are oriented by capture as they are released from the singulation duct into the directing member.

[0021] In another example, a sensor is provided to sense the orientation of an object in the stream, and the object is manipulated to change its orientation in response to the sensed orientation.

[0022] This can be done in another example where the objects are directed onto the first and second paths in response to sensing the first and second orientations, preferably with the first path being arranged to change the orientation of the objects thereon relative to the second path so that the objects are combined with a common flow from the first and second paths that is of the same orientation.

[0023] In one particular end use of the singulation and orientation system described above, objects are transported from the singulation duct to a buffer container where they are stopped to form a supply of objects. This is particularly necessary when the objects are to be fed as a supply to a manipulation tool. In one example of an apparatus operating in this manner, the buffer container rotates with the singulation duct and is then stopped to download the objects. That is, the buffer collects the objects while both the buffer and the singulation duct rotate, and then the buffer is stopped during the download operation. In this example, at least two buffer containers are preferably provided, one of which is stopped while the other is being loaded from the singulation duct.

[0024] Where the objects are supplied to the tool for use one after the other, in one example the objects are supplied directly to the tool from a buffer container. However, in another arrangement the objects are not supplied directly but instead are inserted into an elongate storage member or magazine which forms the supply to the tool. This may for example be a strip of material such as paper onto which the objects are carried in single file, or a strip of material such as plastic within which the objects are carried in single file end to end.

[0025] In addition to orientation, in another example, sensors are provided to sense properties of objects in a stream, some of which may be discarded or replaced depending on the sensed properties. For example, the system may be used to assess the quality or viability of objects, such as screws, and discard unsuitable ones from use. However, many other uses of sensing and measurement systems may be used in many other ways.

[0026] If objects such as screws have a tendency to interlock, a supply duct is preferably provided to transport the objects from the bulk supply to the singulation duct, where the supply duct is urged to ensure that the objects enter the singulation duct.

[0027] In another configuration, objects are fed from a singulation duct to a supply duct that rotates with the singulation duct and carries the objects as they are singulated and oriented relative to an exit opening that is on the axis of rotation of the singulation duct. In this way, the objects emerge from the opening in the same orientation as they were in the flow. This is particularly useful for feeding singulated, oriented, axially moving objects to the axis of an insertion tool.

[0028] In some cases, a measurement device that senses one or more parameters of an object may simply detect the presence of the object, and in other cases, the presence and one or more characteristics of the sensed object may be obtained.

[0029] According to an important optional feature of the present invention, which may be used independently of any of the above or below features, there is provided an object measurement device for sensing at least one parameter of a singulated object.

[0030] According to an important optional feature of the present invention, which may be used independently of any of the above or below features, a control system is provided for recording measurements of an object over time.

[0031] In accordance with an important optional feature of the present invention, which may be used independently of any of the above or below features, a control system is provided for recording measurements of objects relative to their positions in the object buffer device.

[0032] In accordance with an important optional feature of the present invention, which may be used independently of any of the above or below features, a diversion device is provided for diverting selected objects from the object buffer device in response to sensing at least one parameter of the singulated object.

[0033] In accordance with an important optional feature of the present invention, which may be used independently of any of the above or below features, the singulation rate is greater than the minimum required rate so that a replacement object is available if the original tested object does not meet the conditions for progression to the transport device and is discarded.

[0034] According to an important optional feature of the invention, which may be used independently of any of the above or below features, the storage container includes at least first and second separate containers containing respective objects having first and second quality parameters, and a control device is used to select the containers.

[0035] According to an important optional feature of the invention, which may be used independently of any of the above or below features, a transport device carries the objects from the outlet of the duct to a final use location provided with a receptacle for the objects.

[0036] According to an important optional feature of the present invention, which may be used independently of any of the above or below features, the transport apparatus is arranged so that the angular velocity of an object exiting the transport apparatus is approximately zero.

[0037] According to an important optional feature of the invention, which may be used independently of any of the above or below features, the transport device includes a funnel and a slot operable by an actuator to move between a catch position and a release position. In some cases, this arrangement may be provided with a sensor for detecting the pressure and / or velocity of the object. Another important feature is that a sensor may be provided to detect whether and when an object actually reaches the object buffer device, so as to ensure the accuracy of the object delivery operation and to stop the operation in the event of a blockage or inconsistent operation.

[0038] According to an important feature of the present invention, which may be used independently of any of the above or below features, packaging means is provided for containing the singulated and oriented objects.

[0039] According to an important optional feature of the invention, which may be used independently of any of the above or below features, the object supply system includes a system for supplying a surface coating, such as a lubricant or adhesive, to each or some of the objects.

[0040] According to an important optional feature of the invention, which may be used independently of any of the above or below features, there is provided a rotor mounted for rotation about an axis, the rotor defining at least one duct extending outwardly from an inner end adjacent the axis to an outer end spaced a greater radial distance from the axis than the inner end, wherein a quantity of objects are supplied at the inner end of the at least one duct, the inner end being arranged side-by-side adjacent the axis such that a supply conduit acts to deposit objects at the inner end of the at least one duct for entry into the interior slow end of the objects and for separation of the flow of objects within the conduit into another of the at least one duct, the at least one duct being shaped and arranged such that the objects are accelerated as they pass from the inner end to the outer end such that they are separated into the at least one duct and align successively one after the other within the duct as they move towards the outer end.

[0041] According to another important feature of the invention, which may be used independently of any of the above or below features, agitation means are provided for agitating objects fed from the supply conduit so that the objects flow without settling. The agitation means may be present in the supply conduit, on the rotor, or both. The agitation means may be, for example, a vibrator. The agitation means may be, for example, a series of paddles that are rotated relative to the supply conduit or the rotor. The agitation means may be protrusions on the inner wall of the supply conduit.

[0042] According to another important feature of the present invention, which may be used independently of any of the above or below features, a plurality of supply conduits are provided for carrying different types of objects to a rotating body, wherein each supply conduit supplies one or more sets of ducts different from the sets of one or more ducts supplied by any other supply conduit. The inner ends of each set of ducts are preferably axially displaced relative to any other sets of ducts. The apparatus can be used to supply different types of objects to further processes in the required ratios, for example, by adjusting the number of ducts dedicated to each type and the passage speed in the supply conduits for each type of object.

[0043] According to another important feature of the present invention, which may be used independently of any of the above or below features, there is provided a computing means for receiving information about at least one parameter of a rotating body and associated supply conduits, ducts, detectors, diverters and other object buffers.

[0044] According to another important feature of the present invention, which may be used independently of any of the above or below features, the computing means generates a summary report for the operator based on the received information.

[0045] According to another important feature of the invention, which may be used independently of any of the above or below features, the computing means is capable of modifying at least one operating parameter based at least in part on the received information.

[0046] According to another important feature of the invention, which may be used independently of any of the above or below features, the computing means receives information from the plurality of rotating body devices, modifies at least one operating parameter based on the received information, and effects the modification such that the collective operation of the plurality of rotating body devices produces an output of the object that satisfies the operator specified parameters.

[0047] One object of the present invention is to increase the rate at which objects can be presented to assembly equipment so that finished parts can be manufactured more quickly. A further object of the present invention is to provide quality characteristics of each object, along with information about the time it was delivered to each object buffer and its position within the object buffer.

[0048] In a most preferred embodiment, the singulation means is as described in PCT application WO 2018 / 018155, published on 1 February 2018 by the applicant, and that configuration may be used herein.

[0049] The singulation system thus comprises a body of revolution with one or more ducts running from a central region where bulky objects are introduced from a bulk object reservoir to an outer region where the singulated objects are released. The objects are accelerated by inertial forces that depend on the angular velocity of the body of revolution and the geometry of the ducts.

[0050] The singulation rate achieved by the single duct in this device is significantly higher than that achieved by prior art bowl feeders, allowing objects to be transported to the object buffer at a significantly higher rate. Automated assembly stations based on this embodiment can assemble finished products more quickly because the singulation process is not transfer rate-limiting. This type of singulation system requires only a rotary motor, which can be conveniently driven electrically or hydraulically. The singulation system described in published PCT application WO 2018 / 018155 releases objects at intervals determined in part by the distribution of center-to-center distances of large objects. The mean duration and duration variance depend on the size and shape of the objects and the surface texture, which modulates friction with the duct walls. Each object is oriented within the duct to minimize potential energy. For non-spherical objects, the object's long axis will preferentially align with the duct axis. This specification includes measuring object properties within the duct or after release, and means for reorienting the object based on the measured properties. The object buffer in the present invention functions to allow objects to be released from the object buffer at a constant rate, where the maximum rate of release from the object buffer is the average rate of arrival of objects into the object buffer.

[0051] In another embodiment, objects are collected by a funnel and placed in a slot operable by an actuator to move between a catch position and a release position. The width of the slot is selected so that the slot can receive the objects for a length of time corresponding to the release time distribution. After the object is captured, the actuator accelerates it toward the release position, and inertial forces drive the object against the trailing edge of the slot. The trailing edge is shaped to orient the object. For example, the trailing edge itself may have a slot wide enough to accept a screw shaft but narrow enough to exclude a screw head.

[0052] In many cases, the method includes performing an operation on the singulated object while it remains singulated. The operation may include simply viewing or counting the singulated object. However, singulation is particularly effective for treating the singulated object, such as by coating it with a lubricant or adhesive. In other cases, the operation may include performing an analysis or evaluation of the object.

[0053] In some embodiments, the object measurement means is an imaging system that provides information about the size, shape and reflectivity of the object at one or more wavelengths.

[0054] In some embodiments, the object measurement means is acoustic and provides information about density variations within the object. The measurement may detect cracks, for example. The system may reject objects with cracks to prevent possible failures in the finished assembly.

[0055] In some embodiments, multiple measures are used.In some embodiments, information about the object is stored along with information about its location in the object buffer.

[0056] In a preferred embodiment, the object supply system includes a diversion means operable to divert objects to another location depending on at least one measured quality parameter of each object. If the quality parameter meets an operator-specified threshold, the object continues to the object buffer; otherwise, the object is diverted to a container. For example, if the object is a screw, the screw continues to the object buffer if it is determined to be good, and is diverted to a reject bin if it is determined to be bad. In this embodiment, it is desirable to operate the singulation means at a rate slightly higher than the rate at which the object buffer is emptied by the assembly tool, so that if an object is diverted to the reject bin, a replacement object will be available shortly thereafter. In some embodiments, objects that are suitable for use but are surplus are diverted to a storage bin for later reintroduction into the singulation means. This may occur, for example, if the object buffer is full.

[0057] In some embodiments, the object buffer is a packaging container that is replaced with another packaging container when a predetermined number of objects have been placed in the container. In some cases, the packaging container receives only one object in a specific orientation. For example, the packaging container may be a strip of tape with a series of compartments that hold electronic components in specific orientations.

[0058] In some embodiments, the object supply system is associated with multiple large object repositories, each containing different types of objects, and the computing means selects which one of the object repositories to connect to and supply to the singulation means at any one time.

[0059] While a system can be effective with a single duct that produces a high-velocity stream of singulated objects, multiple ducts are often arranged in an array around a central supply conduit. This arrangement can both increase the speed of object singulation and, as described below, allow multiple object types to be singulated simultaneously. Each object type has a corresponding supply conduit that communicates with one or more ducts dedicated to that object type and transports the objects to the axial platform. The axial platforms for each object type are arranged in a staggered pattern along the axis of rotation of the singulation system. For example, one duct singulates #4-40 screws, while another duct singulates #6-32 screws.

[0060] The apparatus defined above can be used to sense at least one measurable parameter of a flow of objects, and includes: conveying an object in the flow of objects within a supply conduit; rotating a rotating body about an axis; the rotating body defining at least one duct extending outward from an inner end adjacent the axis to an outer end spaced outward a greater radial distance from the axis than the inner end; the inner ends arranged side by side adjacent the axis such that the supply conduit acts to deposit objects at the inner ends of the at least one duct for entry into the interior, slower end of the object; the at least one duct shaped and arranged such that objects are accelerated as they pass from the inner end to the outer end so that they separate into the at least one duct and align successively within the duct as they move toward the outer end; and measuring the at least one parameter of the object through each of the at least one duct.

[0061] In some cases, a device is provided for classifying objects so that, for each duct, the objects are directed into one of a plurality of paths as determined by measuring a parameter. The measured parameter can be the orientation of each object. Objects in each orientation are directed into a different path. For example, thread flows will be aligned parallel and anti-parallel to the axis of the duct. Parallel-aligned threads are directed into a different path than anti-parallel-aligned threads. In a preferred embodiment, the different paths are arranged to bring the objects into a common alignment and subsequently merge into a single path. However, given the increased degree of object singulation using the arrangement herein, the measurement of the parameter(s) more effectively obtained can be used for other purposes.

[0062] The above-defined arrangement may therefore provide the advantage that the increased velocity obtained by the rotation of the body, together with the increased acceleration of the objects on the body, provides a better separation of each object from the next for parameter sensing. Furthermore, the increased velocity of the objects may be used to increase the throughput of the system, as parameter sensing or measurement may be performed more quickly.

[0063] In one arrangement, the measurement of the parameter is performed while the object is in the duct. This has the advantage that the position of the object is more clear and unambiguous, as it is controlled by the rotation of the body and the position of the duct. Allowing for a more accurate position of the object, the measurement of the parameter can often be performed more efficiently.

[0064] In this case, the measurement of the parameters is preferably carried out by a measuring device placed on the rotating body. In this way, the measuring device is located at a specific position relative to the duct and therefore relative to the object. This can simplify the operation of the measuring device, since it can be more precisely focused on a specific location. In this case, each duct can include one or more separate measuring devices dedicated to measuring the objects flowing through the duct. That is, when moving along the duct, each object passes multiple sensors and measuring devices, which may be aligned in a row, each detecting a different parameter of the object, allowing a better assessment of the object to be made. However, in some cases, a single sensor can provide all of the information needed.

[0065] Preferably, the portion of the duct adjacent to the measurement device is constructed of a transparent material, making the portion of the duct transparent allows measurements to be performed through the transparent portion while the duct maintains a constant shape so that it continues to control the movement of the object.

[0066] In one arrangement, the walls of the duct or the duct itself are segmented with one or more gaps between the segments. One or more measurement devices are positioned proximate the gaps to measure different parameters of the object without being obstructed by the duct walls. If the duct itself is divided into separate segments, each segment is preferably positioned along the path of the duct, substantially parallel to the average velocity vector of the object in that segment, to minimize disturbances due to the flow of the object along the duct. The object can then be manipulated while in the gap using any of the techniques described herein.

[0067] In another arrangement, object separation can be performed using a magnetic field, where the objects are differentially energized according to selected parameters and then passed through an electric field, such that the differential energization diverts the objects to different paths. Because each object typically has a different or unique charge per unit mass, an arrangement is provided that generates equal charges on each object, such that objects of different masses are separated by passing them through an electric field that acts differently on the objects based on their different masses. This method could be used, for example, to direct objects containing unwanted voids to a reject bin.

[0068] Preferably, the duct is curved such that the outer end is angularly retarded relative to the inner end. This shape typically closely follows the path of the object, as the object can be accelerated under centrifugal and Coriolis forces and move along the path without experiencing excessive friction against the sides of the duct.

[0069] Preferably, the supply conduits are positioned immediately adjacent at the inner end adjacent the axis in such a way that the objects are separated directly into the inner end of the duct and the spacing increases towards the outer end of the duct as the duct moves towards the region of increasing diameter of the rotating body.

[0070] Preferably, the axis of the rotor is vertical so that the disc lies in a horizontal plane, although other orientations may be used.

[0071] Preferably, the sidewalls of each duct through which the objects travel are angled in an axial direction so that acceleration forces on the objects act to move the objects in a common radial plane and eject them from the rotor. That is, the acceleration forces tend to move the objects axially along the rotor toward a common axial position. In this way, even if the objects enter the ducts at positions that are spaced apart along the axis, the shape of the ducts will move them all to the same axial position.

[0072] In one preferred arrangement, each duct is shaped so that acceleration moves the object relative to the duct wall, where the wall is V-shaped to trap the object at the bottom of the V. The wall may include a rifling surface for rotating the object by fitting it into the duct. Additionally, the wall may include one or more openings at a location so that smaller parts are separated from the object by ejection through the opening. Each duct includes an associated second duct parallel to the duct, into which the separated smaller parts enter. This may be used in a system with a large number of such ducts, such that the objects are separated from the first duct by size. In a related preferred arrangement, the openings in the duct wall allow only a portion of the object to pass through, so that the object is aligned with the duct wall. For example, the duct wall may include a slot through which the body of a screw passes but not the head of the screw. If the slot is deep enough, the axis of the screw will be aligned perpendicular to the duct wall.

[0073] In one example, each separation device includes a separation head having a front end positioned so that objects to be separated move toward the front end of the stream, and an actuator for moving the front end between a first position on one side of the stream and positioned to direct the objects toward a second side of the stream, and a second position on the second side of the stream and positioned to direct the objects toward the first side of the stream.

[0074] In this example, the separating head is preferably arranged in a radial plane of the rotor, and the first and second sides are arranged on either side of the radial plane.

[0075] In this example, the separating head preferably includes angled guide surfaces on the first and second sides of the front end so as to form a generally wedge shape. In other embodiments, the separating head may have three or more generally triangular sides, with the bases forming a polygon of each triangle, where the normal of the polygon (in the neutral position) is 180 degrees from the direction of the incident object. The separating head need not culminate in a sharp point; that is, the sides may be trapezoidal. In this arrangement, the base of the separating head is polygonal, and the tip of the separating head resembles the polygon of the base, only differing in scale. For example, the separating head may be generally tetrahedral in shape to direct objects into three distinct paths. For example, the separating head may be generally pyramidal in shape to direct objects into four distinct paths.

[0076] Preferably the actuator is driven by a piezoelectric member, but other driving forces may be used, such as an electromagnetic voice coil.

[0077] Preferably, the actuator is mounted on a tube located on a radial surface of the separating head and extending radially outwardly of the separating head.

[0078] The present invention is not limited to the type or size of the objects involved and can be used with different particles or objects to be separated. The inventive arrangements can be used for objects ranging in size from microns to meters. In the micron size range, the object may be, for example, a flake such as a quantum dot, whose optical properties depend on the object's dimensions and orientation. The object may be, for example, a crystalline body, and the arrangements herein are used to orient the crystalline body surface relative to an internal crystal plane. The crystalline body may be, for example, bifurcation, and the inventive orientation operation is used to align the optical axis for assembly in an optical system. The crystalline body may be, for example, silicon, and the inventive orientation operation is used to provide a specific crystal axis for further processing operations such as laser cutting, ion machining, or etching. The object may be, for example, a MEMS device or part of a MEMS device, such as a micromirror or microlens. The object may be a passive electronic component, such as a resistor or capacitor, that is singulated and oriented by the present invention for packaging or installation on a carrier such as a printed circuit board. The object may be an active electronic component, such as a transistor, LED, or integrated circuit chip, singulated and oriented by the present invention for packaging or installation on a carrier, such as a printed circuit board. The object may be a fastener, such as a button, hardware, screw, bolt, nail, rivet, nut, or washer. The object may be an electronic connector, singulated and oriented for mounting, for example, on a panel assembly. The object may be a manufactured part or subassembly of a manufactured article, singulated and oriented by the present invention for packaging for further assembly. The manufactured part may have an irregular shape. The object may be a plant, such as a tulip bulb, pine tree, or vine, singulated and oriented (root side down) prior to planting.The object may be a bale of material that is singulated and oriented, for example, to orient fibers in a composite material. The object may be a package of food or packaging for manufactured goods that is singulated and oriented by the present invention during packaging. The object may be an envelope, box, parcel, or shipping container that is singulated and oriented by the present invention in a postal or delivery system that tracks and routes each object to its destination. Similarly, the present invention may be used in distribution and inventory control systems. The object may be a package in a transportation system, such as an airport, train station, bus station, or seaport. The object and use types referenced herein are exemplary and do not limit the scope of the present invention to the object and use types described herein.

[0079] As described in some examples herein, ducts are generally straight-sided channels formed in a disk, but ducts can also be circular, elliptical, triangular, square, etc., or partial tubes, typically C-, V-, or L-shaped. Ducts can also be defined by a minimal two- or three-dimensional surface, or a surface defined by contact points that exert a force on an object. Ducts can also be enclosed tubes of many different cross-sectional shapes, such as circular, elliptical, triangular, or square.

[0080] The duct comprises a plurality of paths, each path carrying objects having a different set of orientations, and means are provided for moving the object from a first path to a second path depending on the object's orientation. In some embodiments, at least one of the paths within the duct is shaped and positioned to change the orientation of an object entering the path. In some embodiments, at least one of the paths within the duct is shaped and positioned to change the orientation of an object within the path. In some embodiments, at least one of the paths within the duct is shaped and positioned to change the orientation of an object exiting the path. In some embodiments, at least one of the paths includes means for ejecting the object to a waste bin based at least in part on a measured parameter. In some embodiments, at least one of the paths includes means for ejecting the object to a waste bin based at least in part on a transient characteristic of the object. In some embodiments, at least one of the paths includes means for directing the object to a recirculation bin based at least in part on a measured parameter. In some embodiments, at least one of the paths includes means for directing the object to a recirculation bin based at least in part on a transient characteristic of the object. In a preferred embodiment, the paths within the duct are shaped and arranged so that objects entering the duct at different orientations exit the duct at the same orientation.

[0081] In the present invention, the inertial force on the object calculated in the rotating frame of reference is resisted in at least one direction by a normal force provided by the path surface, and the object accelerates according to the remaining net inertial force. The inertial force generated in the relevant frame of reference depends on the angular velocity and may be much greater than the gravitational force used in prior art systems. The larger force allows the present arrangement to singulate and orient objects at high speeds. The optimal rotation speed depends on the magnitude of the surface force. Generally, micron-sized objects experience strong surface forces resisting motion, and high rotation speeds, such as 100,000 RPM, are appropriate. For meter-sized objects, the surface forces relative to mass are small, and rotation speeds, such as 100 RPM, may provide sufficient throughput. Higher rotation speeds may be used to improve throughput. Lower rotation speeds may be used to limit impact forces on delicate objects.

[0082] The means for moving an object from one path to another can be dynamic or static. In the static case, the shape of the path imposes different normal forces on differently oriented objects at at least one point along the path, causing the differently oriented objects to follow different paths. For example, an object in a radial duct section of the present invention is accelerated outward by centrifugal force and tangentially into the duct wall by Coriolis force. The duct wall may be stepped tangentially so that an object in a first orientation fits within the first step and an object in a second orientation extends beyond the first step. An object in a first orientation experiences no net tangential force and no net torque about the radial axis. An object in a second orientation experiences a net torque about the radial axis and possibly a net tangential force (depending on where the object's center of gravity is located relative to the step). The net torque and / or net tangential force on the object in the second orientation causes the object to follow a different path than the object in the first orientation. In another example, a duct is oriented such that the object in the first orientation does not engage the protrusion and a portion of the object in the second orientation engages the protrusion, and the duct wall includes a tangential wedge-shaped protrusion to change the path of the object in the second orientation. The displacement vector of an object in the duct can include a component parallel to the axis of rotation by tilting a portion of the duct wall relative to the axis of rotation. In another example, the duct wall can be shaped to allow the object in the first orientation to have a displacement parallel to the axis of rotation and prevent the object in the second orientation from having a displacement parallel to the axis of rotation. The process can be repeated to sort objects with multiple different orientations, each into a path with a different displacement parallel to the axis of rotation. In some embodiments, the objects are fed into a different buffer for each object orientation. An object in a first orientation along the path can be rotated to a second orientation by positioning the protrusions along the path so that the protrusions engage and create a torque on the object.In a preferred embodiment, objects of each orientation are rotated to a common orientation before being placed in the buffer.

[0083] The mechanics of the dynamic embodiment are similar to those of the static embodiment described above, except that a sensor system measures the orientation of each object and sends a signal to one or more actuators to change the shape of each object's path. For example, when a sensor detects a first object orientation, a protrusion may extend from the duct wall, acting as a fulcrum to rotate an object incident on the pivot 90 degrees about an axis perpendicular to the duct wall. The protrusion is retracted for an object detected in a second orientation, and no rotation occurs.

[0084] In some embodiments, an operation is performed on the singulated and oriented object during the singulation and orientation process. The operation may be inspection by a sensor at any location along the object's path. In some embodiments, inspection occurs at multiple locations along the object's path, with the path shaped to expose a different surface of the object for inspection by one or more sensors at each location. For example, the object path may be configured to expose each of the six sides of a square box to successive cameras. In some embodiments, information from the sensors is used to track the position of each object. In some embodiments, the sensor information for each object is stored and analyzed. In some embodiments, the object is directed along different paths based on at least one object parameter measured by the sensor. The operation may be labeling or marking, for example, using a laser or dye. The labeling or marking operation may be, for example, a product code, lot code, date code, or information about a measured parameter of the object. The operation may be coating, for example, using a preservative, lubricant, or adhesive. [Brief explanation of the drawings]

[0085] One embodiment of the present invention will now be described in conjunction with the accompanying drawings. [Figure 1A] 1A shows a schematic diagram of a preferred embodiment of the present invention, FIG. 1A is a plan view. [Figure 1B] 1A and 1B show a schematic diagram of a preferred embodiment of the present invention, with FIG. 1B being a side view. [Figure 2] 1 is an isometric view of a classification device showing an arrangement for object singulation in accordance with the present invention; FIG. [Figure 3] FIG. 3 is a vertical cross-section through the device of FIG. 2. [Figure 4A] 4 shows a vertical cross section through the separation device of the apparatus of FIGS. 2 and 3; FIG. [Figure 4B] 4 shows a vertical cross section through the separation device of the apparatus of FIGS. 2 and 3; FIG. [Figure 4C] 4 shows a vertical cross section through the separation device of the apparatus of FIGS. 2 and 3; FIG. [Figure 5] FIG. 10 is a schematic diagram of an alternative singulation and orientation arrangement in accordance with the present invention. [Figure 6A] 1 shows a schematic diagram of another arrangement according to the invention for orienting an object; [Figure 6B] 1 shows a schematic diagram of another arrangement according to the invention for orienting an object; [Figure 6C] 1 shows a schematic diagram of another arrangement according to the invention for orienting an object; [Figure 7] FIG. 10 is a further schematic illustration of an apparatus for directing a stream of singulated and oriented objects, where the objects are conveyed axially of the axis of rotation of the singulation system. [Figure 8A] 1 shows a schematic diagram of an arrangement according to the invention for singulating and orienting different types of objects; [Figure 8B] 1 shows a schematic diagram of an arrangement according to the invention for singulating and orienting different types of objects; [Figure 9A] 10 shows three positions of a further schematic diagram of an arrangement according to the invention for singulating and orienting different types of objects; [Figure 9B] 10 shows three positions of a further schematic diagram of an arrangement according to the invention for singulating and orienting different types of objects; [Figure 9C] 10 shows three positions of a further schematic diagram of an arrangement according to the invention for singulating and orienting different types of objects; [Figure 10A] 1 shows a schematic diagram of a further apparatus for singulating and orienting different types of objects; [Figure 10B] 1 shows a schematic diagram of a further apparatus for singulating and orienting different types of objects; [Figure 11A] 1 shows a schematic diagram of a further apparatus for singulating and orienting different types of objects; [Figure 11B] 1 shows a schematic diagram of a further apparatus for singulating and orienting different types of objects; [Figure 12] FIG. 6B is a schematic diagram of one path (86) of the arrangement of FIG. 6A that acts to change the orientation of an object. [Figure 13] FIG. 6B is a schematic diagram of paths (81) and (86) of the arrangement of FIG. 6A acting to change the orientation of an object. [Figure 14A] FIG. 1 is a schematic diagram of classifying objects by orienting them using tangential steps. [Figure 14B] FIG. 1 is a schematic diagram of classifying objects on a surface with protrusions. [Figure 14C] FIG. 10 is a schematic diagram of classifying objects by tangential orientation using slots. DETAILED DESCRIPTION OF THE INVENTION

[0086] As shown in FIG. 1A, a rotor (50), described in detail below, has one or more integral ducts (51) positioned on the body (50) at angularly spaced intervals, such that the ducts are rotated about the central axis of the body. The ducts are fed with objects (52) by a feed conduit (53), which also acts to singulate the objects and feed them one after the other in a single file. The feed conduit (53) includes a gate (531) that regulates the flow of objects onto the rotor (50). As the objects move from the inner end of the duct to the outer end, they align longitudinally along the duct axis, either parallel to the duct, as shown at (521), or anti-parallel, as shown at (522).

[0087] In the example shown, each object has a longitudinal axis and is shaped so that the object has first and second different orientations about its longitudinal axis. That is, in one example applied to a screw or similar fastener, the object has a head (523) and a body (524), the longitudinal axis is the length of the body, and the head can be front-most or rear-most when the longitudinal axis is aligned with the length of the duct.

[0088] Thus, on the apparatus, objects are formed into a stream of singulated objects one after the other by passing the objects along the singulation duct and rotating the singulation duct about an axis (55) such that the centrifugal force generated by the rotation acts to drive the objects along the singulation duct and to press the objects against the walls (56) of the singulation duct (51) so that the objects slide along the walls (56).

[0089] To orient the object so that its longitudinal axis is transverse to the length of the duct, the portion of the duct designated (57) includes a slot (58) that is shaped and designed to allow only a portion of the object, such as the body, to enter, while the head remains in the duct and cannot enter the slot. As better shown in Figure 1B, the portion of the duct (57) is movable to direct the object into either the first buffer (61) or the second buffer (62).

[0090] That is, the orienting step is accomplished by an abutment structure, in this example a slot (58) that engages with an object in the singulation duct and acts to rotate the longitudinal axis about a transverse axis.

[0091] The object experiences a torque due to the Coriolis force on the portion of the object that cannot enter the slot, and rotates to orient the object relative to both the duct and the slot, so that the head and body are aligned perpendicular to the direction of movement.

[0092] The detector (59) inspects passing objects in the duct and communicates with a diverter (60) at the end of the duct. The diverter (60) operates to direct objects into different paths, either upward or downward. The diverter can take different forms. The diverter (60) shown in FIG. 1B includes a short duct section that operates by changing the angle of the duct upward toward buffer (61) or downward toward buffer (62). Another form of diverter is shown in FIG. 4, which is a preferred form for ejecting defective objects, generally designated (591) adjacent to the detector (59). The diverter directs objects into the buffer (61), which rotates synchronously (at the same angular velocity) as the rotor, or into a reject bin (not shown). As can be more easily seen in FIG. 1B, the diverter can direct objects along different paths toward buffer A (61) and buffer B (62). While only two buffers are shown for illustrative purposes, more preferably, there are three. Each buffer has three possible states. First, the buffer may be rotating in unison with the rotor and receiving objects for storage in an ordered array. Second, the buffer may be undergoing angular acceleration, so that objects are transported from the singulation duct (56) into the buffer container (63) where they are stopped to form a supply of objects. The objects in the buffer container (63) may be used by the tool as a contiguous array, or may be ejected body-first into a tube for use by the tool.

[0093] Angular acceleration can either stop the buffer relative to a fixed reference frame or synchronize the buffer with the rotor. Third, the buffer can be stopped. While stopped, objects in the buffer can be transferred into another fixed buffer. Referring to FIG. 1B, objects from duct 56 are directed into synchronously rotating buffer A. Detector 59 counts objects entering buffer A and generates a signal to accelerate buffer B into synchronous motion when a threshold number of objects are stored in buffer A. When the detector count reaches a second threshold number, corresponding to buffer A being full, a diverter directs objects into buffer B. Note that the object count is understood to represent the number of objects entering the buffer and does not include objects diverted to a reject bin based on measured parameters. While objects are diverted to buffer B, buffer A is stopped and emptied. Once empty, buffer A is ready to receive objects instead of buffer B. Thus, each buffer cycles between the three states described above. To provide a continuous supply of objects, at least three buffers are needed, one for each state.

[0094] As shown in FIG. 1A, six buffers (63) are angularly spaced to align with the duct outlets. In an alternative arrangement, multiple buffers (63) may be associated with each duct outlet by positioning the buffers at angles midway between the duct outlets. For example, there may instead be four or more buffers angularly spaced between each pair of duct outlets. In this alternative embodiment, each time a buffer becomes full; the ring of buffers rotates to the next empty buffer in the ring. Full buffers in a ring may be transferred individually as described above, or in groups by swapping the ring for another when all buffers in the ring are full.

[0095] The apparatus for delivering objects based on measurable parameters of the objects, shown in Figures 2 and 3, includes a feed conduit (10) carrying singulated and oriented objects from a feed (10A) (Figure 3), which delivers the objects in a continuous stream through the conduit to a rotor (11) rotating about an axis (12) for subsequent delivery. In the embodiment shown, the rotor is a vertically positioned flat disk with an axis (12) that provides an upper horizontal surface onto which objects (13) are delivered in a stream from the conduit (10). The conduit is positioned at the center of the disk so that the objects are centered on the disk as it rotates, at a position where there is little outward velocity. The object velocity at this point is from the stream in the feed conduit (10). The velocity at this point on the disk is v = wr, where w is the angular velocity and r is the radius. If objects are placed in an area of ​​too high a velocity change, they will bounce and the stream will become chaotic. The object is placed in the central region to minimize velocity variations.

[0096] The upper surface of the disk forming the rotor has one or more ducts (14) (FIG. 3) extending outward from an inner end (15) adjacent the axis to an outer end spaced outward a greater radial distance from the axis than the inner end. In this embodiment, the outer ends (16) of the ducts are located adjacent to but spaced inward from the ends (17) of the disks (11). In this embodiment, each duct (14) extends from a position closely adjacent the center to the outer periphery (17) of the disks, such that the centers of the ducts are located directly adjacent, and the ducts diverge outwardly to be spaced apart at the periphery of the outer end (16).

[0097] Therefore, the inner end (15) is positioned adjacent to the axis in an array, so that the supply conduit (10) acts to place objects at the inner end (15) of the duct for entry into the inner end of the duct where they will be singulated and oriented. Because the inner end is directly adjacent to the center of the disk, objects there form a central pile of objects that automatically and uniformly sort into the duct opening at the inner end of the duct. Assuming a continuous pile of objects at the center, the rotation of the disk will act to uniformly sort the objects into individual ducts, with the flow defined by the size of the opening relative to the size of the objects. At the beginning of their path along the duct, the objects are directly adjacent or overlapping. However, the passage of the objects along the duct while being accelerated by centrifugal force acts to spread the objects apart, forming a row of non-overlapping objects. As the force increases with increasing radial distance from the axis (12), the objects will be increasingly accelerated, and therefore the distance between the objects will increase along the duct length. The object is axially aligned with the duct at a first portion of the duct, and the object length defines an initial center-to-center distance, with some variation due to different object orientations. The centrifugal acceleration is the same at a given radius. The friction force is measured by the Coriolis force = uN (u = coefficient of friction, N = normal force on the duct wall, provided primarily by the Coriolis force). As set out above, the duct can be shaped to minimize normal force and friction by curving the duct along the net force line (mentioned in the preamble); conversely, the acceleration of the object can be reduced by curving the duct to increase normal force, curving the duct at a constant or decreasing radius, or increasing the coefficient of friction in selected portions of the duct by changing the texture and / or material.

[0098] The singulated objects may be completely separated and define intervals from one another, may be directly behind one another, or may slightly overlap.

[0099] The ducts are therefore shaped and arranged so that objects accelerate as they pass from the inner end to the outer end, so that they align successively one after the other as they move towards the outer end.

[0100] The outer ends (16) are arranged in an angularly spaced array around the periphery of the rotor such that the objects in the row of objects in each duct are ejected outward from the axis of the disk by centrifugal force from the disk. All of the openings are located in a common radial plane of the disk. The ducts may be formed as grooves cut into the top surface of a thicker disk, or by additional walls or two- and / or three-dimensional shaped guides applied to the top surface of the disk.

[0101] An array (20) of object separators (21) is arranged annularly around the outer edge (17) of the disk, with the individual separator devices (21) located at angularly spaced positions around the disk.

[0102] Each separator is operable to direct each object into one of multiple paths as determined by the operation of the separator. In the example shown, the separator is positioned to direct objects upward or downward relative to the face of the outlet (16). As shown in FIGS. 2 and 4A, separator (21) can occupy an initial, intermediate, or starting position in which objects are not separated in one or more directions. As shown in FIG. 4B, the separator can be moved upward to direct objects downward into path (22) for collection into collection chamber (25). Similarly, when the separator is moved to a downward position as shown in FIG. 4C, objects are moved upward along path (24) beyond the top of the separator for collection in chamber (23). Chambers (23) and (25) may be reject bins, sections of ductwork, packaging operations, marking operations, or buffers. The two paths (22) and (24) are separated by a guide plate (26) that ensures that objects move into one or the other of the chambers (23), (25). The guide plate (26) and the walls of the chambers (23), (25) may be covered with a soft material to reduce the impact force on the objects. Objects may be slowed by air currents or curtains made of a compliant material upon entry into the containers (23), (25).

[0103] To control the separator 21, a measurement system, generally designated 28, is provided which is used to measure selected parameters or parameters of the object as it moves from the duct end of the disc edge towards the separator. The measurement device is placed on a mounting ring 28A.

[0104] The measurement system may be of any suitable type known in the art, such as an optical measurement system, that senses the optical properties of the object to determine the particular parameters that need to be measured. Other measurement systems may also be used, as the type of system used and the parameters selected are not part of the present invention.

[0105] Each separation device (21) is associated with a respective sensing device (28) which may include a plurality of sensing components operable to measure a parameter of the object, and the respective or separation device is operated to select a path (22) or a path (24) depending on the parameter measured by the associated sensing device.

[0106] It will be appreciated that the number of paths can be varied, if necessary, depending on the parameters being measured, and can be varied to include more than two paths. Such an option for an increased number of paths can be implemented by providing a subsequent separation device (21) located downstream of the initial separation. In this way, one or both of the paths can be divided into two or more subordinate paths, all of the separation devices being controlled by a control system (29) which receives data from the measurement device (28).

[0107] Thus, the disc (11) has a front face (30) facing the supply conduit, and the ducts (14) lie in the radial plane of the disc and extend outward from the axis to the outer periphery (17) of the disc (11).

[0108] As shown in Figure 2, the ducts (14) are curved so that the outer end (16) is angularly delayed relative to the inner end (15). This creates a side of each duct that is angularly delayed relative to the clockwise rotation direction, indicated by D. This curvature of the ducts is arranged to substantially comply with Coriolis and centrifugal forces so that objects can follow along the duct without excessive pressure against either side of the duct. However, the shape of the duct is arranged so that the Coriolis forces drive objects in the opposite direction downstream of the duct (14).

[0109] As best shown in Figure 2, the ducts (14) are immediately adjacent to the inner end (15) adjacent the axis and are spaced apart increasingly toward the outer end (16). At the inner end (15), the ducts are immediately adjacent, and the maximum number of ducts is determined by dividing 2*π by the angle of the opening (15) relative to the width of the duct end. In arrangements not shown here where the ducts include branches, each dividing into one or more branches along its length, the number of ducts can be increased.

[0110] In the embodiment of Figures 2 and 3, the sensing device (28) and the separating device (21) are both located within the outer periphery (17) of the disk. In this way, objects are directed as they pass from the outer end of the duct to the arrangement of separating devices.

[0111] As shown in FIG. 2, a wall (98) may be used to stop the outward movement of an object. The wall (98) may be located, for example, at the end of the buffer. Preferably, the wall (98) has a layer of soft, compliant material (99), such as rubber, to cushion the impact of the object and reduce the potential for damage to the object. As best shown in FIGS. 4A, 4B, and 4C, each separating device generally includes a separating head (40) having a tip (41) that is in the radial plane of the disk (11), toward which objects ejected from the outer end (16) move. The separating head (40) includes inclined guide surfaces (42) and (43) on either side of the tip (41). Thus, the separating head (40) is generally wedge-shaped. The separating head is mounted on a lever (44) mounted within a tube (45), such that the lever and its drive mechanism are protected within the tube located behind and thereby protected by the separating head. An actuator (46) for moving the tip is positioned between first and second positions above and below the radial plane, defined by the object's path. Thus, FIG. 4A shows the center and neutral positions. In FIG. 4B, the tip (41) moves upward, positioned to direct the object below the radial plane toward the side of the radial plane. In the position shown in FIG. 4C, the tip moves downward toward the second side of the radial plane, positioned to direct the object toward the first side or upper side of the radial plane. This movement of the wedge-shaped head and its tip requires little movement of the tip (41) and causes separation simply by using the object's own momentum and sliding over the guide surfaces (42) and (43). Therefore, the separation head does not need to collide with or generate lateral forces on the object, as it only needs to move to a position where the object can generate the required separation force.

[0112] Considering the provision of a lever, the actuator 46 is required to generate only short-range movement and therefore may be actuated by a piezoelectric element. Alternatively, the movement may be performed by a small electromagnetic coil. This design allows for the use of components capable of generating the high-speed motion required to occupy the two positions of Figures 4B and 4C quickly enough to accommodate the high-speed movement of the object. As shown, the actuator 46 is located outside the separation head and in the radial plane of the separation head.

[0113] The inventive arrangement thus provides a system for singulating and orienting objects, such as screws, where the objects are fed in a feed zone and separated to form ducts and multiple streams of objects at the inlets of the ducts.

[0114] As best shown in FIG. 1, the object buffering device (63) provides a supply of objects to be transported, as shown at (65), to a transport member (66) for transporting the singulated and oriented objects from the object buffering device (63) to a manipulation tool (67), such as a screwdriver.

[0115] As an alternative to a driver (67), the objects from the buffer (63) can be fed to a manipulation device (71), such as a marker, as shown at (70), where an action is applied to the oriented object, so that the action is performed on each object at the same orientation.

[0116] As shown in Figure 5, an alternative arrangement is shown where the orientation is located beyond the end of the singulation duct rather than within the singulation duct itself.

[0117] In this arrangement, a rotating body (75) is arranged on which an object (74) is placed in a central area by a supply conduit (77).

[0118] In this arrangement, the supply conduit (77) may include an agitation device (79) so that the supply duct is vibrated to ensure that objects enter the singulation duct(s) and do not become locked due to friction or interlocking.

[0119] Under the influence of centrifugal force, objects move along a duct (76) integral with the rotor (75) from the inner opening to the outer opening. Coriolis forces align the objects against the duct wall (78). Objects exiting the duct traverse an air gap (80) and are directed into a fixed duct (81), which constitutes an object buffer in this embodiment via a series of wedges (82), and the orientation of each object is measured by a detector (83). Objects determined to be within the desired orientation range continue into the fixed duct (81), while objects with other orientations are rejected by a diverter (84) (and potentially reintroduced into the supply duct (77)). In a related configuration (not shown), the diverter (84) directs objects into different buffers at different orientations. For example, a first buffer might be a tube filled end-to-end with objects oriented with orientation vectors parallel to the tube axis, and a second buffer might be filled end-to-end with objects oriented anti-parallel to the tube axis. After filling, both tubes are removed and the second tube is rotated 180 degrees to align the orientation of all objects in the second tube with the objects in the first tube.

[0120] Preferably, the fixed duct has a cross-section slightly larger than the object, so that the fixed duct wall preserves the object's orientation. Preferably, the fixed duct is curved so that an entering object strikes a duct wall on one side of the duct. The duct wall aligns the object longitudinally. In some embodiments, the object is buffered and used end-to-end. In some embodiments, the duct wall includes an abutment structure, such as a slot, for object alignment. An object entering a fixed duct strikes the fixed duct wall at a glazing angle, loses momentum, and ultimately comes to a halt. Optionally, the object may be further carried by the air pressure difference between the inlet and outlet of the fixed duct.

[0121] Figures 6A through 6C illustrate alternative methods for creating a stream of objects with different orientations relative to a common orientation in the object buffer. In Figure 6A, the stream of objects moves from left to right and is singulated under the influence of centrifugal force. The objects are initially oriented parallel and then antiparallel to the duct wall due to Coriolis forces. The orientation of each object is determined by a detector proximate to the stream in communication with a diverter. If the object is in the desired orientation, the object continues along the first path. If not, the object is diverted to another path by the diverter (84). In one arrangement (not shown), the path operates to engage objects that are not correctly oriented and redirect them back into the supply conduit.

[0122] The arrangement shown in Figure 6A is a π radian object rotator about an axis perpendicular to the longitudinal axis and may be used separately or in combination with the orientation methods described above or below. In this arrangement, a diverter (84) operates to orient objects oriented antiparallel to a following path (81) and objects oriented parallel to a following path (86). Path (86) feeds objects into the buffer from the top. Path (81) feeds objects into the buffer from the bottom. Objects entering the buffer are propelled to the right. The buffer is shaped to preserve the orientation of objects entering along path (81) and path (86). Because the objects enter from opposite directions with opposite orientations, the objects in the buffer have the same orientation as shown.

[0123] The object is then manipulated to change its orientation in response to the sensed orientation, and the object is directed along first and second paths (81), (86) in response to the first and second orientations. The first path (81) is arranged to change the orientation of objects thereon relative to the second path such that the objects are combined with a common flow (63) from the first and second paths that has the same orientation.

[0124] The arrangement shown in FIG. 6B is a π / 2 radian object rotator about an axis orthogonal to the longitudinal axis, and may be used separately or in combination with the orientation methods described above or below. The case shown in this arrangement is a surface-mount integrated circuit chip (100) with four-fold rotational symmetry. Dot (101) conventionally represents the pin 1 position, which can be in any one of eight positions following singulation: four orientations pointing toward the singulation duct wall and four orientations pointing away from the singulation duct wall. Detector (83) determines the object orientation. Diverter (84) operates to direct objects with pin 1 in the upper right and lower right corners onto paths (811) and (861), respectively. Path (861) feeds objects into the buffer from above. Path (811) feeds objects directly into the buffer. Objects entering the buffer are propelled to the right. The buffer is shaped to preserve the orientation of objects entering along the path. Because the objects enter from orthogonal directions, the objects in the buffer have the same orientation as shown. It should be understood that object rotations of π / 2 radians and -π / 2 radians are mirror images of each other in the arrangement shown in FIG. 6B. The oriented objects in the buffer are fed to a packaging operation, generally designated (103). The objects are placed in pockets (104) of tape (105). The path lengths, or travel times, along the two paths (811) and (861) are arranged so that an object extracted onto path (861) is flipped and returned to path (811) at the same location from which it was removed. Paths (76), (811), and (861) can all be mounted on a common rotor, or paths (861) and (811) can be held fixed while path (76) rotates to provide the singulation operation.

[0125] The arrangement shown in FIG. 6C is a π radian object rotation about the vertical axis, which may be used separately or in combination with the orientation methods described above or below. Objects oriented away from the singulation wall are diverted onto path (811) and move directly to the buffer. Objects oriented facing the singulation wall are diverted onto path (861) with a π radian twist (862). The duct walls of path (861) are shaped to constrain the objects to follow the path axis. Therefore, the π radian twist in path (862) flips the object's orientation by π radians, and then places the object in the buffer. The oriented objects in the buffer then pass, for example, through a marking operation (864), where the marked objects are then directed to a packaging operation (103), where they are placed into pockets (104) of tape (105).

[0126] 6A to 6C show orthogonal object rotations, it should be understood that other angles of rotation are possible and that rotations may be applied sequentially to achieve a desired object orientation.

[0127] FIG. 7 illustrates a method for converting a radial flow of singulated and oriented objects in a duct (89) placed on a body (88) rotating about an axis (824) into an axial flow of singulated and oriented objects flowing along an exit duct (90). The objects are placed in a central region of the rotating body and enter the duct as shown in more detail in FIGS. 1 through 3. The objects are oriented in a region near the outer periphery of the rotating body, in a manner better shown in FIGS. 1, 6A, 6B, and 6C, in a region called the alignment zone. Objects exiting the alignment zone enter a duct, labeled path (91), which curves radially inward toward the axis (824) and becomes axial at its terminal end (90). Centrifugal force and friction resist the movement of the objects along path (91), so a force must be provided in the direction of path (91). The force can be supplied by a pressure gradient created by applying a vacuum to the terminal end (91A) of path (91) at the exit (90). Other methods may be used, such as air pressure delivered to the path 91 at a point (not shown) along the object's direction of travel. The path 91 may also take the form of, for example, a moving belt with receptacles for receiving the object (not shown).

[0128] Note that the arrangement shown may cause rotation in the object at the terminal end. An optional end 91B coupled with a rotating joint can be rotated in the opposite direction to reduce the rotation of the object.

[0129] As such, objects are fed from singulation duct (89) to a feed duct (91) having an end (90) located on the axis of rotation of the singulation duct, such that the objects are fed in the same oriented flow at end (90) (e.g., by including the arrangement of FIG. 6A within path (91)) for delivery to a tool or driver. The illustrated singulation duct can produce an axial flow of objects in any direction because gravity is small compared to the inertial forces generated within the singulation duct.

[0130] Figures 8A and 8B show arrangements suitable for singulating and orienting different types of objects. Figure 8A shows a rotor (901) with two ducts (911) and (912). Duct (911) is fed with objects via a supply conduit (921) that connects to a mass supply (not shown) of a first object type. Duct (912) is fed with objects via a supply conduit (922) that connects to a mass supply (not shown) of a second object type. The concentric supply conduits are fixed and not attached to the rotor (901). In some embodiments, as shown, duct (911) is housed in a duct (914) to constrain the object orientation. Thus, in the arrangement of Figure 8A, singulated streams of two different types of objects can be fed in the same line via ducts (911) and (912). Figure 8B shows an alternative arrangement, in which supply conduits (921), (922), and (923) supply objects from the sides to the central regions of rotors (901), (902), and (903), respectively. The supply conduits may be flexible hoses or rigid pipes. The supply conduits are fixed and not attached to the rotors. Rotators (901), (902), and (903) contain ducts (911), (912), and (913), respectively. The rotors may rotate at different speeds to supply different types of objects in the required amounts to downstream operations. Alternatively, rotors (901), (902), and (903) may rotate in unison as a single body.

[0131] Figures 9A to 9C show a sequence of steps in another method for changing an object's orientation and placing the object end-to-end in a buffer. A detector (106) determines the object's orientation in a singulation duct (107). An anti-parallel aligned object enters a slot (108) in a rotor (111). Preferably, the slot (108) contains a spring (109) that contracts and stores the object's kinetic energy. As the spring is compressed, the rotor rotates, and the slot (108) moves to a release position (110) shown in Figure 9B. The stored energy in the spring (109) then ejects the object in the opposite orientation with substantially the same kinetic energy as when it entered. Note that the spring (109) can be mechanical or electromagnetic. Preferably, the rotor (111) has slots on opposing faces to limit the range of angular motion required to capture the second object. For objects aligned parallel to the singulation duct axis, the rotor rotates to provide a path (112) for the object to pass straight through to the buffer.

[0132] When the detector determines that the object is in a first orientation, the second rotor (111) is rotated to a first position, aligning the duct (112) through the rotor with the object path (107), allowing the object to pass unimpeded, maintaining the first orientation, into the supply duct or buffer (114). The supply duct (114) is a tube cartridge. When the detector determines that the object is in a second orientation, the second rotor is rotated to a second position, aligning a recess in the rotor with the object path. The object enters the recess and acts against the spring, converting the object's kinetic energy into potential energy in the spring.

[0133] The second rotating body (111) rotates to a release position, where the object is released in a different orientation. In some cases, the second rotating body has a casement (not shown) that holds the object while rotating to the release position. In the release position, the potential energy stored in the spring is converted into kinetic energy for the object. The configuration shown places the axis of rotation (116) of the body (111) a significant distance from the object itself. In some cases, the axis (116) may be at the center of gravity of the object or within the object, reducing the energy required to move between the positions of Figures 9A and 9B.

[0134] The spring (109) may also be an electromagnetic spring. For objects with a net charge or a net charge separation (dipole), an electric field may be applied at will to hold the spring in a fixed position or even increase the energy stored in the spring to a predetermined level. The second rotor is then rotated to the release position, and the electric field is turned off or reversed. The potential energy of the spring is transferred to the object, and the object is ejected from the cavity in a different orientation. The kinetic energy of the object may be further increased in the release position by reversing the electric field.

[0135] 10A and 10B show a two-stage process in which objects are singulated by ducts (120) on a rotating body (121) and then ejected in all directions around the periphery. The objects are captured by a funnel structure (123), preferably made of a conformable material, which reduces the kinetic energy of the objects.

[0136] In FIG. 10A, the funnel directs the object toward the release duct (124) when the detector (125) detects the presence of the object and generates a signal that rotates the second rotor (126) so that the orienting duct (127) aligns with the release duct to capture the object (128). The orienting duct (127) is shaped to guide the object toward the adjacent slot (130). The rotor and integral orienting duct then rotate about axis (131), causing a portion of the object to enter the adjacent slot and generating an inertial force that causes the object's longitudinal axis to be perpendicular to the duct wall in the same manner as described with reference to FIG. 1A. Radial movement of the object due to centrifugal force is prevented by a casing around the second rotor (not shown). Aligned objects are released into a buffer (132) at a release position (133). The buffer delivers the singulated and oriented objects to a tool (134).

[0137] In FIG. 10B, the funnel constrains the object orientation so that its longitudinal axis is parallel and antiparallel to the funnel axis. A detector (125) measures the object orientation and generates a signal to direct a diverter (135) to objects oriented antiparallel to a buffer (137) and objects oriented parallel to an alignment wheel (136) with a pocket (138) that maintains the parallel orientation. The wheel then rotates the distance of one pocket position, providing an empty pocket for the next parallel-oriented object. An outer case holds the objects in the pockets between a capture position (139) and a release position (140). As the pockets between the capture and release positions fill, each increment of the wheel captures one object and releases one object in a direction angularly displaced from the capture location. Thus, as shown, objects are captured in a parallel orientation and released in a substantially antiparallel orientation along a path (141) to the buffer (137). The objects are provided to the tool (134) from the buffer (137).

[0138] The structure of Figures 11A and 11B is very similar to the structure of Figures 10A and 10B and uses the same orientation system as shown in those embodiments. As in the embodiment shown in Figure 7, objects are placed in the central region of the rotating body (88) and enter the duct (89) as shown in more detail in Figures 1 to 3. The objects are singulated in the duct (89) that is placed on the body (88) that rotates about an axis (824). While in the embodiment of Figure 7, the objects are commonly oriented on the rotating body, in the embodiment of Figures 11A and 11B, the objects are commonly oriented after exiting the axial port (90). Specifically, objects with longitudinal axes enter the axial port (90) in an orientation that is either parallel or anti-parallel to the axis of rotation.

[0139] In FIG. 11A, the axial port directs the object toward the supply duct (91) when the detector (125) detects the presence of the object and generates a signal that rotates the second rotor (126) so that the directing duct (127) aligns with the supply duct (91) to capture the object (128). The directing duct (127) is shaped to guide the object toward the adjacent slot (130). The rotor and integral directing duct then rotate about axis (131), causing a portion of the object to enter the adjacent slot and generating an inertial force that causes the object's longitudinal axis to be perpendicular to the duct wall in the same manner as described with reference to FIG. 1A. Radial movement of the object due to centrifugal force is prevented by a casing around the second rotor (not shown). The aligned object is released into the buffer (132) at the release position (133).

[0140] In FIG. 11B, detector 125 measures the orientation of objects proximate axial port 90 and generates a signal to direct diverter 135 to objects oriented antiparallel to buffer 137 and parallel to alignment wheel 136, which has pockets shaped to capture the objects at position 139 and maintain the parallel orientation. The wheel then rotates one pocket position, providing an empty pocket for the next parallel-oriented object. An outer case holds the objects in the pockets between capture position 139 and release position 140. As the pockets between the capture and release positions fill, each increment of the wheel captures one object and releases one object in a direction angularly displaced from the capture location. Thus, as shown, objects are captured in a parallel orientation and released by transport means 141 into buffer 137 in a substantially antiparallel orientation. The objects are provided to the tool (134) from the buffer (137).

[0141] In addition to the slot arrangement (58) (FIG. 1A) described above, many other arrangements for changing orientation are possible for orienting an object within a duct, which may be either a unifying duct or a downstream separation duct. In one arrangement (not shown), the object may be oriented by simple friction between the object and the wall it moves along, provided there is sufficient clearance within the duct for the object to rotate within the duct. In this arrangement, if the object has areas of greater or lesser friction, the friction will cause the area of ​​the object that has the greatest frictional effect with the wall to be positioned so that it is trailing and the area of ​​lesser frictional effect is preceding.

[0142] Other arrangements can use the bounce effect described below. Many other surface arrangements can be designed that engage an object and rotate the object around an axis to obtain a change in orientation. It will also be understood that some objects have many different axes around which to change orientation, and the arrangements described herein can be used repeatedly to reorient the object around all axes to obtain a selected one of eight different orientations.

[0143] Referring to Figure 12, another arrangement similar to Figures 6A, 6B, and 6C is shown in which the orientation of an object is determined by a sensor (83) and directed by a deflector (84) along one of two separate paths. In one path, the orientation is maintained, and in the other path, the orientation is reversed. In Figure 12, the second path is indicated by (142), and the orientation is changed by introducing the object (148) into a path (145) that includes a ricochet device (146). The object passes through a gap (143) in which a detector (144) is positioned to sense the nature or orientation of the object. The ricochet device is positioned to impact the object at the required location so that the bounce causes the object to change orientation. Thus, as shown, if the ricochet device impacts the ricochet device head first, the object will reverse direction along path (145) and become torso or tail first. The rebound device (146) can be moved or driven to change the direction of rebound to different paths depending on the data from the sensor (144).

[0144] In Figure 13, another arrangement similar to that of Figure 6 is shown. In this arrangement, deflector (84) is replaced by a bounce deflector (821) that can move between two different positions depending on the orientation of the object detected by sensor (83). In one position, where the orientation is determined to be the required orientation, deflector (821) moves away from the path, allowing the object to pass from path 76 to path 81 while maintaining the same orientation. In the second position, the bounce deflector strikes an object determined to be of the opposite orientation, causing the object to enter path (86) and simultaneously strike the object in a manner that reverses its orientation during the bounce.

[0145] FIG. 14A shows a radial portion of a duct (825) rotating around an axis (824), generating centrifugal and Coriolis inertial forces along the duct and into the duct wall, respectively, as shown. The duct shape as shown is for simplicity and illustrative purposes only. The duct wall may generally be curved, with both radial and tangential components. Objects (826) and (827) are moving along a path (828) and are accelerated by centrifugal forces that increase the separation between the objects. Object (826) in a first orientation is stable along path (828) because the normal force from the duct wall of path (828) counters the Coriolis force on the duct wall. Object (827) in a second orientation is unstable along path (828) and tilts toward path (829) due to a tangential step in the duct wall (830). Object 827 is subjected to a torque about axis 831 toward path 829. Objects with different orientations, perpendicular to the direction of the duct rotation axis, will therefore fall into different paths according to the arrangement shown in Figure 14A.

[0146] Figure 14B shows another arrangement suitable for changing the orientation of objects moving along path 833. In one arrangement, protrusion 834 is arranged to engage the object at the orientation of object 827 and generate a torque that rotates the object 90 degrees. Object 826 passes under protrusion 834, preserving the same orientation. In a second arrangement, a detector (not shown) measures the orientation of each object, and, in response to the measured orientation, a control system actuates protrusion 835 to engage the selected object and rotate the selected object from a first orientation to a second orientation.

[0147] Figure 14C shows an arrangement for sorting objects tangentially depending on their orientation. Objects 826 and 827 are accelerated along path 836 by centrifugal force and held against the duct wall of path 836 by Coriolis force. Object 827 reaches slot 839 and is supported at the top and bottom of slot 839 by portions of the duct wall, indicated by 840 and 841. In some embodiments, slot 839 may be opened or closed by an actuator depending on sensor measurements of the object's orientation. Thus, object 826 continues along path 836. Object 826 reaches slot 839 and is supported only by a small portion of the duct wall, indicated by 840. Therefore, object 826 is pulled through slot 839 by the Coriolis force and travels along path 837 across the gap between paths 838. Objects of different orientations are therefore sorted tangentially by the arrangement shown in Figure 14C.

[0148] The arrangements shown in Figures 14A, 14B and 14C may be used in any combination with each other or with any combination of the arrangements described above within the scope of the present invention.

Claims

1. 1. A method for supplying objects in a stream from a supply of a plurality of said objects, each said object having an axis of orientation, said objects being shaped to have first and second different orientations of said axis of orientation, comprising: providing a supply of a plurality of said objects; conveying said objects from a supply to a singulation duct; forming the objects into a stream of objects to be singulated one after the other by passing the objects along the singulation duct and rotating the singulation duct about an axis of rotation such that centrifugal forces generated by the rotation drive the objects along the singulation duct and press the objects against the walls of the singulation duct so that the objects slide along the walls; orienting the objects in the flow by engaging and rotating at least some of the objects in the flow with engaging portions of the singulation duct so that all of the objects at positions in the flow are oriented with their axes of orientation perpendicular to the direction of movement of the objects along the singulation duct.

2. The method of claim 1 , further comprising applying an action to the objects oriented at a position in the stream such that the action of the next step is performed on each of the oriented objects.

3. The method of claim 1 or 2, wherein the object is oriented while in the singulation duct.

4. The method of claim 3 , wherein the object is oriented by the engagement portion that engages the object while it is in the singulation duct.

5. The method of any one of claims 1 to 4, wherein the object is a screw or fastener having a head and a body, and the axis of orientation is the longitudinal direction of the body.

6. 6. The method of claim 5, wherein the singulation duct wall has a slot formed therein, the slot having a width such that the body fits into the slot while the head remains within the singulation duct to orient the object such that the orientation axis is perpendicular to the direction of movement of the object along the singulation duct.

7. 3. The method of claim 1 or 2, wherein the object is captured by a capture element at a position beyond the end of the singulation duct, and the captured object is oriented by the capture element to rotate the object in a required direction as it is released from the singulation duct.

8. The method of claim 7, further comprising the steps of: forming a buffer for storing the oriented plurality of the objects after the singulation; pausing the object in the buffer to provide the object to a next processing unit; The method of any one of claims 1 to 7, further comprising the step of: transporting the singulated and oriented objects from the buffer to the next processing device.

9. 9. The method of claim 8, wherein the buffer rotates with the singulation duct, after which the buffer is stopped to transport the object to the next processing device.

10. 9. The method of claim 8, including the step of loading the buffer from the singulation duct while the other of the buffers is stopped, and then transporting the object from the buffer while the other of the buffers is being loaded from the singulation duct.

11. A method according to any one of claims 1 to 7, wherein a sensor is provided for detecting characteristics of the object in the flow.

12. The method of claim 11 , wherein the sensor detects the orientation of the object in the stream, and the object is manipulated to change its orientation in response to the detected orientation.

13. A method as claimed in any one of claims 1 to 7, wherein a rotating body is provided mounted for rotation about the axis of rotation, the rotating body defining at least one singulation duct extending outward from an inner end of the singulation duct adjacent the axis of rotation to an outer end of the singulation duct that is spaced a greater radial distance from the axis of rotation than the inner end, wherein a plurality of the objects are supplied at the inner end of at least one singulation duct, and at least one singulation duct is shaped and arranged such that the objects are accelerated as they pass from the inner end to the outer end, and as they move towards the outer end they become separated within the at least one singulation duct and line up within the at least one singulation duct.

14. The object has, prior to the orienting step, one of a first orientation and a second orientation, the second orientation being opposite to the first orientation; a sensor is provided for sensing the first orientation and the second orientation of the object in the stream; the object is directed along a first path according to the first orientation and along a second path according to the second orientation; reversing an orientation of the object in the second path from the second orientation to the first orientation; The method of any one of claims 1 to 7, further comprising combining the objects from the first path and the second path into a common flow such that when combined, all of the objects are oriented in a direction perpendicular to a direction of movement of the same object.

15. 15. The method of claim 14, wherein the first path is arranged to supply the objects to the common flow from a first direction, and the second path is arranged to supply the objects to the common flow from a second direction opposite the first direction.

16. the second path includes a twist section for reversing the orientation of the object; 16. The method of claim 14 or 15, wherein the orientation of the object is reversed by flipping as the object passes through the twisted section of the second path.

17. the second path includes a movable part for reversing the orientation of the object; 16. The method of claim 14 or 15, wherein the object's orientation is reversed by bouncing off the moveable part.

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