Automated singulation and kitting

Abstract

A dispenser comprising: a feeder for receiving a cluster of items and feeding the items of the cluster of items downstream; a multi-levelled, differential speed conveyor configured to receive items from the feeder, singulate items, and provide singular items downstream; and a sorter for receiving the singular items and selectively dispensing the singular items.

Description

AUTOMATED SINGULATION AND KITTINGFIELD

[0001] This relates to automated singulation and kitting.BACKGROUND

[0002] The use of kitting systems is known in manufacturing, assembly, and shipping operations, where grouping multiple products together and treating them as a single unit can highly reduce the logistical tracking required. The kitting system process involves the gathering and packaging of a series of individual items before they are packaged as a unit.SUMMARY

[0003] According to one aspect of the present invention, there is provided a dispenser comprising: a feeder for receiving a cluster of items and feeding the items of the cluster of items downstream; a multi-levelled, differential speed conveyor configured to receive items from the feeder, singulate items, and provide singular items downstream; and a sorter for receiving the singular items and selectively dispensing the singular items.

[0004] According another aspect of the present invention, there is provided a feeder comprising: a rotatable arm comprising a sweeping edge; a conveyor for transporting a cluster of items downstream past the rotatable arm, the conveyor comprising an item-bearing surface spaced from the sweeping edge of the rotatable arm; a sensor for sensing the size of the items in the cluster of items; and a spacing adjuster for adjusting the spacing between the sweeping edge of the rotatable arm and an item-bearing surface of the conveyor based on the size of the items; wherein the rotatable arm is configured to separate the items of the cluster of items by rotationally sweeping a top portion of the cluster of items with the sweeping edge.

[0005] According to another aspect of the present invention, there is provided a dispensing system comprising: a plurality of upper dispensers longitudinally disposed at indexed longitudinal positions, each upper dispenser being configured to receive a cluster of items and dispense singular items; a plurality of lower dispensers provided at the indexed longitudinal positions, each lower dispenser being configured to receive a cluster of items and dispensesingular items; an upper conveyor configured to receive and transport singular items from each of the upper dispensers; and a lower conveyor configured to receive and transport singular items from each of the lower dispensers; wherein each upper dispenser or lower dispenser is configured to operate in parallel relative to any other upper dispenser or any other lower dispenser; wherein an upper dispenser is vertically stacked on top of a lower dispenser at each of the indexed longitudinal positions.BRIEF DESCRIPTION

[0006] The description is framed by way of example with reference to the drawings which show certain embodiments. However, these drawings are provided for illustration only, and do not exhaustively set out all embodiments.

[0007] Figure 1 shows a side view of an example dispenser configured for singulation.

[0008] Figure 2 shows a cross section of the example dispenser.

[0009] Figure 3 shows a top perspective view of the example dispenser.

[0010] Figure 4 shows a perspective view of an example sweeper of the example dispenser.

[0011] Figure 5 shows a rear view of the example dispenser.

[0012] Figure 6 shows a front view of the example dispenser.

[0013] Figure 7 shows a top view of the example dispenser.

[0014] Figure 8 shows a perspective view of an example sorter of the example dispenser.

[0015] Figure 9 shows a perspective view of an example kiting system.

[0016] Figure 10 shows a front view of the example kiting system.

[0017] Figure 11 shows a rear view of the example kiting system.DETAILED DESCRIPTION

[0018] According to the present invention, there is provided a kitting system comprising a plurality of dispensers configured to operate in parallel. The dispensers may be arranged as an upper dispenser array stacked on top of a lower dispenser array. The kitting system is configured to receive a cluster of items and output singular items for further processing.

[0019] Each dispenser is configured to receive a cluster of items, singulate the cluster of items, and provide singular items to a downstream part of the kitting system, which may be a conveyor.

[0020] Dispenser

[0021] Figures 1 to 8 show an example dispenser 10. The dispenser 10 comprises a feeder 20 for receiving a cluster of items and feeding the items of the cluster of items downstream, a singulation device 30 for receiving items from the feeder 10 and providing singular items downstream, and a sorter 50 for receiving the singular items from the singulation device 30 and selectively dispensing the singular items.

[0022] Feeder

[0023] An example feeder 20 is shown in Figures 1 to 3. The feeder 20 is configured to receive a cluster of items, which may be homogenous. For example, a cluster of homogenous items may be a cluster of similarly sized nut packets comprising almond packets, walnut packets, and cashew packets - these are considered homogenous as they are sufficiently similar in nature and size. Further, a cluster of items refers to a plurality of items that are not singular, that is, each individual item is not accessible or obtainable without additional singulation. In other words, the items of the cluster of items cannot be accessed in isolation without additional singulation, and the cluster of items is treated as a single unit as seen from an overarching kiting system.

[0024] The feeder 20 may comprise a container 23 comprising an opening. In the example shown, the feeder 20 is a semi-open structure comprising a base, side walls, and an open top. The cluster of items, as a single unit, may be disposed inside the container 23 via the open top manually and / or by an automated means (e.g. a robot).

[0025] In another example, the container 23 may comprise a selectively openable top. In this way, the opening of the container 23 may be normally inaccessible and selectively openable for receiving a cluster of items into the container 23.

[0026] The feeder 20 may comprise a feeder conveyor 21, which may be integral with or detachably connected to the container 23. The feeder conveyor 21 is configured to transport the items in the cluster of items from the container 23 to a downstream part of the dispenser 10. The feeder conveyor 21 may comprise an incline conveyor comprising an item-bearing surface, which may be provided on a conveyor belt. In use, the items of the cluster of items received at the container 23 are transported to the feeder conveyor 21. This may be achieved with a separate conveyor or by gravity, that is, by angling the base of the container 23 downwards such that any items in the container 23 are naturally moved to the feeder conveyor 21.

[0027] The feeder conveyor 21 may comprise ridges 22 spaced along the longitudinal conveying direction. Each ridge may span substantially the full width of the feeder conveyor 21. The spaced ridges 22 interact with the received items at predetermined spatial intervals. The spacing of the ridges 22 may preferably be uniform. The height of each ridge 22 as well as the spacing of the ridges 22 may be configured so as to perform partial singulation on the items of the received cluster of items by each ridge 22 acting as a divider to create separation between the items.

[0028] In some examples, the spacings between the ridges are between 150 mm and 250 mm. The spacings may be uniform or non-uniform.

[0029] The container 23 may comprise an angled side wall 24 that is outwardly angled relative to the feeder conveyor 21 and the other side walls, which may be substantially vertical. The angled side wall 24 provides a slope which may facilitate the disposition of a cluster of items into the container 23 by providing a guiding sloping surface. For example, a robot or a person can empty a cluster of items onto the top portion of the angled side wall 24. In this way, the items would experience a shorter fall and be less likely to suffer damage from impact. Further, the angled side wall 24 (and the container 23 in general) may be shaped to direct the items towards the feeder conveyor 21.

[0030] The angled wall 24 may mitigate dead zones within the feeder 20 while keeping the size of the feeder conveyor 21 relatively small. A dead zone refers to a zone in the feeder 20 such that any items therein are not easily transported downstream via the feeder conveyor 21. An example dead zone may be a portion of the container 23 where items are prone to become stuck or caught.

[0031] The feeder 20 preferably comprises a sweeper 40 provided at or near the top of the feeder conveyor 21. The feeder conveyor 21 may be configured to transport the items of the cluster of items to the sweeper 40, which is a downstream part of the dispenser 10 relative to the container 23.

[0032] An example sweeper 40 is shown in more detail Figure 4. In examples where the feeder conveyor 21 comprises an incline conveyor, the feeder conveyor 21 may be angled so that one end of the feeder conveyor 21 is higher than the other end of the feeder conveyor 21.

[0033] The incline conveyor may therefore ascendingly convey the received items towards the sweeper 40. The incline conveyor may operate according to a cadence. That is, the incline conveyor may operate periodically based on a period comprising an ON portion and an OFF portion. The cadence refers to the absolute duration as well as the relative duration of the ON and OFF portions. During the ON portion, the incline conveyor is active and ascendingly conveys the received items. During the OFF portion, the incline conveyor is inactive - the items on the incline conveyor either remain stationary or fall along the incline conveyor due to gravity.

[0034] The incline conveyor may binarily switch from the ON portion to the OFF portion (that is, without gradual and smooth deceleration), creating a sudden halt in the ascending movement the items on the incline conveyor. This sudden halt in combination with the ridges 22 acting as dividers may reduce the number of items stacking on top of each other and cause the overall height of the cluster of items to tend to the height of the ridges 22.

[0035] The sweeper 40 comprises a rotatable arm 41, a shaft 49, supporting arms 43, a frame 44, and a sweeper actuator 45.

[0036] The rotatable arm 41 as shown comprises two rectangular, planar members connected at shaft 49, which defines the axis of rotation for the rotatable arm 41.

[0037] In another example, the rotatable arm 41 may assume a different form and comprise different constituent parts. The connection between the rotatable arm 41 and the shaft 49 may occur by way of appropriate fasteners but may be adapted depending on the specific rotatable arm employed.

[0038] The rotatable arm 41 is configured to rotate in the opposite direction to the rotation of the feeder conveyor 21 such that a sweeping edge of the rotatable arm 41 sweeps against the ascending movement of any items on the incline conveyor. Generally speaking, the sweeping action of the rotatable arm 41 causes items of the feeder conveyor 21 to move upstream rather than downstream. The sweeping edge of the rotatable arm 41 preferably covers substantially the entire width of the feeder conveyor 21 such that no item can proceed further downstream without interacting with the rotatable arm 41.

[0039] The rotatable arm 41 is preferably made of a material that exhibits sufficient rigidity to sweep upstream upper items in the cluster of items but not sweep upstream lower items which are directly on the item-bearing surface of the feeder conveyor 21.

[0040] In one example, the rotatable arm 41 is made of polyurethane. Particularly, the two rectangular, planar members may be polyurethane sheeting.

[0041] In one example, the rotatable arm 41 is configured to flex away from its normal planar state upon engaging the items on the feeder conveyor 21. This can help ensure that the items are not damaged as a result of the sweeping action of the rotatable arm 41. Further, the rotatable arm 41 is preferably free of any protrusions, ridges, or similar structures that may damage (e.g. scratch, puncture, dent) the items upon contact.

[0042] The shaft 49 is connected to supporting arms 43, which are in turn mounted to the frame 44. The shaft 49 is connected on either end to the support arms 43 in a manner that allows the rotatable arm 41 to rotate relative to the support arms 43 and the frame 44 about the rotational axis of the shaft 49.

[0043] The sweeper 40 may further comprise a cross member 42 provided further downstream from the rotatable arm 41. The cross member 42 is configured may take the form of a bar which laterally stretches (relative to the longitudinal conveying direction of the feeder conveyor 21) across the entire width of the feeder conveyor. The cross member 42 is configured to provide structural support to the arms 43.

[0044] The sweeper 40 may further comprise a barrier (not shown) provided further downstream from the rotatable arm 41. The barrier is configured to help prevent any items which are over a predetermined height from passing and may take the form of a bar which laterally stretches (relative to the longitudinal conveying direction of the feeder conveyor 21) across the entire width of the feeder conveyor 21 so that no items above the predetermined height can bypass the barrier. The barrier may in some examples longitudinally cover the remaining section of the feeder conveyor 21 so that items may not pile up after passing the barrier.

[0045] The sweeper actuator 45 is connected to the sweeper frame 44 at a point 46 so that the sweeper actuator 45 may pivot relative to the sweeper frame 44. In one example, the sweeper actuator 45 is a linear actuator, but different actuator types could also be used. The sweeper actuator 45 is connected to the cross member 42 at a point 47 in a manner such that the sweeper actuator 45 can pivot relative to the cross member 42. Thus, cross member 42, support arms 43, sweeper frame 44 and the sweeper actuator 45 form a linkage where expansion or contraction motion generated by the sweeper actuator 45 causes the support arms 43 to rotate relative to the sweeper frame 44. By way of the sweeper actuator 45, the spacing between the rotatable arm 41 and the feeder conveyor 21 may be adjusted. Specifically, the sweeping edge of the rotatable arm 41 may be brought closer to or further away from the item-bearing surface of the feeder conveyor 21.

[0046] To avoid doubt, a reference to the adjustment of the spacing between the rotatable arm 41 and the feeder conveyor 21 refers to an adjustment made by way of the sweeper actuator 45, not a change in the separation between the sweeping edge of the rotatable arm 41 and the item-bearing surface of the feeder conveyor 21 over the course of the rotation of the rotatable arm 41.

[0047] The feeder 20 comprises a controller (not shown) for controlling actuation of the feeder conveyor 21 and the sweeping actuator 45. The feeder 20 comprises one or more sensors (not shown) for providing feedback to the controller, thereby forming a closed control loop.

[0048] The one or more sensors may comprise a first sensor for sensing the size of the received items and a second sensor for providing positional feedback on one or more of the rotatable arm 41, the supporting arms 43, and the sweeper actuator 45. The controller may be configured to receive data from the first sensor and the second sensor and to adjust the spacing between the sweeping edge of the rotatable arm 41 and the item-bearing surface of the feeder conveyor 21 based on the size of the received items.

[0049] The sweeper 40 may assist in controlling the rate at which items pass from the feeder conveyor 21 into the singulation device 30. The sweeper regulates the item flow and allows them through at a cadence. Preventing a surplus of items from entering the singulation device 30.

[0050] The sweeper 40 can perform partial singulation by the rotating arm 41 (in combination with the ridges 21) reducing the overall height of the received cluster of items. Separation between the received items may be created by the rotating arm 41 sweeping upper items of the cluster items away from the lower items on which the upper items were previously stacked. This may result in a more even distribution of items across the item-bearing surface of the feeder conveyor 21 along the longitudinal, conveying direction.

[0051] The controller may be configured to control the cadence of the feeder conveyor 21, the rotational frequency of the rotatable arm 41, and the positions of the rotatable arm 41, the supporting arms 43, the cross member 42, and the sweeper actuator 45 relative to the feeder conveyor 21. By controlling one or more of these parameters, the controller may control the rate at which received items get transported via the feeder conveyor 21 to the singulation device 30, which is a downstream part of the dispenser 10 relative to the feeder 20. By controlling one or more of these parameters, the controller may control the degree of singulation achieved at the feeder 20 of the dispenser 10.Singulation device

[0052] The singulation device 30, being a further downstream part of the dispenser 10, is configured to received items of the received cluster of items from the feeder 20. In a preferred example where the feeder 20 comprises a sweeper 40, the received items pass through the sweeper 40 before entering the singulation device 30.

[0053] An example singulation device 30 is shown in Figures 1 to 7. The singulation device 30 comprises a multi-levelled, differential speed conveyor 37. The singulation device 30 is configured to singulate items by the multi-levelled, differential speed conveyor 37 separating the items received from the feeder 20.

[0054] The singulation device 30 comprises a plurality of panels 36 defining an enclosure for the multi-levelled, differential speed conveyor 37. The panels 36 may each comprise a plurality of slots 31, which may reduce the material cost and allow for maintenance to be done without full disassembly of the singulation device 30. The panels 36 also function as structural support for the multi-levelled, differential speed conveyor 37.

[0055] The multi-levelled, differential speed conveyor 37 comprises a first conveyor 32, a second conveyor 33, and a first redirector 34 at the first conveyor level 37.1. At the first level 37.1 of the multi-levelled, differential speed conveyor 37, separation between items may be created using the first conveyor 32 and the second conveyor 33. The first conveyor 32 and the second conveyor 33 run in parallel and are configured to transport items away from the feeder 20 in a direction 38.

[0056] The first conveyor 32 functions at a first speed and the second conveyor 33 functions at a second speed. This differential-speed configuration can help generate separation between items passing through the first conveyor level 37.1, thereby contributing to singulation.

[0057] The differential-speed configuration may be achieved by providing shafts that have different diameters to the first conveyor 32 and the second conveyor 33. In some examples, the first conveyor 32 and the second conveyor may be configured to operate at 20 to 30 meter / minute. The faster conveyor may be 30-40% faster than the slow conveyor. This speed difference has been empirically determined to result in effective singulation.

[0058] When an item enters the singulation device 30 it falls onto the first conveyor 32, the second conveyor 33, or both (overlapping both conveyors 32 and 33) at the first conveyor level 37.1 at the top of the singulation device 30. The item is then moved by the first conveyor 32, the second conveyor 33, or both, in the direction 38 towards an end of the first conveyor level 37.1 distal the feeder 20. During this process the item may make contact with the first redirector 34 which is an inclined panel positioned on an angle over the first conveyor level 37.1. In the example shown, the inclined redirector 34 is positioned across the first conveyor 32 so that it covers one end of the first conveyor 32 and redirects any item it makes contact with towards the second conveyor 33.

[0059] Generally speaking, the first redirector 34 is configured to redirect items towards a single conveyor on the first conveyor level 37.1 as the items received from the feeder 20 are being transported towards the end of the first conveyor level 37.1 distal the feeder 20. In this way, the first conveyor level 37.1 may comprise a full-width portion proximate the feeder 20 and a narrowing portion extending from the full-width portion to the end of the first conveyor level 37.1 distal the feeder 20. The full-width portion has a width substantially corresponding to the total width of all parallel, differential-speed conveyors on the first conveyor level 37.1. The width of the narrowing portion decreases with displacement in the direction 38, which may be a linear relationship or a non-linear relationship depending on the form of the first redirector 34. The length of the narrowing portion corresponds to the length of the first redirector 34.

[0060] The redirection afforded by the first redirector 34 may contribute to singulation. As two adjacent items (which may be just touching, overlapping, or having some amount of separation) engage the first redirector 34 and are redirected onto a conveyor operating at a different speed, separation between the two adjacent items tends to increase.

[0061] Generally speaking, the angle of the first redirector 34 relative to the vertical is sufficiently steep such that items do not stagnate on the first redirector 34 and / or the conveyor 32. The angle of the first redirector 34 relative to the longitudinal is configured such that items do not stagnate on the first redirector 34 and / or the conveyor 32, taking into account thefriction between the item's surface and the surface of the first redirector 34 as well as the friction between the item's surface and the conveyors' surface.

[0062] Generally speaking, the height of the redirector is configured to accommodate the largest dimension of the variety of items the dispenser 100 is configured to receive.

[0063] Once an item reaches the end of the first conveyor level 37.1 it is allowed to freely fall to a second differential-speed conveyor level 37.2 directly below the first conveyor level 37.1. As multiple items reach the end of the first conveyor level 37.1 distal the feeder 20, any items which are stacked on top of each other may rotate as they begin to fall, generating separation between the items that were previously stacked.

[0064] Generally speaking, the height of the fall (i.e. the separation between adjacent conveyor levels) is configured to accommodate the largest dimension of the variety of items the dispenser 100 is configured to receive.

[0065] The conveyors of the first conveyor level 37.1 may operate according to a cadence. That is, the conveyors may operate periodically based on a period comprising an ON portion and an OFF portion. The cadence refers to the absolute duration as well as the relative duration of the ON and OFF portions. During the ON portion, the conveyors are active and convey the items received from the feeder 20 towards the fall to the second conveyor level 37.2. During the OFF portion, the conveyors are inactive - the items on the conveyors either remain stationary or move towards the fall due to existing momentum.

[0066] The conveyors may binarily switch from the ON portion to the OFF portion (that is, without gradual and smooth deceleration), creating a sudden halt in the movement of the items on the conveyors of the first conveyor level 37.1. This sudden halt can separate adjacent items, particularly at the ledge of the fall to the second conveyor level 37.2. For example, two overlapping items may arrive at the ledge as the conveyor 33 switches from the ON portion to the OFF portion. The item-bearing surface of the conveyor 33 preferably has more friction than the surface of the item, which may be a smooth plastic. Consequently, the top item of the two overlapping items may undergo further displacement due to existing momentum and enter the fall while the bottom item of the two overlapping items remains on the ledge. In this way,further separation is created between the two overlapping items, thereby contributing to singulation.

[0067] Generally speaking, the conveyors of the first conveyor level 37.1 operating in cadence in combination with the fall mechanism can contribute to singulation by creating separation between adjacent items and / or magnifying existing separation between items in proximity.

[0068] The singulation device 30 preferably comprises a second redirector 35 provided intermediate the first conveyor level 37.1 and the second conveyor level 37.2. An item falling from the first conveyor level 37.1 will make contact with the second redirector 35 which will disperse the items among a first conveyor 132 and a second conveyor 133 of the second conveyor level 37.2.

[0069] The second redirector 35 may be a simple component such as an angled panel attached to the panels 36. Different shapes may be used depending on the distribution desired between the first and second conveyors 132 and 133 of the second conveyor level 37.2. In the shown example the second redirector 35 is a panel angled towards the first conveyor 132 of the second conveyor level 37.2, so the items falling from the first conveyor level 37.1 will tend to land on the first conveyor 132 of the second conveyor level 37.2, though partial overlap with the second conveyor 133 of the second conveyor level 37.2 may occur.

[0070] Generally speaking, of the conveyor of the second conveyor level 37.2, the second redirector 35 redirects to the conveyor that is vertically aligned with the conveyor of the first conveyor level 37.1 and the first redirector 34 redirects away from.

[0071] The second redirector 35 provides a guiding sloping surface intermediate the second conveyor level 37.2 and the first conveyor level 37.1, which can help reduce the likelihood of damage to the falling items by reducing the fall distance.

[0072] The number, positioning, and shape of the second redirector 35 may be adapted based on the configuration of the first conveyor level 37.1.

[0073] The conveyors of the second conveyor level 37.2 may be substantially similar to the conveyors of the first conveyor level 37.1 with the notable exception that they are configured to transport items in a direction 39 opposite the direction 38. This may result in more efficient space utilisation as providing counter- moving conveyors in two vertically adjacent conveyor levels allows for a more compact singulation device 30 (hence a more compact dispenser 10).

[0074] The singulation device 30 comprises at the second conveyor level 37.2 a third redirector 134 that is substantially similar to the first redirector 34. In the example shown, the third redirector 134 is configured to redirect items on the first conveyor 132 of the second conveyor level 37.2 to the second conveyor 133 of the second conveyor level 37.2 as the items are being transported towards an end of the second conveyor level 37.2 distal the fall from the first conveyor level 37.1 to the second conveyor 37.2.

[0075] Once an item reaches the end of the second conveyor level 37.2 it is allowed to freely fall to a third differential-speed conveyor level 37.3 directly below the second conveyor level 37.2. The fall from the second conveyor level 37.2 to the third conveyor level 37.3 may contribute to singulation in a substantially similar manner to the fall from the first conveyor level 37.1 to the second conveyor level 37.2.

[0076] The singulation device 30 preferably comprises a fourth redirector 135 intermediate the second conveyor level 37.2 and the third conveyor level 37.3 that is substantially similar to the second redirector 35.

[0077] The singulation device 30 comprises at the third conveyor level 37.3 a first conveyor 232 (to which the fourth redirector 135 is configured to redirect items falling from the second conveyor level 37.2) and a second conveyor 233. The first and second conveyors 232 and 233 of the third conveyor level 37.3 are substantially similar to the first and second conveyors 32 and 33 of the first conveyor level 37.1 and the first and second conveyors 132 and 133 of the second conveyor level 37.2.

[0078] The first and second conveyors 232 and 233 of the third conveyor level 37.3 are configured to transport items in the direction 38.

[0079] The singulation device 30 comprises at the third conveyor level 37.3 a fifth redirector 234 that is substantially similar to the first redirector 34 and the third redirector 134. In the example shown, the fifth redirector 234 is configured to redirect items on the first conveyor 232 of the third conveyor level 37.3 to the second conveyor 233 of the third conveyor level 37.3 as the items are being transported towards an end of the third conveyor level 37.3 distal the fall from the second conveyor level 37.2 to the third conveyor 37.3.

[0080] Generally speaking, the multi-levelled, differential speed conveyor 37 comprises at least two conveyor levels. The conveyor levels may be substantially similar to each other including the interplay between constituent parts. The notable exception is that two vertically adjacent levels have opposing conveying directions e.g. direction 38 for the first and third conveyor levels 37.1 and 37.3 and direction 39 for the second conveyor level 37.2 as shown.

[0081] Further, the invention is not limited by the number of differential-speed conveyors at each conveyor level. While the Figures show two conveyors at each conveyor level 37.1, 37.2 and 37.3, in other examples a conveyor level may comprise a different differential-speed conveyor arrangement e.g. three parallel differential-speed conveyors. Preferably, each conveyor level comprises the same differential-speed conveyor arrangement.

[0082] While the example as shown depicts a single first redirector 34, in another example there may be provided multiple redirectors on any conveyor level of the multi-levelled, differential speed conveyor 37 depending on the differential-speed conveyor arrangement. For example, there may be two redirectors provided for three parallel differential-speed conveyors for redirecting items towards a central conveyor.

[0083] Further, the invention is not limited by which conveyor the redirection occurs at. Taking the first conveyor level 37.1 as an example, the Figures depict the first redirector 34 redirecting items on the first conveyor 32 towards the second conveyor 33. In another example, however, the first redirector 34 may redirect items on the second conveyor 33 towards the first conveyor 32.

[0084] The conveyors of each conveyor level preferably comprise a conveyor belt made of a material that is sufficiently rigid and possesses minimal dampening qualities such that whenitems fall on a conveyor, the items will bounce in a manner that minimises damage. This may occur on entering the singulation device 30 and further whenever falling from an upper conveyor level to a lower conveyor level.

[0085] In one example, the conveyors of each conveyor level comprise a conveyor belt made of thermoplastic polyurethane.

[0086] Generally speaking, providing more conveyor levels may lead to better singulation characterised by more consistent separation between adjacent items at the output of the singulation device 30. In any case, the items arriving at the end of lowest conveyor level of the multi-levelled, differential speed conveyor are considered singular items. It will be understood that this is not a guarantee of perfect singulation at all times, but rather that the items have undergone a singulation process.

[0087] Sensors may be provided to detect the speed and displacement of each conveyor of each conveyor level. The sensors may provide this information to a controller for controlling the acceleration and deceleration of each conveyor of each conveyor level. This controller may cooperate with the controller responsible for controlling the feeder to limit the amount of items being processed in the singulation device. Overfeeding items into the singulation device can cause items to be brought closer and / or overlap upon redirection.

[0088] Sorter

[0089] The dispenser 100 comprises a sorter 50 for receiving singular items from the singulation device 30 and selectively dispensing the singular items. The sorter 50 is provided downstream relative to the singulation device 30.

[0090] An example sorter 50 is shown in more detail Figure 8.

[0091] Once an item reaches the end of the lowest conveyor level of the multi-levelled, differential speed conveyor 37 (the third conveyor level 37.3 in the shown example), the item is distributed out of the singulation device 30. The item falls onto the sorter 50 which comprises a hub 51 that is configured to be actuated by an actuator 56.

[0092] The actuator 56 may comprise a stepper motor.

[0093] The sorter 50 comprises a plurality of arms 52, which may be integral with or detachably connected to the hub 50. The arms 52 are configured to rotate in concert with the hub 50 in response to actuation provided by the actuator 56.

[0094] In the example shown, there are provided four arms 52 radially extending from and evenly distributed around the hub 50, which is at the centre of the four arms 52.

[0095] Generally speaking, each instance of actuation by the actuator 56 is configured to cause the arms 52 to rotate by approximately 360 / n degrees, where n is the number of arms 52.

[0096] In the example shown, each arm 52 assumes a paddle form and comprises a rib 53 and a flap 54 downwardly extending from the rib 53. The rib 53 may be made of a flexible material. The flap 54 may be weighted relative to the rest of the arm 52. Preferably, the flap 54 comprises a plurality of projections 55 on the underside.

[0097] The surface 57 may have grooves 58 which match the projections 55 on the dispenser arms 52. Preferably, the projections 55 and grooves 58 are shaped so that the dispenser arms 52 may not separate from a surface 57 while the dispenser wheel 51 rotates. This allows the dispenser arms 52 to be flexible but not bend around an item.

[0098] Generally speaking, the arms 52 are configured to ensure stability in response to actuation provided by the actuator 56. For example, the arms 52 may each be shaped in such a way and / or be given a weight distribution that helps minimise overshoots and dampen oscillations.

[0099] As items exit the singulation device 30, they will fall onto a surface 57 between two of the dispenser arms 52. The dispenser arms 52 should be of a sufficient length such that even if the items were to be disposed by the singulation device 30 at an angle, they would be caught by an arm 52 and not fall off the dispenser 100. The surface 57 preferably has sufficiently low friction such that an item thereon can slide downwards under gravity and engage one or more of the arms 52 rather than come to a halt at a top portion of the surface 57 outside the radial length of the arms 52.

[0100] The surface 57 may be on an angle and the hub 51 may be on an angle relative to the conveyors of the multi-levelled, differential speed conveyor 37 so that the rotational axis of the hub 51 is substantially perpendicular to the surface 57.

[0101] The dispenser arms 52 are configured to prevent an item slipping off the sorter 50 via a gap between the bottom of the dispenser arms 52 and the surface 57. This may be achieved by providing a clearance between the bottom of the dispenser arms 52 and the surface 57, where is clearance is sufficient to avoid contact between the dispenser arms 52 and the surface but also not large enough to allow an item to slip off between a gap. This clearance may be configurable depending on the size of the received items.

[0102] Further, the projections 55 and the grooves 57 may also help prevent an item slipping off the sorter 50 via a gap between the bottom of the dispenser arms 52 and the surface 57 by eliminating the formation of such a gap.

[0103] The sorter 50 comprises a weight sensor and a controller (not shown). The surface 57 on which the items fall onto may be an instrumentation surface of the weight sensor, which is configured to measure the weight of the item or items currently on the surface 57.

[0104] Having knowledge of the expected weight (which may be given as an acceptable range) for a single item in the received cluster of items, the controller may be configured to estimate the number of items currently on the surface 57 and cause the actuator 56 to either rotate clockwise or anticlockwise, thereby selectively dispensing the singular items received from the singulation device 30.

[0105] In a first scenario, the controller determines that the weight detected by the weight sensor is within the acceptable range for a single item and causes the actuator 56 to cause the arms 52 to rotate in a first dispensing direction, which may be the clockwise direction or the anticlockwise direction. In doing so, the item or items received between the two arms 52 proximate the end of the singulation device 30 will be dispensed further downstream.

[0106] This first scenario may be considered a "success" scenario where the sorter 50 determines that a single item has been received from the singulation device 30 irrespective ofhow many items have actually been received. In other words, there may be false positive cases where multiple items are received and are erroneously dispensed downstream.

[0107] In a second scenario, the controller determines that the weight detected by the weight sensor is not within the acceptable range for a single item and causes the actuator 56 to cause the arms 52 to rotate in a second dispensing direction opposite the first dispensing direction. In doing so, the item or items received between the two arms 52 proximate the end of the singulation device 30 will not be dispensed further downstream.

[0108] This second scenario may be considered a "reject" scenario where the sorter 50 determines that multiple items have been received from the singulation device 30 irrespective of how many items have actually been received - this corresponds to a determination that the measured weight exceeds the acceptable range. Further, the sorter 50 may determine that a single item has been received but is faulty due the measured weight being lower than the acceptable range.

[0109] Following the second scenario, the rejected items may be dispensed by the arms 52 rotating in the second dispensing direction into a recycler configured to transport rejected items back to the feeder 20.

[0110] Preferably, the recycler comprises a recycling conveyor 60 that is configured to ascendingly transport rejected items towards and above the container 23. The rejected items upon reaching an end of the recycling conveyor 60 distal the sorter 50 and proximate the feeder 20 would fall off the recycling conveyor 60 into the container due to gravity.

[0111] In another example, the recycler may comprise a recycling container for temporarily holding the rejected items. Once the recycling container is sufficiently full, a person may manually transport the rejected items back to the feeder 20.

[0112] A rejected item after undergoing the recycling process would become a part of the cluster of items and no longer be considered a singular item until after having undergone singulation via the singulation device 30.

[0113] Kitting System

[0114] According to the present invention, there is also provided a kitting system comprising a plurality of dispensers. An example kitting system 100 is shown in Figures 9 to 11.

[0115] The kitting system 100 comprises a plurality of upper dispensers 11 longitudinally disposed along a longitudinal axis 90 at indexed longitudinal positions e.g. positions 90.1, 90.2, 90.3, and so on. In the example shown, there are eleven upper dispensers 11 corresponding to indexed longitudinal positions 90.1 to 90.11. Each upper dispenser is configured to receive a cluster of items and dispense singular items.

[0116] To avoid doubt, the longitudinal direction in the context of the kitting system 100 is different from the longitudinal direction in the context of a single dispenser 10.

[0117] The plurality of upper dispensers 11 may collectively be considered an upper dispenser array.

[0118] Each upper dispenser 11 may be a dispenser 100.

[0119] The kiting system 100 comprise a plurality of lower dispensers 10 provided at the same indexed longitudinal positions 90.1 to 90.11. Each lower dispenser is configured to receive a cluster of items and dispenser singular items.

[0120] The plurality of lower dispensers 10 may collectively be considered a lower dispenser array.

[0121] Each lower dispenser 10 may be a dispenser 100.

[0122] Preferably, there is an equal number of upper dispensers 11 and lower dispensers 10. Each upper dispenser 11 may be vertically stacked on top of a corresponding lower dispenser 10 at each of the indexed longitudinal positions. Stacking an upper dispenser 11 on top of a lower dispenser 10 may involve providing fasteners and supporting structures in addition to the dispenser 100.

[0123] Each upper dispenser 11 or lower dispenser 10 is configured to operate in parallel relative to any other upper dispenser 11 or any other lower dispenser 10.

[0124] The kitting system 100 comprises an upper conveyor 102 running longitudinally along the plurality of upper dispensers 11. The upper conveyor 102 is configured to receive and transport singular items from each of the upper dispensers 11. The upper conveyor 102 is provided at a height at or below the end point (which may be a sorter 30) of each of the upper dispensers 11.

[0125] The kiting system 100 comprises a lower conveyor 101 provided below the upper conveyor 102 and running longitudinally along the plurality of lower dispensers 10. The lower conveyor 101 is configured to receive and transport singular items from each of the lower dispensers 10. The lower conveyor 101 is provided at a height at or below the end point (which may be a sorter 30) of each of the lower dispensers 10.

[0126] The upper conveyor 102 and the lower conveyor 101 may each be a trough conveyor comprising a flat trough portion and angling portions at each end of the conveyor.

[0127] The upper conveyor 102 and the lower conveyor 101 may be configured to converge at a convergence point 103 and proceed further downstream. In the example shown, the upper conveyors 102 and the lower conveyor 101 converge and proceed downstream for further processing by a person.

[0128] Alternatively, the upper conveyor 102 and the lower conveyor 101 do not converge and separately proceed further downstream for different processing.

[0129] In use, a person or an automated means (e.g. a robot) may provide a cluster of homogenous items at an entry point of some or all upper and lower dispensers 11 and 10. The entry point may be a feeder 20. The received items of the cluster of items may then undergo singulation via a singulation device, which may be the singulation device 30 comprising a multilevelled, differential speed conveyor 37. Each dispenser 10 or 11 then selectively dispenses singular items at the end point, which may be a sorter 50. This may involve determining, in a first scenario, that a single non-faulty item has been obtained at the end point and subsequently dispensing the item or items onto a conveyor 101 or 102 for further processing. The selective dispensing may further involve determining, in a second scenario, that a single non-faulty item has not been obtained at the end point and dispensing the item or items intoa recycler, which then transports the rejected item or items back to the entry point. The recycler preferably comprises a recycling conveyor 60. The rejected item or items become a part of a cluster of items and re-enter a dispenser 10 or 11.

[0130] The kiting system 100 with its stacked dispenser arrays may provide a compact automated singulation and kiting solution that reduces floorspace usage and allows for parallel processing of a received cluster of items.

[0131] The invention is not limited by the number of dispensers. While the Figures show eleven dispensers in each dispenser array, there may be provided fewer or more dispensers in each dispenser array in other examples. While the Figures show two dispenser arrays, there may be provided fewer or more vertically stacked dispenser arrays in other examples - fewer or more conveyors would also need to be provided accordingly.

[0132] Interpretation

[0133] The term "comprises" and other grammatical forms is intended to have an inclusive meaning unless otherwise noted. That is, they should be taken to mean an inclusion of the listed components, and possibly of other non-specified components or elements.

[0134] While the present invention has been explained by the description of certain embodiments, the invention is not restricted to these embodiments. It is possible to modify these embodiments without departing from the spirit or scope of the invention.

Claims

CLAIMS1. A dispenser comprising: a feeder for receiving a cluster of items and feeding the items of the cluster of items downstream; a multi-levelled, differential speed conveyor configured to receive items from the feeder, singulate items, and provide singular items downstream; and a sorter for receiving the singular items and selectively dispensing the singular items.

2. The dispenser of claim 1, wherein the multi-levelled, differential speed conveyor comprises a first conveyor level and a second conveyor level, each of the first conveyor level and the second conveyor level comprising a first conveyor configured to operate at a first speed and a second conveyor configured to operate at a second speed.

3. The dispenser of claim 2, wherein the first conveyor level and the second conveyor level each comprise a redirector configured to redirect items from the first conveyor to the second conveyor.

4. The dispenser of claim 3, wherein the redirector is an angled panel positioned over the first conveyor.

5. The dispenser of any one of claims 2 to 4, wherein the first conveyor and the second conveyor of the first conveyor level and the first conveyor and the second conveyor of the second conveyor level are configured to operate according to a cadence.

6. The dispenser of any one of claims 2 to 5, wherein the multi-levelled, differential speed conveyor is configured to transport items from the first conveyor level to the second conveyor level via free fall at an end of the first conveyor level.

7. The dispenser of claim 6, wherein the multi-levelled, differential speed conveyor comprises a redirector intermediate the first conveyor level and the second conveyor level, theintermediate redirector being configured to cause freefa Hing items to tend to land on the first conveyor of the second conveyor level.

8. The dispenser of any one of claims 2 to 7, wherein the first conveyor and the second conveyor of the first conveyor level and the first conveyor and the second conveyor of the second conveyor level each comprise a conveyor belt made of thermoplastic polyurethane.

9. The dispenser of any one of claims 2 to 8, wherein the first speed and the second speed differ by 30% to 40%.

10. The dispenser of any one of claims 2 to 9, wherein the first conveyor and the second conveyor of the first conveyor level are configured to convey items in a first direction, wherein the first conveyor and the second conveyor of the second conveyor level are configured to convey items in a second direction opposite the first direction.

11. The dispenser of any one of claims 1 to 10, wherein the feeder comprises a sweeper for reducing the overall height of the received cluster of items.

12. The dispenser of any one of claims 1 to 11, wherein the feeder comprises an incline conveyor for ascendingly conveying the received cluster of items to a fall from the feeder to the multi-levelled, differential speed conveyor.

13. The dispenser of claim 12, wherein the incline conveyor comprises ridges spaced along the conveying direction.

14. The dispenser of any one of claims 1 to 13, wherein the sorter comprises a surface configured to receive the singular items and a plurality of rotatable dispenser arms configured to selectively dispense the singular items.

15. The dispenser of claim 14, wherein the rotatable dispenser arms and the surface are configured to maintain a received singular item between two arms of the rotatable dispenser arms and in contact with the surface.

16. The dispenser of claim 14 or claim 15, wherein the sorter comprises a weight sensor, wherein the surface is an instrumentation surface of the weight sensor.

17. The dispenser of claim 16, wherein the sorter comprises a controller configured to, in response to determining that a measured weight corresponds to a single non-faulty item, rotate the rotatable dispenser arms in a first dispensing direction, and wherein the controller is configured to, in response to determining that a measured weight corresponds to multiple items or a single faulty item, rotate the rotatable dispenser arms in a second dispensing direction opposite the first dispensing direction.

18. The dispenser of claim 17, further comprising a recycler configured to transport items dispensed by the rotatable dispenser arms rotating in the second dispensing direction back to the feeder.

19. The dispenser of claim 18, wherein the recycler comprises a recycling conveyor for ascendingly conveying items towards and above the feeder.

20. A feeder comprising: a rotatable arm comprising a sweeping edge; a conveyor for transporting a cluster of items downstream past the rotatable arm, the conveyor comprising an item-bearing surface spaced from the sweeping edge of the rotatable arm; a sensor for sensing the size of the items in the cluster of items; and a spacing adjuster for adjusting the spacing between the sweeping edge of the rotatable arm and an item-bearing surface of the conveyor based on the size of the items; wherein the rotatable arm is configured to separate the items of the cluster of items by rotationally sweeping a top portion of the cluster of items with the sweeping edge.

21. The feeder of claim 20, wherein the rotatable arm comprises two rectangular, planar members connected at a shaft defining the axis of rotation for the rotatable arm.

22. The feeder of claim 20 or claim 21, wherein the rotatable arm is made of polyurethane.

23. The feeder of any one of claims 20 to 22, further comprising a barrier configured to help prevent any items exceeding a predetermined height from passing.

24. The feeder of any one of claims 20 to 23, wherein the conveyor is configured to operate according to a cadence.

25. A dispensing system comprising: a plurality of upper dispensers longitudinally disposed at indexed longitudinal positions, each upper dispenser being configured to receive a cluster of items and dispense singular items; a plurality of lower dispensers provided at the indexed longitudinal positions, each lower dispenser being configured to receive a cluster of items and dispense singular items; an upper conveyor configured to receive and transport singular items from each of the upper dispensers; and a lower conveyor configured to receive and transport singular items from each of the lower dispensers; wherein each upper dispenser or lower dispenser is configured to operate in parallel relative to any other upper dispenser or any other lower dispenser; wherein an upper dispenser is vertically stacked on top of a lower dispenser at each of the indexed longitudinal positions.

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