Field of Invention

The invention relates to intermodal devices, and in particular, systems and methods for packing goods in said intermodal devices.

Background of the invention Intermodal systems involve standard intermodal devices, which include shipping containers, and modular containers that fit within shipping containers. Within these modular containers, packaging material such as KLT boxes are commonly loaded. Regrettably, much of the packaging material is single use, leading to a detrimental environmental impact. This is changing, however, with a small range of systems available that are suited for re-use. As an example, the system described in WO2019216827 describes such a reusable system, the contents of which are incorporated by reference.

This leads to a subsequent problem of how to transform the used materials so that they may be re-used. Each re-use would desirably be applicable for transporting any article, regardless of the articles previously transported by the re-usable materials. This begs the question of how to ensure these materials are suitable, without knowing the near history. Dirt, dust, chemicals, or any undesirable contaminants may be easily transferred between articles unless adequate cleaning has been performed. Further, whilst re-use has economic benefits, the time for sanitizing the materials and re-configuring them for the next articles to be transported may take a significant time to turn around, destroying the intrinsic value of re-usable materials. For the materials to be cleaned and unloaded manually is time-consuming and inefficient.

Summary of the Invention

According to a first aspect of the invention, the invention provides for a divider removal system for removing a plurality of selectively releasable dividers from a divider plate, the system comprising: a divider removal assembly having a plurality of dowels, said dowels arranged to release the dividers from the divider plate; a support for engaging the divider plate and providing a reaction force against a force applied by said dowels; wherein the dowels are arranged to approach the dividers from a first side of the divider plate.

According to a second aspect of the invention, the invention provides for a divider insertion system comprising; a selectively movable arm having a head for inserting a divider into an aperture of a divider plate; said head including a nozzle for delivering the divider and an actuator arranged to punch said divider.

According to a third aspect of the invention, the invention provides for a divider inspection system comprising; a divider conveyor for arranging a plurality of dividers sequentially; a brush conveyor for receiving the dividers from the divider conveyor, said brush conveyor comprising a plurality of bristles arranged to move along an inspection path, said dividers arranged to be engaged by said bristles; a vision system for capturing images of the dividers; a control system for analysing said images; wherein said control system is arranged to reject unsuitable dividers not meeting pre-determined conditions. According to a fourth aspect of the invention, the invention provides for a method for removing a plurality of selectively releasable dividers from a divider plate, the method comprising the steps of: engaging the divider plate with a support; a plurality of dowels approaching the dividers from a first side of the divider plate; releasing said dowels through contact by said dowels; said support providing a reaction force against a force applied by said dowels.

According to a fifth aspect of the invention, the invention provides for a method for inserting a divider into a divider plate, the method comprising the steps of: moving a selectively movable arm such that a head of said arm is proximate to an aperture of said divider plate; punching said divider into engagement with the aperture using an actuator in said head, and so; inserting a divider into the aperture.

According to a sixth aspect of the invention, the invention provides for a divider for insertion into an aperture of a divider plate, the divider comprising: a divider base arranged to be inserted into said aperture; each divider base having a resiliently retractable circumferential lug; said lug arranged to be compressed by a lip in said aperture on insertion; said lug further arranged to expand on passing to said lip so as to lock the divider into the aperture. Brief Description of the Figures It will be convenient to further describe the present invention with respect to the accompanying drawings that illustrate possible arrangements of the invention. Other arrangements of the invention are possible and consequently, the particularity of the accompanying drawings is not to be understood as superseding the generality of the preceding description of the invention.

Figures 1A and IB are respective perspective and side drawings of an automated system. Figure 1C is a perspective view of an automated system with open doors.

Figure 2 is a process flow diagram.

Figures 3A and 3B are perspective views of an unstacker and opener station adjacent a washer and dryer station.

Figures 4A and 4B are perspective views of another unstacker and opener station adjacent a washer and dryer station.

Figure 5 is a side view of a vertical carousel chain.

Figures 6A-6C are perspective views of the vertical carousel chain. Figure 7 is an end view of the unstacker and opener station.

Figure 8 is a detailed side view of transfer gantries.

Figure 9 is a detailed side view of unloading gantries.

Figures 10A and 10B are perspective views of a re-configurator.

Figure 11 is a top view of a re-configurator. Figure 12A is a perspective view of a re-configurator.

Figure 12B is a side view of a re-configurator.

Figure 12C is a detailed side view of a re-configurator.

Figure 13 is a detailed perspective view of a loading end of a re-configurator. Figures 14A and 14B are perspective views of a pin removal system.

Figures 15A-15G are detailed perspective views of the pin removal system. Figures 16A-16D are side views of another pin removal system.

Figure 16E is a detailed side view of the pin removal system of Figure 16D. Figures 17A and 17B are perspective views of a pin ejector.

Figure 18 is a perspective view of a step feeder system.

Figure 19 is a perspective view of a vision system.

Figure 20 is a perspective view of a vision system.

Figure 21 is a side view of the re-configurator showing the conveyor system. Figure 22 is a perspective view of a pin delivery system.

Figure 23 is a perspective view of a pin delivery system showing the tube feeding. Figure 24 is a perspective view of a pin delivery system showing pin insertion. Figure 25 is a perspective view of an end-effector.

Figure 26 is a top view of a divider plate.

Figure 27 is a perspective view of a pin delivery system showing an imaging unit. Figure 28 is a perspective view of an unloading end of the re-configurator.

Figure 29 is a side view of an automation system.

Figure 30 is a process flow diagram.

Figures 31A and 3 IB are respective side and perspective views of a divider. Figures 32A and 32B are side views of a divider base. Figures 33A and 33B are respective perspective views of the top and bottom surface of a divider plate.

Figures 34A and 34B are respective side and bottom views of a divider inserted into an aperture. Figures 34C and 34D are respective perspective and side views of a divider removal device in action.

Detailed Description Automated system

Figures 1A and IB show an automated system 1 for processing packaging material, such as KLT boxes (also called “Euro containers”) and dividers / pins. The automated system may be configurable to be housed within shipping container(s), such as a 45-ft, 40-ft, or two 20-ft shipping containers. It will be appreciated that the system may be configurable to fit other housing dimensions. In a further embodiment, each or all of the stations described below may be permanently mounted as a separate structure, or within a larger factory environment. Thus, whilst the embodiment of Figures 1 A and IB is highly portable, the invention may also encompass a fixed structure used in a fixed environment. For clarity, the following description may refer to the portable system, though this does not diminish the potential for a fixed facility for any, or all, of the stations.

The housing may include the necessary ports for electrical power supply, water supply, and drainage.

The invention may include any one or a combination of aspects, such as: 1) Unstacker and opener 10;

2) Washer and dryer 20;

3) Transition zone 30;

4) Re-configurator 40; 5) Inspection system 50; and

6) Stacking station 60.

Thus, each station may be used separately from the others, or they may be combined to encompass the full automated system 1. For example, the re-configurator 40 may be used in isolation, with materials provided to it that have been cleaned in a separate process at the same or different location.

Each station shall be described in the following sections of the description.

For example, an automation system may comprise: 1. Operator Interface

2. 2x Step Feeders

3. Pin Failure Vision Camera and Ejection System

4. 2x Pin Removal Machines

5. Full Board Conveyor from Input to Output 6. 16x Articulated Robots

7. Air-Lubricated Tube Feeding System

8. Structural Frame for Component Mounting

9. Robot Controllers (PLC)

10. Air Compressor 11. Power Supply

12. Climate Control System (As required by PLC)

13. Washer and dryer machine

Figure 1C shows the automated system housed within a 45-ft container with double-opening doors 101. The automated system may be transported on a container truck (not shown) to a loading/unloading dock for collecting used KLTs / boxes 102 and delivering clean re-configured boxes. Alternatively, the housing may be self-propelled through integration with a prime mover. The system may be set up by 1 or 2 human operators. The whole automated system will be fully functioning from within the container. All stations will be equipped with an “Auto-Lock Mode” which will be triggered before shutdown. When “Auto-Lock Mode” is triggered, all end-effectors and moving assemblies will be locked in place to ensure rigidity during freight shipment. The robots will store the datum point in the internal memory to ensure that no manual calibration process is required upon each deployment. A fully welded tubular and I- beam steel frame will be rigidly mounted to the container walls in the container. The structure will provide rigidity to prevent excessive vibration or displacement of components. The structure will also provide all rigid mounting points required for all components.

Figure 2 shows a flow diagram of the full process from unstacking used boxes to stacking clean re-configured boxes. Both used and clean boxes are stackable on pallets, which may be transported using forklifts to the user’s desired destination. This may save storage space, manpower and transport time.

1) Unstacker and opener Figures 3A and 3B show an unstacker and opener station 10 at the loading end of the automation system. Used boxes 102 are transported on a pallet 111 and delivered into the unstacker and opener station 10 by a pusher. Individual boxes 102 are placed on a conveyor system which transfers them from the unstacker and opener station 10 to the washer and dryer station 20. The boxes are moved upwards and away from the loading end through the transition zone towards the unloading end, as indicated by the arrows. During the transfer, the box 102 is oriented and unlocked. Each box contains at least one divider plate (may also be called “divider board”, “board” or “separate base”) and each divider plate may contain at least one divider (may also be called “divider pin” or “pin”). The inversion process also dislodges the divider plate from the base of box 102.

The divider plate(s) and box fall separately into the washer and dryer station 20. At the end of the station, the box and divider plate(s) are placed on separate conveyor belts. Figures 4A and 4B show another arrangement of the unstacker and opener system.

In another embodiment shown in Figure 5, the stacked boxes are delivered on a pallet to the loading point and loaded onto a conveyor belt. An extendable gantry robot 80 will pick the box with plates and place them to the loading point on the vertical carousel 270. As the box moves upwards in the carousel, it will enter a station where a specially designed actuator which provides the specific actions of opening the box will do so automatically. The box will then continue upwards along the carousel to the highest point; where it will be flipped along with the rotating movement of the carousel carriage. (Imagine a Ferris wheel where the carriages are fixed and do not align with gravity.) The carriage will be designed to hold on to the box until a full 180-degree flip is completed. The carriage will then release the box on to the conveyor. The divider plate will fall due to gravity and the box cupped over the dislodged divider plate will be moved by the conveyor into the washing line.

Figures 6A-6C and 7 show an arrangement of a vertical carousel system. The opened boxes 112 and divider plates 114 are separated moved in the direction of the arrows.

2) Washer and dryer

Figure 1A, 1C and 4B show a washer and dryer station 20.

For example, water usage may be about 2 drums (300 to 400 litres). After washing and drying, the boxes 102 and divider plates 104 are moved by a conveyor system into the transition zone 30.

3) Transition zone

The container will have openings on both long sides to allow for service access and ventilation to the articulated robots and conveyor systems. A dedicated HMI controller will be included as a handheld device connected via an overhead harness, allowing for input and selection of configuration files, process monitoring, fault trigger identification and emergency stop triggering.

In an embodiment, the transition zone 30 may include a bridging conveyor system to separate and transfer the clean divider plates, dividers, and boxes from the washer and dryer station 20. The cleaned divider plates and dividers to transit to the re configurator station 40, while the cleaned boxes will be transferred to the box conveyor

47. An operator may be stationed in the transition zone 30 to aid the transfer. Alternatively, an automated pick and place system replaces or enhances human interaction. The pick and place system may include object identification capability to identify and differentiate articles. In another embodiment, the transition zone 30 may include a buffer zone. The operator may add or remove divider plates and dividers in the buffer zone depending on the requirements of the reconfigured plates. For example, if the used boxes (input) contain more divider plates or dividers than the clean boxes (output), the excess divider plates or dividers are stored in the transition zone 30. Conversely, if the input contains less divider plates or dividers than that required by the output, more divider plates or dividers are loaded into the transition zone. The buffer zone ensures smooth work flow even if the divider plates are moved at different speeds in the washer and dryer 20 and re-configurator 40.

In an alternative embodiment, the transition zone may contain pick-and-place gantry robots (Figures 8 and 9).

There may be two gantry robots 105 and 106 to transfer the box and divider plates from the washer/dryer conveyor to the respective conveyors. These gantry robots will be equipped with end-effectors that will be able to handle both boxes and divider plates, as well as to rotate them to the desired orientation. The processes occurring in the transfer gantry after drying is as follows:

Step 1:

Gantry pick-and-place (P&P) robot 105 will pick the box and cover (if there is a separable cover) from lane 1 of the washer/dryer. The P&P end-effector is equipped with a rotator head that will flip the box into the desired orientation and place it on the box conveyor (in the middle of the line) which goes directly to the end of the configuration line. Gantry P&P robot 106 will then pick the box from lane 2 of the washer/dryer; this P&P end-effector equipped with a rotator head similarly flipping the box to the desired orientation and placing it on to the same box conveyor after the first box has moved away.

In another embodiment, the robots 105 and 106 will place the box and/or cover on the same conveyor.

Step 2:

Gantry P&P robot 105 will then pick up divider plates left on lane 1 of the washer/dryer. This P&P end-effector is equipped with a rotator head that flips a first divider plate to the desired orientation and place it on to lane 1 of the configuration line conveyor. The P&P end-effector picks up the second divider plate without flipping and places it on the lane 1 conveyor. The gantry P&P robot 106 picks up divider plates left on lane 2 of the washer/dryer. This P&P end-effector is equipped with a rotator head flips a first divider plate to the desired orientation and place it on lane 2. The same gantry P&P end-effector picks up the second divider without flipping and places it on lane 2 of the configuration line conveyor (without flipping as it is already in upright orientation).

In another embodiment, the robots 105 and 106 will place divider plates on the same conveyor.

Step 3:

The box may comprise an integrated cover or a separable cover. If the box has a separable cover, robot 105 picks up the box cover left on lane 1 of the washer/dryer conveyor and place it onto the cover conveyor which goes to the end of the configuration line. Robot 106 similarly picks up the box cover left on lane 2 and place it onto the same cover conveyor.

Step 4:

The washer/dryer machine may suspend to balance the Cycle Speed to the Configurator lanes 1 and 2.

Alternatively, robot 105 may pick up the divider plate and robot 106 may pick up the box from the same lane from the washer/dryer station, and place the item in the respective box and divider plate in the transition zone as needed.

Figure 9 shows that another set of gantry pick-and-place robots may be positioned in the unloading zone after the re-configurator. Two gantry robots 107 and 108 pack divider plates into clean boxes and stack them into pallets.

The processes occurring in off-loading after drying is as follows:

Step 1:

Lanes 1 and 2 have independent vision systems equipped with servo X-Y axis to scan-check the completed divider plates.

Step 2:

Gantry P&P 107 picks up the finished first divider plate on lane 1 after vision inspection, this P&P 107 end-effector is equipped with a rotator head, and places the divider plate inside the box on the conveyor in the middle of the lane. The same P&P 107 end-effector picks up the finished second divider plate, flips it over to the correct orientation and places it inside the box on the conveyor in the middle of the lane. Gantry P&P 108 picks up the finished first divider plate on lane 2 after vision inspection. This P&P 108 end-effector picks up the finished second divider plate, flips it over to the desired orientation and places it inside the box on the conveyor in the middle of the lane. Step 3:

If the box contains a separable cover, a box-unloading extendable gantry P&P picks up the cover from the common cover conveyor in the middle of the lane, and transfers the cover to the finished box with at least one divider plate (or “divider board”) with dividers, and transfers the entire box with the cover to the pallet outside the container.

4) Re-configurator

A buffer tray may be added to or removed from the re-configurator for ensuring smooth operation of the re-configurator, such that it does not depend on the flow of the washer/dryer system.

There will be a stack of divider plates placed within reach of the above- mentioned pick and place robots 1 and 2 which are in charge of loading divider plates on to the configuration line. The stack of divider plates will be in a user-accessible area to be easily replenished by an operator.

Should the system receive information that a double divider plate configuration is required after an originally single plate configuration, it will alternate the picking of divider plates between the washer/dryer output conveyor and the additional divider plate stack. The re-configurator station 40 may contain a programmable control, upon which an operator may input parameters (number of dividers per plate, location of dividers, number of divider plates, number of divider pins, conveyor speed, etc.).

The system may use direct outputs from a software that uses AI and visual recognition to optimize and plan the most efficient layout for the dividers on each plate. This layout will then be sent to the robotic arms to insert dividers at the assigned apertures.

Brief Description of the 3D Packing using AI and visioning

1. When a user uploads a 3D model of an object into the AI optimization packing system, the system derives parameters for planning the layout of the dividers to protect the object during transport. Parameters for the planning process may include but are not limited to: the object’s weight, shape, packing tightness, and centre of gravity. A user may input values of the parameters, override or correct values. Alternatively, the parameters may be input into the control system using AI and visual recognition/visioning.

2. The control system will perform a series of calculations to produce an optimised packing configuration that packs the optimum number of items into a box.

3. The automation system outputs the packing layout to the re-configurator and robotic arms to generate the re-configured divider plates.

Figures 10A-10C and 11 show various components of the re-configurator 40 within a structural frame 43. The input end faces the transition zone, and the output end faces the unloading end of the automation system. The re-configurator 40 contains two rows of identical board conveyors 44 for divider plates 201 so that two divider plates can be re-configured simultaneously. Dividers are removed at the pin removal stations 81 and fed into step feeders 83, which in turn feeds the dividers to the pin conveyor 46. This saves space and provides a high processing speed for divider plates. Having a dual lane conveyor also affords redundancy in the event of faults or errors, as one line can continue production while the other line is serviced. The system may include safety controls such as an emergency stop switch or Human Machine Interface (HMI). The system may also include a colour strobe which lights up when the emergency stop switch is activated.

A row of 8 robotic arms 45 is suspended above each row of divider plate / board conveyor 44. A tube feed shuttle 51 provides dividers to both rows of robotic arms. A pin / divider conveyor 46 is positioned between robotic arms 45 to provide a shared pool of dividers / pins. Boxes are transported to the end of the re-configurator 40 by a box conveyor 47. Figures 12A-12C show the re-configurator 40 in more detail.

Figure 13 shows the board conveyors 44. Used divider plates will be loaded onto the conveyor 44. The loading point may be configured to connect to additional conveyors from the transition zone as required.

Dividers from the divider plate 201 are removed at a divider removal station 81 (Figure 14 A) and fall into a chute 82 that directs the dividers into the hoppers of a step feeder 83 for reuse (Figure 14B).

The divider removal station is described in further detail with reference to Figures 15A-15G. The divider removal station includes a support board, which in this case is a comb support board 91 the divider plate 95 may be held in position on the board conveyor 44 by a board holder 92. When the divider plate reaches the position proximate to the support board, the board holder and support board move relative to each other until the dividers contact and are engaged by the support board. At this point, the relative pressure applied by the board holder and support board is arranged to hold the divider plate in place. The support board may also include a coupling surface arranged to couple with the dividers to prevent movement as they are being removed.

In those embodiments where the support board includes a coupling surface, such a coupling surface may include an elastomeric layer arranged to hold the dividers in place through friction. Alternatively, the coupling surface may include an array of apertures arranged to receive the dividers, with the apertures having lugs to mechanically prevent movement of the dividers. In a still further embodiment, Figures 15A to 15F show the coupling surface as a comb of quills or struts, and thus forming a comb support plate 91. The embodiment of Figures 15A to 15F therefore provide a combination of apertures (interstitial spaces between the quills) and friction (with the selectively releasable dividers being held by a resilient force acting on the dividers as the resilient quills are deflected on receiving each divider.

In the embodiment of Figures 15A to 15F, when the divider plate is directly in front of the comb support board 91, the relative movement between the support board and board holder is provided through a tilting section 93 of the board holder 92 which rotates the divider plate. In this embodiment, the support board is substantially fixed and the board holder movable. It will be appreciated that relative movement may be achieved by the board holder moving to a fixed support board, the support board moving to a fixed board holder or both moving. The tilting section may rotate the board holder by about 90° (Figure 15D), thus bringing the divider plate 95 and dividers 96 in contact with the comb support board 91. The dividers 96 engage with quills of the comb support board 91 (Figure 15E). The tilting section 93 may contain an array of cylindrical dowels that are actionable against the selectively releasable dividers 96. The dowels will take on the form of a hollow cylinder with a chamfered (angled) edge to reduce friction when pushing against the clip. The number of cylindrical dowels may be 1623, or other pre-determined number depending on the number of apertures on the divider plate. The tilting section may include an actuator for pushing the dividers out in a one-shot removal process. The quills 94 of the comb support board 91 may be made of a range of materials. The quills must be flexible enough to resilient deflect as the dividers are inserted, but also stiff enough to apply the frictional force mentioned previously. The quills must also be thin enough to not interfere with the spacing of the dividers which may be close packed. One example of a suitable quill may include a hardened steel fibre. Such a fibre may have a diameter in the range of 0.5mm to 1.75mm, such that the quills bend and fit into the spaces around the dividers. The quills may also be coated to prevent surface damage to the dividers. The quills 94 ensure that the divider plate is well supported during the removal process, and prevents deformation of the dividers due to the large force applied for removal (Figure 15F). The quills 94 may be retractable. When the quills are retracted, the dividers fall under gravity into the chute leading to the step feeder. This enables an automated divider removal process without human intervention, and also offers shorter processing time. The tilting section 93 is arranged to rotate through the use of a rotational actuator. The rotational actuator may include a rotational motor mounted to the tilting section, and arranged to selectively rotate on the conveyor section 44 receiving a divider plate 95. To this end, detection of the divider plate may include location sensors in the conveyor section, or optical sensors adjacent to the conveyor section 44.

The conveyor section may include operable tabs that act to secure the divider plate in place during rotation. Alternatively, the conveyor section may have a “tacky” surface to short term adhesion during rotation. Other such means, including suction may also be used. Figures 16A-16E, 17A and 17B show another divider removal system 90. First, the divider plate 901 is moved to the removal station. The plate 901 is then clamped on both sides by clamps 908, 909 which are arranged to clamp peripheral edges of the divider plate 901. On delivery to the divider removal system, the plate 901 is inverted such that the dividers/pins face downwards. A divider removal assembly 902 moves towards the plate from a first side so as to be proximate to a batch of dividers to be removed, and presses a dowel 903 into the base of the divider 904. A prop support 905 may be positioned on the other side, that is a side opposed to the first side, of the plate. The prop support may be movable. The support plate may be a flat surface or may contain props 906 arranged to support the divider plate as the dowel is pressed against the divider. In so doing, the prop and prop support provide a reaction force against this force. The prop support may extend one or several props. These may then be arranged to support that part of the plate where the dividers are being removed. To this end, where batches of dividers are removed simultaneously, the props may be arranged adjacent to the batches. When the divider plate 901 is in position, the prop support extends props until they contact the plate on a face opposite to that of the divider removal assembly.

A cylindrical wall of the dowel engages a base of the divider and pushes out the divider 904. As the dowel engages the base, the dowel may disengage a locking assembly of the base in order to unlock the divider. A chute 907 below the removal station collects and directs divider pins to the step feeder for reuse. The divider plate and divider removal assembly are arranged to move relative to each other. In this embodiment, the divider removal assembly remains static and the divider plate is moved by a motor mounted to the clamps 908, 909. The motor is connected to a screw threaded rod for precisely moving the clamped divider plate. When a first batch of dividers is removed, the motor 910 then moves the plate 901 until the divider removal assembly is proximate to the next batch of dividers, and the removal process is repeated. This process continues until all the dividers are removed. In some embodiments, the batches may be a single row of dividers. In other embodiments, several rows may be removed simultaneously.

It is noted that the means of removal of the pins is in accordance with that shown in Figure 34C. Only one dowel is shown for clarity, and it will be appreciated that an array of dowels corresponding to the pins may be used.

It will further be appreciated that the array of dowels may be sufficient to remove all the pins simultaneously. Alternatively, a movable section housing the dowels may be arranged such that sections of the pins are removed, before the dowel array is moved to the next section. In this alternative, several removal steps may be required before the entire pins are removed. The hoppers of the step feeder 83 outputs dividers onto the divider conveyor 46 where they are arranged sequentially (Figure 18). The divider conveyor includes an inspection station having a brush conveyor, such as the rotary holder 300 (Figure 20), for transporting the dividers along an inspection path. In the present embodiment, the inspection path is circular, but also may be other shapes including linear. The inspection station further includes a vision system 50 arranged to inspect the dividers as they are delivered onto the divider conveyor 46 by the step feeders 83 (Figure 19). The vision system 50 may comprise multiple cameras to capture images of the same divider from multiple angles. The captured images are processed by a control system and compared in real-time to pre-determined conditions, for example by assessing deformation of each divider. The deformation may include: i) Exceeding a threshold, such as greater than 4 mm from a longitudinal axis of the divider; ii) Portions of the divider sheared off; iii) Deformation of the divider base, etc.

In this case, the divider may be deemed unsuitable and rejected by the control system. Said rejection may include being blown by blast of compressed air into a collection bin. If a rotary holder is used to transport the dividers, the air jet blows the divider out of the holder such that the divider falls into the collection bin.

The rotary holder 300 is made of firm brushes which hold the dividers 22 securely enough between its bristles 306, but loosely enough such that the divider’s surface and coating will not be damaged. It also allows the dividers to be dislodged with a jet of compressed air.

The vision system may comprise two vision cameras 291 and 292 coupled with backlights 301 and 302 respectively. The first vision camera 291 will capture the image as the dividers enter the rotary brush. The second vision camera 292 will capture the image after the dividers have rotated 90-degrees. This two-camera system may assist in ensuring compliance of the divider dimensions in both axes.

The dividers 22 will then continue along the rotary brush 304 to the ejection point, where the air outlet nozzle 303 is (shown at the arrow tip of “eject air nozzle”). If a particular divider has failed the conditions in either one or both of the images captured, the air nozzle will blast a jet of air when that particular divider reaches the ejection point.

The rejected divider will be pushed out of the brush holder 300 and against the wall of the reject chute 305, where it will fall down by gravitational force into a collection point for later inspection by operator. The dividers which meet the criteria for use will continue along the rotary brush and be passed on to the belt conveyor for insertion in the configurator.

This automated attrition system shortens processing speed and reduces human error. It will be appreciated that the deformation tolerance may be adjusted for different requirements.

An operator may inspect the dividers in the collection bin for a final review.

The board conveyors 44 and divider conveyor 46 may use servo motors for high precision (Figure 21). The dual lane conveyor layout allows for space saving over a single continuous conveyor. This also affords redundancy in the event of any faults or errors, as one lane is able to continue production while the other is being serviced. The divider conveyor 46 acts as a divider source to deliver dividers to at least one set, and for example 8 sets, of tube feed shuttles 48 which divert the dividers directly to the end-effector 49 of each robotic arm 45 via a tube shuttle 51 (Figures 22- 28). The direct feeding to the end-effector eliminates the need for a picking operation, cutting down critical cycle time. The tube shuttle 51 may be flexible tubing made of PFA, silicone, PP, PE, or other suitable polymer. The diameter of the tube shuttle 51 may be 16 mm, or other suitable diameter depending on the largest cross-sectional diameter of the divider. The tube shuttle will be transparent to allow monitoring of the pin flow, and be lubricated by compressed air pulses. The flexibility of the tube will allow seamless delivery to all positions taken by the end-effector.

Movement of the dividers in the tube shuttle 51 may be assisted by compressed air pulses. Compressed air pulses will be constantly fed into the tubes to agitate the dividers as they move along the shuttle, such as to prevent the dividers from getting stuck to the inner walls of the tube due to friction. The end effector 49 may be equipped with an actuator for driving the dividers into an aperture of the divider plate. Such an actuator may include an individual pneumatically-powered pistons for punching the dividers (Figure 25). The head may be a single or dual nozzle head. The pistons may be tilted at an angle to the divider plate to reduce the force needed to insert the dividers, thus reducing power usage, chance of deformation, wear and tear to the divider plates and dividers. The dual outlets will ensure that a pin is always primed to be inserted once the robot has travelled to the desired position.

Figure 26 shows the aperture distribution of a divider plate 210. This divider plate 210 contains 1623 apertures and 150 dividers may be inserted into this divider plate. It will be appreciated that the system may process divider plates containing other numbers of apertures. The divider plate 210 is divided into 8 segments, with apertures of each segment designated to one robotic arm.

Based upon a pre-determined pattern of dividers to be applied to respective divider plates, a control system calculates and designates dividers for each robotic arm depending on the proximity of divider insertion and total number of dividers. For example, a segment may be designated more dividers if the dividers are in close proximity. Conversely, a segment may be designated fewer dividers if the dividers are spaced further apart. Having multiple robotic arms which are selectively movable by the control system provides redundancy in the system. In the event that a robotic arm is faulty, the control system redistributes the dividers among the remaining 7 robotic arms, to ensure smooth operation and high throughput of the automation system. 6-axis articulated robot was chosen for its high precision and speed, small footprint and workspace volume, with sufficient reach and payload capabilities for this application.

Vision system

A laser vision inspection system 50 is installed over the output end of the board conveyor 44 to give the divider plates and dividers (the re-configured divider plates 201’) a final inspection. The inspection system 50 captures 3-dimensional imaging data of the re-configured divider plates 211. 4 laser imaging units will capture information in real time. This means that the boards will be in continuous, undisrupted motion while the inspection is taking place. Finally, the re-configured divider plates 211 are loaded into the clean boxes. A clean empty box may be positioned ready at the end of the box conveyor line, which may be between the two plate configurator lines. As shown in Figures 10A, 10B, 11, and 29, Gantry robot A 107 at line 1 picks up the latest completed divider plate from the end of line 1 and places it into the empty box ready in the center box conveyor line. Gantry robot B 108 at line 2 then picks up the latest completed divider plate from the end of line 2, flips it around into the desired orientation, and then places it into the same empty box in the center, on top of the first divider plate.

The unloading extendable robot may also serve as the pick and place robot for the covers. At this point, it may pick up a cover from the end of the cover conveyor and place it on to the ready box with two divider plates. The same unloading extendable robot may then pick up the now covered box with both divider plates inside, and place the entire assembled box on to the pallet. The unloading point can be configured to connect to additional conveyors from other process stations as required. Figure 30 shows a flow diagram of the re-configuration process.

It is appreciated that each of the unstacker and opener station, washer and dryer station, transition zone, and re-configurator can be modified, used as standalone units, and combined with other suitable stations to form different automation systems, whilst still falling the scope of the invention.

Improved Divider

Figures 31A and 3 IB show a divider pin 21 for insertion in a divider plate. It will be appreciated that the divider base 211 having a locking assembly, which in this embodiment is a c-clip 212, may be equally applicable for use with different divider pin heads, and so the head 216 shown in Figures 31A and 3 IB is to be consider as an example but not limiting to the use of the base 211. The c-clip design allows for easy insertion (no orientation needed) but does not allow for removal without a specific tool. The divider cannot be simply removed by pulling, and avoids unintentional removal of the dividers during packing and transportation. In addition, this divider design is specifically suitable for an automation application, where the divider will be inserted/removed by a machine.

An improved divider 21 (Figures 31A-31B) contains a divider base 211 with an H-beam cross-section and may include a locking assembly. The locking assembly shown in the Figures 32B includes the divider base having a resiliently compressible lug which is arranged circumferentially about the base. In the present embodiment, the lug is represented by a compressible C shaped clip 212 which sits within a circumferential groove of the divider base 211 (Figures 32A-32B). The divider by itself does not sit securely in the separate base. The divider and c-clip are manufactured as 2 individual components and then assembled. Alternatively, they may also be manufactured as one component using a suitable process, such as additive manufacturing or injection molding. The c-clip sits securely in the divider but has room to move and adjust so it can properly locate and fit into the hole on the separate base. Once in the separate base, there is a very secure connection.

The divider is manufactured to fit into an aperture 221 on a divider plate (Figures 33A-33B). A top side of the aperture 221 may have a countersink feature 222 to assist in the positioning of the divider above the aperture. The countersink feature 222 provides additional support to maintain the inserted divider in an upright position. The c-clip is chamfered and will resiliently retract or compress when pressed against the sharp edges of the base. The aperture includes a lip, which compresses the c-clip as it passes through the aperture, and once passed the lip, the c-clip diameter expands, allowing for the c-clip to re-expand after passing through the tighter section of the base. The lip provides an interference fit and prevents the c-clip from being removed, and so locking the divider into the aperture, without the correct tool and force.

When the divider is inserted into an aperture of a divider plate, the neck 223 of the aperture pushes 213 the sides of the C-clip inwards to a squeezed position to close the gap of the “C”. The C-clip may contain a chamfer to direct the forces inwards. The C-Clip is designed to act like a spring. When inserted, the clip is forced to compress through the hole in the separate base. After passing through the smaller hole, the clip reaches a larger area and is allowed to re-expand to its original shape. This locks the clip and divider to the separate base. The aperture may contain a lip 225 that engages the divider base within the aperture and prevents the divider from being dislodged without a divider removal device.

A bottom side of the aperture 221 may contain a void 224. As the C-clip 212 is pushed past the neck 223 and into the void 224, the C-clip 212 expands to engage with the sides of the void 224 and a lip 225.

Figure 34A shows a cross-sectional view of the uncompressed C-clip 212 in the void. Figure 34B is a bottom view of the divider within an aperture.

The inserted dividers do not need any orientation for insertions into the aperture, and it cannot be pulled out easily by hand. A divider removal device 231 may be used to assist removal (Figure 34C and 34D). The divider removal device 231 may be a dowel having a circumferential ring at one end for engaging the contact face, or any suitable device such as a hollow cylindrical shape. To remove the divider, a cylindrical tool must be inserted from the bottom of the separate base. The tool hits the bottom chamfer, or contact face, of the clip and compresses the clip. While compressing the clip, the machines continues to apply an upward force, releasing the divider from the base. When an end of the device 231 is pushed into the bottom side of the aperture, the rims of the device 231 engage with the chamfers of the C-clip 212 and compress it into a squeezed position until the divider can be removed through the neck of the aperture.

It is appreciated that the various embodiments relating to the divider head and base can be modified and are interchangeable to form different dividers, whilst still falling within the scope of the invention.