High-output flexible feeding of discrete parts

A system for feeding parts, the system comprising:

• a pick-and-place robot operable according to a sequence, the sequence comprising moving the pick-and-place robot between a pick-up position in a picking area for picking parts from a part-retaining device when in the picking area, and a drop-off position for placing any picked parts into respective empty part carriers moving through the loading station;
• the part-retaining device defining a plurality of part holders fixed relative to each other for alignment with the pick-up position when the part-retaining device is in the picking area, each part holder comprising a pocket having a geometry complementary to at least a portion of a part for nesting of the part in the pocket;
• a first transfer device operable to move the part-retaining device between a receiving area to receive a plurality of parts and the picking area with the plurality of parts thereon while the pick-and-place robot repeatedly operates according to the sequence;
• and
• a second transfer device operable to:
• move a plurality of empty part carriers through the loading station;
• divert occupied part carriers exiting the loading station to a downstream process;
• and
• return empty part carriers to the loading station;
• at least one processor operable to, for each part carrier exiting the loading station:
• receive sensor data for the part carrier;
• determine whether the part carrier is occupied or empty based on the sensor data;
• in response to determining that the part carrier is empty, operating the second transfer device to return the empty part carrier to the loading station;
• and
• in response to determining that the part carrier is occupied, operating the second transfer device to divert the occupied part carrier to the downstream process.