High-output flexible feeding of discrete parts

A method of configuring a system for feeding parts to an assembly mechanism, the system comprising:

• a first part-retaining device defining first part holders, the first part holders being spaced apart by a first pitch, each part holder of the first part holders configured to receive and hold a respective first individual part having a first shape and first dimensions;
• an agitator device coupled to the first part-retaining device and configured to agitate the first part-retaining device, an agitation of the first part-retaining device to move a plurality of the first individual parts placed on the first part-retaining device to align some of the plurality of first individual parts with respective first part holders during the agitation, the first part holders to receive and hold the first individual parts aligned therewith;
• a transporter;
• a series of first part carriers coupled to the transporter, the first part carriers of the series of first part carriers each having a respective first portion configured to receive and hold one of the first individual parts, the first portions, when the series of first part carriers are coupled to the transporter, being spaced apart by a gap equal to the first pitch;
• a pick-and-placer device having grippers, the grippers being spaced apart by a distance equal to the pitch, the pick-and-placer device configured to simultaneously grip, with the grippers, a plurality of first individual parts held by the first part holders and to transfer, to a corresponding plurality of part carriers of the first series of carriers, the first individual parts gripped by the grippers,
• the method comprising:
• uncoupling the first part-retaining device from the agitator device;
• coupling to the agitator device a second part retaining device defining second part holders, the second part holders being spaced apart by a second pitch, each part holder of the second part holders configured to receive and hold a respective second individual part having a second shape and second dimensions;
• uncoupling the series of first carriers from the transporter;
• coupling to the transporter a series of second part carriers, the second part carriers of the series of second part carriers each having a respective second portion configured to receive and hold one of the second individual parts, the second portions, when the series of second part carriers are coupled to the transporter, being spaced apart by a gap equal to the second pitch;
• and
• reconfiguring the pick-and-placer device to simultaneously grip, with the grippers, a plurality of second individual parts held by the second part holders and to transfer, to a corresponding plurality of part carriers of the series of second carriers, the second individual parts gripped by the grippers, wherein at least one of the following (a) through (c) is true:
• (a) the second pitch is different from the first pitch,
• (b) the second shape is different from the first shape, and
• (c) the first dimensions are different from the second dimensions.

A flexible feeding device comprising:

• a disperser;
• a part retainer comprising one or more pockets arranged to retain at least one of a plurality of discrete parts in a particular attitude, the part retainer located below the disperser;
• a vibrator coupled to the part retainer;
• an excess part removal device operably connected to the part retainer;
• a pick-and-placer programmed to pick at least one of the plurality of discrete parts from the part retainer;
• a plurality of carriers designed to receive the at least one of the plurality of discrete parts from the pick-and-placer and hold the at least one of the plurality of discrete parts during transportation;
• a transporter comprising a track on which the plurality of carriers moves in a closed loop;
• a carrier inspection disc comprising a carrier inspector programmed to identify a state of the carriers which of the plurality of carriers are empty, which of the plurality of carriers are full, and which one or more of the plurality of discrete parts are not passable;
• a part remover programmed to remove the one or more of the plurality of discrete parts that are not passable;
• a gate programmed to allow the plurality of carriers that are full to continue for further processing and the plurality of carriers that are empty to be recirculated within range of the pick-and-placer;
• a transfer station oriented to obtain the plurality of discrete parts from the plurality of carriers for processing;
• a first re-entry track positioned next to the carrier inspection disc directing the plurality of carriers that are empty originating from the carrier inspection disc towards the transporter;
• and
• a second re-entry track positioned next to the transfer station directing the plurality of carriers that are empty originating from the transfer station towards the transporter.

A method of flexible feeding comprising:

• positioning carriers that are initially empty at a loading station;
• placing bulk parts in a metering device;
• dispensing a metered amount of the bulk parts into an agitating system;
• agitating the metered amount of the bulk parts;
• removing parts that did not get captured in holders;
• picking parts that got captured in the holders with a pick-and-placer;
• placing parts that got picked by the pick-and-placer into the carriers;
• inspecting the carriers to determine a state of the carrier if the carriers are empty;
• if an inspected carrier is not empty:
• positioning the inspected carrier at a transfer station,
• obtaining parts from the inspected carrier with a transfer device,
• transferring obtained parts to a downstream processor;
• and
• if the inspected carrier is empty, positioning the inspected carrier at the loading station.

A system of flexible feeding comprising:

• a flexible feeding device configured to perform a plurality of flexible feeding operations comprising:
• positioning carriers that are initially empty at a loading station,
• placing bulk parts in a metering device,
• dispensing a metered amount of the bulk parts into an agitating system,
• agitating the metered amount of the bulk parts,
• removing parts that did not get captured in holders,
• picking parts that got captured in the holders with a pick-and-placer,
• placing parts that got picked by the pick-and-placer into the carriers,
• inspecting the carriers to determine if the carriers are empty,
• positioning the inspected carriers at a transfer station,
• obtaining parts from the inspected carriers with a transfer device, and
• transferring obtained parts to a downstream processor;
• a data processor;
• and
• a medium comprising machine-readable instructions executable by the data processor and configured to cause the data processor to generate signals useful in synchronization of at least two of the plurality of flexible feeding operations.

A system of flexible feeding comprising:

• a flexible feeding device:
• a data processor;
• and
• a medium comprising machine-readable instructions executable by the data processor and configured to cause the data processor to generate signals that instruct the flexible feeding device to execute a plurality of flexible feeding operations, the plurality of flexible feeding operations comprising:
• positioning carriers that are initially empty at a loading station,
• placing bulk parts in a metering device,
• dispensing a metered amount of the bulk parts into an agitating system,
• agitating the metered amount of the bulk parts,
• removing parts that did not get captured in holders,
• picking parts that got captured in the holders with a pick-and-placer,
• placing parts that got picked by the pick-and-placer into the carriers,
• inspecting the carriers to determine if the carriers are empty,
• positioning the inspected carriers at a transfer station,
• obtaining parts from the inspected carriers with a transfer device, and
• transferring obtained parts to a downstream processor.