WO2015089653A1

WO2015089653A1 - Apparatus for carrying, inspecting and selectively releasing successively carried items and method for performing same

Info

Publication number: WO2015089653A1
Application number: PCT/CA2014/051172
Authority: WO
Inventors: Louis Roy; James White
Original assignee: Optel Vision Inc.
Priority date: 2013-12-20
Filing date: 2014-12-05
Publication date: 2015-06-25

Abstract

An apparatus for carrying, inspecting and selectively releasing successively carried items which comprises an upper carrier assembly, an item control unit, an item inspection unit and an item ejection mechanism. The upper carrier assembly defines an item traveling path and includes a vacuum assembly to capture the successively carried items from above and carry them along the item travelling path. The item control unit tracks a real-time position of each item. The item inspection unit inspects each item in order to validate at least one characteristic thereof and categorize them as a conform item or a non-conform item based on the validation of the at least one characteristic. The item ejection mechanism selectively releases one of the conform items and the non-conform items from the upper carrier assembly. A method for performing the inspection and selective release of successively carried items is also provided.

Description

APPARATUS FOR CARRYING, INSPECTING AND SELECTIVELY RELEASING SUCCESSIVELY CARRIED ITEMS AND METHOD FOR

PERFORMING SAME

CROSS REFERENCE TO RELATED APPLICATION

[0001]This application claims the benefit under 35 U.S.C. § 1 19(e) of United States provisional patent application no. 61/918.849 which was filed on December 20, 2013. The entirety of the aforementioned application is herein incorporated by reference.

FIELD OF THE INVENTION

[0002]The present invention relates to the field of sorting apparatuses. More particularly, it relates to an apparatus for carrying, inspecting and selectively releasing successively carried items, where the items are retained from above during at least an inspection phase and are selectively released according to a result of the inspection. The present invention also relates to a method for carrying out same.

BACKGROUND

[0003]Apparatuses and methods for carrying, validating and releasing successively carried items, such as, without being limitative, cartons, are known in the art. However, known apparatuses tend to suffer from several drawbacks.

[0004] For example, known apparatuses often use a lower conveyor belt to carry the items, from below, between, for example, a printing unit used for printing information on the item, an inspection unit used for inspecting the item in order to determine whether the item and the printed information is conform or nonconform, and an ejection assembly for releasing the items which were determined to be non-conform.

[0005]When such apparatuses are installed on an existing production line, the installation required the production line to be opened and modified in order to accommodate the additional apparatus, i.e. to add the section of the lower conveyor belt of the apparatus between existing components of the production line. Such a modification of the production line is costly and can be problematic when the available space is limited. Moreover, in many cases, known apparatuses tend to slow down the existing production line when installed (or mounted) thereon.

[0006] In view of the above, there is a need for an improved apparatus and a corresponding method for transport, inspection and selective release of successively carried items which would be able to overcome or at least minimize some of the above-discussed prior art concerns.

SUMMARY OF THE INVENTION

[0007]According to a first general aspect, there is provided an apparatus for carrying, inspecting and selectively releasing successively carried items. The apparatus comprises an upper carrier assembly, an item control unit, an item inspection unit and an item ejection mechanism. The upper carrier assembly defines an item traveling path and includes a vacuum assembly configured to generate a vacuum suction sufficient to capture the successively carried items from above and carry the successively carried items along the item travelling path. The item control unit tracks a real-time position of each one of the successively carried items carried by the upper carrier assembly along the item traveling path. The item inspection unit inspects each one of the successively carried items carried by the upper carrier assembly in order to validate at least one characteristic thereof, each one of the successively carried items being categorized as being a conform item or a non-conform item based on the validation of the at least one characteristic. The item ejection mechanism selectively releases one of the conform items and the non-conform items from the upper carrier assembly.

[0008] In an embodiment, the vacuum assembly comprises a plurality of independent vacuum modules adjacent to one another, each one of the vacuum modules being selectively deactivatable to release the one of the conform items and the non-conform items from the upper carrier assembly.

[0009] In an embodiment, each one of the vacuum modules comprises at least one suction cup configured to capture and carry the one of the successively carried items, the successively carried items being engageable with the at least one suction cup when the vacuum module is active.

[0010] In an embodiment, the apparatus further comprises at least one printing unit configured to print information onto at least one surface of the successively carried items carried by the upper carrier assembly.

[0011] In an embodiment, the at least one printing unit is mounted upstream of the item inspection unit along the item travelling path.

[0012] In an embodiment, the at least one printing unit is operatively connected to the item control unit to allow data exchange therebetween, the at least one printing unit being controlled by the item control unit according to the real-time position of each one of the successively carried items carried along the item traveling path, tracked by the item control unit.

[0013] In an embodiment, the at least one characteristic validated by the inspection unit comprises the information printed by the printing unit on the surface of the successively carried items.

[0014] In an embodiment, the apparatus further comprises at least one seal application unit applying a tamper evidence seal onto a surface of the successively carried items carried by the upper carrier assembly.

[0015] In an embodiment, the at least one seal application unit is mounted upstream of the item inspection unit along the item travelling path.

[0016] In an embodiment, the at least one seal application unit is operatively connected to the item control unit to allow data exchange therebetween, the at least one seal application unit being controlled by the item control unit according to the real-time position of each one of the successively carried items carried along the item traveling path, tracked by the item control unit.

[0017] In an embodiment, the at least one characteristic validated by the inspection unit comprises the tamper evidence seal applied by the seal application unit on the surface of the successively carried items.

[0018] In an embodiment, the ejection mechanism releases the conform items at an outfeed end, from a lower surface of the upper carrier assembly, and retains the non-conform items in contact with the upper carrier assembly, the upper carrier assembly carrying the non-conform items to an upper surface thereof.

[0019] In an embodiment, the apparatus further comprises a lateral item ejection assembly comprising at least one of an item diverter, an item pusher, and an air jet, the lateral item ejection assembly being configured to propel laterally the nonconform items from the upper surface of the upper carrier assembly.

[0020] In an embodiment, the item ejection mechanism is mounted downstream of the item inspection unit along the item travelling path.

[0021] In an embodiment, the item ejection mechanism comprises an ejection assembly configurable in an operative configuration to release the one of the conform items and the non-conform items onto an outfeed station and configurable in a non-operative configuration to retain the other one of the conform items and the non-conform items in contact with the upper carrier assembly.

[0022] In an embodiment, the item ejection mechanism comprises at least one ejection blade extending progressively outwards from the upper carrier assembly in the operative configuration and positioned inward of the upper carrier assembly in the non-operative configuration.

[0023] In an embodiment, each one of the vacuum modules comprises a valve operative to control the gas flow in the vacuum module and momentarily deactivate the vacuum module to release the one of the conform items and the non-conform items onto an outfeed station.

[0024] In an embodiment, the outfeed station comprises a lower carrier assembly running below the upper carrier assembly.

[0025] In an embodiment, the items are successively carried on a lower carrier assembly towards the apparatus and the upper carrier assembly extends above a section of the lower carrier assembly.

[0026] In an embodiment, at least one of the item inspection unit and the item ejection mechanism is operatively connected to the item control unit to allow data exchange therebetween, the at least one of the item inspection unit and the item ejection mechanism being controlled by the item control unit according to the real-time position of each one of the successively carried items carried along the item traveling path, tracked by the item control unit.

[0027] In an embodiment, the item control unit is operatively connected to the item inspection unit and the item ejection mechanism to allow data exchange therebetween, the item control unit receiving inspection data from the item inspection unit and controlling the item ejection mechanism based on the received inspection data.

[0028] In an embodiment, the item control unit comprises at least one sensor mounted proximate to an infeed end of the upper carrier assembly, a rotary encoder and a controller, the at least one sensor and the rotary encoder cooperating to track the real-time position of each one of the successively carried items along the item travelling path and being operatively connected to the controller to allow data exchange therebetween.

[0029] In an embodiment, the at least one sensor initially senses at least a section of each one of the successively carried items to determine an initial position thereof and the rotary encoder tracks the position of each one of the successively carried items along the item travelling path, according to the initial position thereof.

[0030]According to another general aspect, there is also provided a method for performing the inspection and selective release of successively carried items. The method comprises the steps of: successively capturing and retaining, from above, each one of the successively carried items along an item travelling path; tracking in real time a position of each one of the successively carried items along the item travelling path; inspecting each one of the successively carried items being retained from above in order to validate at least one characteristic thereof; categorizing each one of the successively carried items as being a conform item or a non-conform item, based on the validation of the at least one characteristics thereof; and selectively releasing one of the conform items and the non-conform items onto an outfeed station at a release location along the item travelling path.

[0031] In an embodiment, the step of selectively releasing the one of the conform items and the non-conform items onto the outfeed station at the release location along the path comprises deactivating at least one vacuum module corresponding to the one of the conform items and the non-conform items located at the release location.

[0032] In an embodiment, the items are continuously conveyed along the item traveling path.

[0033] In an embodiment, the method further comprises the step of printing information onto a surface of the successively carried items retained from above.

[0034] In an embodiment, the at least one characteristic being validated comprises the information printed onto the surface of the successively carried items. [0035] In an embodiment, the method further comprises the step of applying a tamper evidence seal onto a surface of the successively carried items retained from above.

[0036] In an embodiment, the at least one characteristic being validated comprises the tamper evidence seal applied onto the surface of the successively carried items.

[0037] In an embodiment, wherein the step of selectively releasing one of the conform items and the non-conform items onto an outfeed station at a release location along the item travelling path comprises configuring an ejection assembly in an operative configuration to release the one of the conform items and the non-conform items and in a non-operative configuration to retain the other one of the conform items and the non-conform items along the item travelling path.

[0038] In an embodiment, the step of selectively releasing one of the conform items and the non-conform items onto an outfeed station at a release location along the item travelling path comprises releasing the conform items from a lower surface of an upper carrier assembly. In such an embodiment, the method further comprises the step of retaining the non-conform items in contact with the upper carrier assembly, the upper carrier assembly carrying the non-conform items to an upper surface thereof.

[0039] In an embodiment, the method further comprises the step of laterally propelling the non-conform items from the upper surface of the upper carrier assembly.

[0040] In an embodiment, the step of successively capturing and retaining, from above, each one of the successively carried items along an item travelling path is performed by an upper carrier assembly extending above a section of a lower carrier assembly. In such an embodiment, the method further comprises the step of successively carrying the items on the lower carrier assembly towards the upper carrier assembly.

[0041] In an embodiment, the step of tracking in real time a position of each one of the successively carried items along the item travelling path comprises the sub steps of initially sensing at least a section of each one of the successively carried items to determine an initial position thereof and tracking the position of each one of the successively carried items along the item travelling path, according to the initial position thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

[0042] Other objects, advantages and features will become more apparent upon reading the following non-restrictive description of embodiments thereof, given for the purpose of exemplification only, with reference to the accompanying drawings in which:

[0043] Figure 1 is a perspective view of an apparatus for inspecting and selectively releasing successively carried items according to an embodiment, the apparatus being shown with an item being carried thereby;

[0044] Figure 2 is a perspective view of the apparatus for inspecting and selectively releasing successively carried items of Figure 1 and shown in combination with a plurality of items and a lower carrier assembly;

[0045] Figure 3 is a top plan view of the apparatus for inspecting and selectively releasing successively carried items, the plurality of items and the lower carrier assembly of Figure 2;

[0046] Figure 4 is a side elevation view of the apparatus for inspecting and selectively releasing successively carried items, the plurality of items and the lower carrier assembly of Figure 2; [0047] Figure 5 is a front elevation view of the apparatus for inspecting and selectively releasing successively carried items, the plurality of items and the lower carrier assembly of Figure 2.

[0048] Figure 6 is a schematic representation of a control unit of the apparatus for inspecting and selectively releasing successively carried items of Figure 1 , along with components of the apparatus cooperating with the control unit.

[0049] Figure 7 is a side elevation view of a vacuum chain for the apparatus for inspecting and selectively releasing successively carried items, according to another embodiment wherein the vacuum chain includes a plurality of independent vacuum modules for capturing, retaining and carrying items from above.

[0050] Figure 8 is a perspective view of a plurality of independent interconnected vacuum modules for capturing, retaining and carrying items from above, according to yet another embodiment.

[0051] Figure 9 is a perspective view of one of the vacuum modules of Figure 7. DETAILED DESCRIPTION

[0052] In the following description, the same numerical references refer to similar elements. The embodiments, geometrical configurations, materials mentioned and/or dimensions shown in the figures or described in the present description are preferred embodiments only, given solely for exemplification purposes.

[0053] Moreover, although the embodiments of the apparatus for validating and selectively releasing successively carried items and corresponding parts thereof consist of certain geometrical configurations as explained and illustrated herein, not all of these components and geometries are essential to the invention and thus should not be taken in their restrictive sense. It is to be understood, as also apparent to a person skilled in the art, that other suitable components and cooperation thereinbetween, as well as other suitable geometrical configurations, can be used for the apparatus, as will be briefly explained herein and as can be easily inferred herefrom by a person skilled in the art. Moreover, it will be appreciated that positional descriptions such as "above", "below", "left", "right" and the like should, unless otherwise indicated, be taken in the context of the figures and should not be considered limiting.

[0054] Referring generally to Figures 1 to 6, in accordance with one embodiment, there is provided an apparatus 20 for printing, validating and selectively releasing successively carried items 70. In an embodiment, the printing, validation and selective release occur in a continuous motion, i.e. without interrupting a continuous displacement of the items 70.

[0055] In the illustrated embodiment, the apparatus 20 includes a frame 19 with an upper carrier assembly 22 mounted thereon. The upper carrier assembly 22 defines an item traveling path and includes a vacuum assembly 24, for capturing, retaining, and carrying the items 70, between a printing unit 30 used for printing information on a surface of each one of the items 70, an item inspection unit 40 used for inspecting successively each one of the items 70, and an item ejection mechanism 50 for selectively releasing the items 70 from the upper carrier assembly 22, according to the results of the inspection. Each one of the printing unit 30, the item inspection unit 40 and the item ejection mechanism 50 is mounted along the item traveling path, along which each one of the items 70 travels in a travelling direction. In the embodiment shown, the vacuum assembly 24 comprises a vacuum belt. However, one skilled in the art will understand that in alternative embodiments, such as the alternative embodiments of Figures 7 to 9, which will be discussed below, the vacuum assembly 24 can be other assembly or mechanism for capturing, retaining and transporting or carrying the items 70, such as, without being limitative, a vacuum chain (See Figure 7), a plurality of interconnected independent vacuum modules (See Figure 8), or the like. [0056] It will be understood that the apparatus 20 for printing, validating and selectively releasing successively carried items 70 can be used within a production line, or at an end thereof. Moreover, in an embodiment, the apparatus 20 can be used as an independent device, away from a production line.

[0057]The upper carrier assembly 22 captures, from above, successively carried items 70 being fed to the apparatus 20. In an embodiment, the capture of the items 70 is performed by the vacuum assembly 24, such as the vacuum belt, of the upper carrier assembly 22. In order to capture the items 70, the vacuum assembly 24 creates a negative pressure, and thereby generates a vacuum suction (or suction force) in the vicinity of the upper carrier assembly 22 in order to draw and retain the items 70 in contact with the upper carrier assembly 22. In the illustrated embodiment, the vacuum belt of the vacuum assembly 24 includes two belts 25a spaced apart from one another, with a plurality of successive suction cups 25b in-between, to generate the negative pressure required to capture and retain the successively carried items 70 against the upper carrier assembly 22. In an embodiment, the upper carrier assembly 22 forms a closed loop.

[0058]As mentioned above, in alternative embodiments, other vacuum assemblies 24, mechanisms or devices can be used to generate the desired suction force required to capture and retain the successively carried items 70 engaged with the upper carrier assembly 22.

[0059] For example, in an alternative embodiment shown in Figure 7 wherein the features are numbered with reference numerals in the 100 series, the capture of each one of the items 170 is performed by the activation of specific successive suction cups 125b substantially aligned with each one of the item 170 to be captured and carried along the upper carrier assembly 122. In such an embodiment, the suction cups 125b are operable independently from one another and can be activated when an item 170 to be captured and carried is aligned with a corresponding one of the suction cups 125b. It will be understood that a combination of successive suction cups 125b can be required for capturing and carrying an item 170 or a single suction cup 125b can be used. In an embodiment, in order to provide a sufficient negative pressure, the suction cups 125b are connected to a vacuum pump (not shown) operative to generate the negative pressure. In an embodiment, each suction cup 125b is also connected to a corresponding valve, such as a spool valve (not shown), operative to control the gas flow and thereby activate/deactivate the specific suction cup 125b. As can be seen, in the embodiment shown, each one of the suction cups 125b is mounted to a corresponding vacuum module 125c and the vacuum modules 125c are linked to one another to form a vacuum chain 129 traveling along the upper carrier assembly 122 to displace the suction cups 125b therealong.

[0060] Referring to Figures 8 and 9, another alternative embodiment of the vacuum assembly 224 of the upper carrier assembly 222, wherein the features are numbered with reference numerals in the 200 series, is shown. In the embodiment shown, the vacuum assembly 224 includes a plurality of adjacent vacuum modules 225c interconnected to one another and operatively mounted to a rotating chain 292. The vacuum modules 225c are connected to a vacuum pump (not shown), and are interconnected to one another by connecting vacuum hoses 291 . Each vacuum module 225c includes a suction cup 225b and is independently activatable/deactivatable to capture/release an item (not shown). In the embodiment, each one of the vacuum modules 225c is activated by default, i.e. by default a negative pressure is generated at the vicinity of the suction cup 225b of each vacuum module 225c, and each one of the vacuum modules 225c includes a valve 293, such as a spool valve, to control gas flow to and/or from the suction cup 225b and deactivate the vacuum module 225c, i.e. stop the negative pressure at the vicinity of the suction cup 225b of the corresponding vacuum module 225c. Once again, it will be understood that only one vacuum module 225c, or a combination thereof, can be activated/deactivated to capture, retain and release each one of the items. [0061] Referring back to Figures 2 to 5, in the embodiment shown, the successive items 70 are fed successively and automatically at an infeed end 23 of the upper carrier assembly 22 by a lower carrier assembly 28, such as a lower conveyor, running below the apparatus 20. In an embodiment, the distance between the lower carrier assembly 28 and the upper carrier assembly 22 of the apparatus 20 is configured such that the negative pressure created by the vacuum assembly 24 is sufficient for the items 70 conveyed on the lower carrier assembly 28 to be captured by the apparatus 20 at the infeed end 23. In an alternative embodiment, at least one component of the vacuum assembly 24 of the upper carrier assembly 22, such as, without being limitative, the suction cup 25b, can be displaced momentarily towards a surface of a corresponding one of the items 70, aligned therewith, in order to capture the latter.

[0062] In an embodiment, the speed of the upper carrier assembly 22 is greater than the speed of the lower carrier assembly 28, thereby resulting in the items 70 being spaced apart along the upper carrier assembly 22 when being captured thereon. One skilled in the art would however understand that, in an alternative embodiment, the speed of the upper carrier assembly 22 can be substantially similar to the speed of the lower carrier assembly 28.

[0063] In an alternative embodiment (not shown), the items 70 can also be fed to the apparatus 20 through other means than a lower carrier assembly. For example and without being limitative, the items 70 can be fed to the apparatus 20 manually by an operator or by gravity via a chute directed towards the infeed end 23 of the apparatus 20.

[0064] Referring to Figures 1 to 6, in an embodiment, the apparatus 20 further comprises an item control unit 81 . The item control unit 81 includes at least one sensor 32 positioned proximate to the infeed end 23, upstream of the other units, assemblies and/or mechanisms interacting with the item, such as the printing unit 30, the item inspection unit 40 and the item ejection mechanism 50, and configured to determine an initial position of an item 70 on the upper carrier assembly 22 and a controller 83 operatively connected with one another. In an embodiment, the at least one sensor 32 of the item control unit 81 determines the initial position of an item 70 by sensing at least a section of the item, such as a leading edge of the item 70 to determine the position thereof. The item control unit 81 also includes a rotary encoder 82 for subsequently tracking the position of the item 70 in real time along the item travelling path, according to the initial position of the item 70 and the angular motion of an actuator, such as a driving shaft 84 of a rotary engine (or motor) (not shown), of the upper carrier assembly 22. The controller 83 of the item control unit 81 is operatively connected to the units interacting with the items, such as the printing unit 30, the item inspection unit 40, and the item ejection mechanism 50 in order to allow data exchange therebetween. Hence, in an embodiment, the controller 83 of the item control unit 81 subsequently synchronizes the operation of the units interacting with the items, such as the printing unit 30, the item inspection unit 40, and the item ejection mechanism 50, according to the real-time position of the item 70 carried by the upper carrier assembly 22 and tracked by the rotary encoder 82, according to the initial position of the item 70 and the angular motion of an actuator, such as a driving shaft 84 of a rotary engine (or motor).

[0065]As mentioned above, once an item 70 has been captured by the upper carrier assembly 22 of the apparatus 20, in an embodiment, the item 70 is first carried towards the printing unit 30. The printing unit 30 is mounted upstream of the item inspection unit 40 along the item travelling path, as it is positioned close to the infeed end 23 of the upper carrier assembly 22 and performs the printing of information onto a predetermined surface of the item 70. For example and without being limitative, information that can be printed on the item 70 includes graphics, human readable information, linear bar codes and/or 2D bar codes.

[0066] In an embodiment, the item control unit 81 activates the printing unit 30 when an item 70 is precisely positioned in front of a printing head thereof, such that the desired information is accurately printed at a predetermined position on the predetermined surface of the item 70. Precise tracking of the position of the item 70 along the upper carrier assembly 22, combined with a stable retention of the item 70 by the upper carrier assembly 22 by the vacuum assembly 24, can allow high quality printing to be performed by the printing unit 30.

[0067] One skilled in the art would however understand that, in an alternative embodiment, no printing step can occur as the items 70 are conveyed along the upper carrier assembly 22. In such an embodiment, the apparatus is free of printing unit 30. In an embodiment, information can be printed on the items 70 before being fed to the apparatus 20. In an alternative embodiment, the items 70 can be inspected for other features than printed information.

[0068] For example, in an embodiment (not shown), the apparatus 20 can include a seal application unit 36 to perform the application of a tamper evidence seal onto the surface of the item 70. The seal application unit 36 is mounted upstream of the item inspection unit 40 along the item travelling path. One skilled in the art will understand that, in an embodiment, an apparatus 20 can include both a seal application unit 36 and a printing unit 30 or can be provided only with one of the seal application unit 36 and the printing unit 30, as described above. For example and without being limitative, the tamper evidence seal can be a strip of material, an adhesive substance, or the like which is attached to at least two sections of the item 70 such that opening of the item 70 results in breaking of the seal.

[0069] In an embodiment, the item control unit 81 activates the seal application unit 36 when an item 70 is precisely positioned in front of it, such that the seal is precisely applied at a predetermined position on the predetermined surface(s) of the item 70.

[0070] In the illustrated embodiment of Figures 1 to 6, following the above described printing and/or seal application steps, the items 70 are carried further along the upper carrier assembly 22 towards the inspection unit 40, for automatic inspection thereof. In an embodiment, the automatic inspection performed by the inspection unit 40 is executed to validate the quality and conformity of the information printed on the items 70 by the printing unit 30. For example and without being limitative, the inspection unit 40 can evaluate and validate the conformity and/or readability of the bar code and/or the conformity of the colors of graphics printed on the items 70. One skilled in the art will easily understand that, in an alternative embodiment, the automatic inspection performed by the inspection unit 40 can be performed regarding information pre-printed onto the items, i.e. information printed onto the items 70 previously to the items 70 being fed to the apparatus 20.

[0071] In an embodiment, as mentioned above, the inspection performed by the item inspection unit 40 can be executed to validate other characteristics or features of the items 70, which are required to be validated independently or in combination with the printed information. For example and without being limitative, the additional characteristics can concern the tamper evidence seal, the dimensions, and/or the integrity of the items 70 or the like.

[0072] In the illustrated embodiment, the item inspection unit 40 includes a scanner for scanning information, such as a code, printed on the item 70. One skilled in the art will however understand that, in an alternative embodiment, the item inspection unit 40 can include additional or different detection equipment, such as, without being limitative, a camera and/or one or more sensors.

[0073] Once again, in an embodiment, the item control unit 81 activates the item inspection unit 40 when an item 70 is precisely positioned in a predetermined inspection position. The precise real-time tracking of the position of the item 70 along the upper carrier assembly 22 combined with a stable retention of the item 70 onto the surface of the upper carrier assembly 22 by the vacuum assembly 24 during the inspection can allow a high quality inspection to be performed by the item inspection unit 40.

[0074] Following the inspection of the item 70 by the item inspection unit 40, the inspection data gathered by the item inspection unit 40 is transmitted to the item control unit 81 and the items are categorized as being conform items 70b or nonconform items 70a. Conform items 70b are the items for which the inspected characteristics were determined to be valid according to predetermined parameters and non-conform items 70a are the items for which the inspected characteristics were determined to be non-valid according to predetermined parameters.

[0075] The item control unit 81 tracks the items 70 in real-time and controls the item ejection mechanism 50 in order to proceed with the selective release of the items 70, based on the above categorization determined from the inspection data received from the item inspection unit. In an embodiment, the item ejection mechanism 50 is mounted downstream of the item inspection unit 40 along the item traveling path and operates to release conform items 70b on an outfeed station and discard non-conform items 70a. In other words, the item ejection mechanism 50 automatically performs sorting of the items 70 based on whether the item is categorized as being a conform item 70b or a non-conform item 70a.

[0076]As can be seen in Figures 2 to 5, in an embodiment, the outfeed station is the lower carrier assembly 28 running below the upper carrier assembly 22. One skilled in the art will however understand that, in an alternative embodiment, the outfeed station can be distinct form the lower carrier assembly 28. For example and without being limitative, the outfeed station can be a stationary table, an empty container, or the like.

[0077] In the embodiment shown in Figures 1 to 5, the item ejection mechanism 50 operates to release the conform items 70b onto the lower carrier assembly 28 at a release location, such as an outfeed end 26 of the upper carrier assembly 22. The outfeed end 26 is located at or close to a lower surface 21 of the upper carrier assembly 22 and opposite to the infeed end 23. One skilled in the art will understand that, even though in the illustrated embodiment the lower carrier assembly 28 onto which the conform items 70b are released is the same carrier assembly as the one used for feeding the items 70 to the apparatus 20, in an alternative embodiment, the lower carrier assembly onto which the conform items 70b are released can be distinct from the carrier assembly used for feeding the items 70 to the apparatus 20. Moreover, in an alternative embodiment, the release location of the upper carrier assembly 22 can be different than the shown outfeed end 26.

[0078] In the illustrated embodiments, the discarding of non-conform items 70a is performed by retaining the non-conform items 70a onto the upper carrier assembly 22 following the outfeed end 26. Thus, the non-conform items 70a follow the upper carrier assembly 22 and are rotated of 180° to be brought onto an upper surface 27 of the upper carrier assembly 22 for subsequent discarding. It will be understood that, in an embodiment, for the non-conform items 70a to be retained on the upper carrier assembly 22 and rotated upward onto the upper surface 27 thereof, the curvature of a transition phase between the lower surface 21 and the upper surface 27 of the upper carrier assembly 22 is configured for the suction force of the vacuum assembly 24 to be sufficient to retain the nonconform items 70a onto the surface of the upper carrier assembly 22 during the transition phase. In an alternative embodiment where the vacuum assembly 24 includes independent suction cups 25b (see Figures 7 to 9), a single vacuum module 125c, 225c, or the like, can be used to retain the non-conform items 70a onto the surface of the upper carrier assembly 22 during the transition phase between the lower surface 21 and the upper surface 27 of the upper carrier assembly 22, thereby allowing flexibility regarding the configuration of the curvature of the transition phase.

[0079] Once the non-conform items 70a are brought onto the upper surface 27 of the upper carrier assembly 22, the non-conform items 70a can subsequently be discarded using a lateral item ejection assembly 34 configured to propel laterally the non-conform items from the upper surface of the upper carrier assembly. In the embodiment shown, the lateral item ejection assembly 34 is an item pusher (embodied by an actuator), however, one skilled in the art will understand that, in alternative embodiments, the lateral item ejection assembly 34 can be another mechanism such as, for example and without being limitative, a diverter, an air jet, or the like, to laterally eject the non-conform item 70a from the upper surface 27 of the upper carrier assembly 22. When laterally ejected, the non-conform items 70a can be discarded into a discarding receptacle (not shown). In an embodiment where a pusher, an air jet, or the like is used for the discarding of the non-conform items 70a, the pusher or air jet can be activated by the item control unit 81 when a non-conform item 70a is determined to be positioned in a discarding position, in front of the pusher or the air jet, such that the activation thereof results in the non- conform item 70a being ejected laterally.

[0080] In an embodiment, a reject confirmation sensor (not shown) is provided at the upper surface 27 of the upper carrier assembly 22, following the section where non-conform items 70a are discarded. The reject confirmation sensor is configured to confirm that each one of the non-conform items 70a has been properly ejected from the upper carrier assembly 22.

[0081] In the embodiment shown in Figures 1 to 5, the selective release of the conform items 70b onto the lower carrier assembly 28 at the outfeed end 26 of the upper carrier assembly 22 is performed using an ejection assembly including retractable ejection blades 52. The retractable ejection blades 52 are selectively configurable in an extended configuration (shown in Figure 1 ) and a retracted configuration (not shown). The extended configuration is understood to be an operative configuration and the retracted configuration is understood to be an inoperative configuration.

[0082]As can be seen in Figure 1 , in the extended configuration, the ejection blades 52 extend progressively outwards from the surface of the upper carrier assembly 22 in order to drive the conform items 70b away from the vacuum assembly 24 and break the engagement between the conform item 70b and the upper carrier assembly 22 provided by the suction force of the vacuum assembly 24. In other words, when configured in the extended configuration, the ejection blades 52 drive the conform items 70b sufficiently away from the vacuum assembly 24, such that the conform items 70b are no longer drawn towards the upper carrier assembly 22 by the suction force of the vacuum assembly 24 and are consequently released therefrom.

[0083]When configured in the retracted configuration, the ejection blades 52 are positioned inward of the upper carrier assembly 22 and consequently do not contact the items 70 being conveyed on the upper carrier assembly 22. The ejection blades 52 are configured in the retracted configuration when a nonconform item 70a is brought to the outfeed end 26, in order to allow non-conform item 70a to be retained onto the upper carrier assembly 22 for subsequent ejection further along the item traveling path of the upper carrier assembly 22.

[0084]The configuration of the ejection blades 52 of the ejection assembly is controlled by an actuator (not shown) operatively connected to the item control unit 81 . The actuator selectively moves the ejection blades 52 between the extended configuration and the retracted configuration. The item control unit 81 tracks the real-time position of the items 70 being carried by the upper carrier assembly 22 and commands the actuator to configure the ejection blades 52 in the extended configuration when the item 70 being brought at the outfeed end 26 is a conform item 70b and into the retracted configuration when the item 70 being brought at the outfeed end 26 is a non-conform item 70a. In an embodiment, given that it is assumed that the quantity of conform items 70b will be greater than the quantity of non-conform items 70a, the default configuration of the ejection blades 52 is the extended configuration and the ejection blades 52 are momentarily retracted only when a non-conform item 70a is detected and is brought at the outfeed end 26.

[0085] One skilled in the art will understand that, in an alternative embodiment, an alternative ejection mechanism 50, different from the ejection mechanism described above and shown in Figures 1 to 5, can be provided for performing the selective release of the conform items 70b or non-conform items 70a.

[0086]For example and without being limitative, the ejection blades 52 can be replaced by a plurality of alternative mechanical assemblies configurable in an operative configuration and an inoperative configuration and which allow the items 70 to be selectively released or retained on the upper carrier assembly 22, according to the results of the validation of the item 70. For example and without being limitative, in an embodiment, a blocking member can be used for blocking a section of the vacuum assembly 24 momentarily, thereby releasing the conform item 70b from the upper carrier assembly 22.

[0087] Referring to Figures 7 to 9, in an alternative embodiment, the ejection mechanism 250 (see Figure 9) can be configured such that selective release of the conform items 170b, 270b at the release location, such as the outfeed end 226, can be performed by momentarily deactivating suction cup(s) 125b, 225b of specific vacuum module(s) 125c, 225c, which correspond to the conform items 170b, 270b to be released (i.e. cancelling the negative pressure at the such suction cup(s) 125b, 225b of the specific vacuum module(s) 125c, 225c) in order to release the conform items 170b, 270b from the upper carrier assembly 122 as they successively reach the release location and retain the non-conform items 170a against the upper carrier assembly 122. One skilled in the art will understand that, in an alternative embodiment, the selective release of the conform items 170b, 270b can be performed by momentarily generating a positive pressure at the suction cup(s) 125b, 225b of specific vacuum module(s) 125c, 225c.

[0088]For example and without being limitative, in the embodiment of Figures 8 and 9, each vacuum module 225c includes a valve 293, such as a spool valve, controlled to momentarily cancel the negative pressure at a corresponding one of the suction cups 225b when a conform item 270 is to be released. In the embodiment shown, the spool valve 293 includes a push button 293a pushable to prevent gas flow to and/or from the suction cup 225b and momentarily deactivate the specific vacuum module 225c when release of a conform item 270b is required. When a non-conform item is to be retained onto the upper carrier assembly 222, no action is performed and the corresponding vacuum module 225c remains active, thereby retaining the non-conform item 270a onto the upper carrier assembly 222.

[0089]One skilled in the art will understand that, according to another alternative embodiment (not shown), the ejection mechanism 50 can release the nonconform items onto the lower carrier assembly (or any other suitable location) at an outfeed end of the upper carrier assembly and retain the conform items thereon for subsequent release.

[0090]According to yet another alternative embodiment (not shown), the upper carrier assembly can present a substantially horizontal lower section and an inclined lower section, downstream of the substantially horizontal lower section. In such an embodiment, the conform or non-conform items can be released from the upper carrier assembly at an outfeed end of the substantially horizontal lower section and the other ones of the conform and non-conform items can be retained onto the upper carrier assembly to be subsequently released at the release end of the inclined lower section. In such an embodiment, the nonconform items can be released onto a discard chute having an extremity located below the release end of the inclined lower section. The release of the items can be achieved using the above described assemblies or other known assemblies or techniques. For example and without being limitative, the non-conform items can be released onto the discard chute as a result of the absence of vacuum force at the release end of the inclined lower section.

[0091]A method for performing the validation and selective release of successively carried items 70 using the above described apparatus 20 is also provided. In an embodiment, the method includes a first step of successively capturing and retaining, from above, each one of the successively carried items 70 along an item traveling path defined by the upper carrier assembly 22. The method further includes the step of tracking the position of each one of the successively carried items 70 in order to know the position of each item in real time. In an embodiment, information is subsequently printed onto a surface of each one of the successively carried items 70 being retained from above and each item is inspected in order to validate at least one characteristic thereof.

[0092] As mentioned above, in an embodiment, no printing step can be performed. In an embodiment, a step of applying a tamper evidence seal onto a surface of each one of the successively carried items retained from above can also be performed. It will be understood that the step of printing information onto a surface of each one of the successively carried items and the step of applying a tamper evidence seal onto a surface of each one of the successively carried items are not mutually exclusive and can therefore be both performed. However, in an embodiment, only one or none of these steps can be performed.

[0093] In an embodiment, the validation step can relate to pre-printed information or other characteristics of the item 70 engaged with the upper carrier assembly 22, as mentioned below. In an embodiment where a printing step is performed, the at least one inspected characteristic can also include the information previously printed on the surface of the item 70. One skilled in the art will however understand that the inspection and validation of various supplemental characteristics of the item 70 can also be performed, independently or in combination with the inspection of printed information. For example and without being limitative, these characteristics can relate to the tamper evidence seal, the dimensions and/or integrity of the item 70, i.e. verifying that the item is free of scratch, bumps, or other similar damages. In an embodiment, the validation step is performed by a non-contact inspection of the items as they are continuously carried along the upper carrier assembly 22.

[0094] Following the inspection, each one of the successively carried items 70 is categorized as conform or non-conform based on the validation of the at least one characteristics thereof. Finally, the successively carried items 70 are selectively released based on the categorization previously performed.

[0095] In an embodiment, the conform items 70b are released onto an outfeed station and the non-conform items 70a are retained in contact with the upper carrier assembly 22 to be discarded further along the item traveling path. One skilled in the art will however understand that, in an alternative embodiment, the non-conform items 70a can be released onto the outfeed station and the conform items 70b can be retained in contact with the upper carrier assembly 22 to be discarded further along the item traveling path. In other words, the conform items 70b are released at a first location along the item traveling path and the nonconform items 70a are released in a distinct location, spaced-apart from the first location, along the item traveling path of the upper carrier assembly 22.

[0096]Several alternative embodiments and examples have been described and illustrated herein. The embodiments of the invention described above are intended to be exemplary only. A person skilled in the art would appreciate the features of the individual embodiments, and the possible combinations and variations of the components. A person skilled in the art would further appreciate that any of the embodiments can be provided in any combination with the other embodiments disclosed herein. It is understood that the invention can be embodied in other specific forms without departing from the central characteristics thereof. The present examples and embodiments, therefore, are to be considered in all respects as illustrative and not restrictive, and the invention is not to be limited to the details given herein. Accordingly, while specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the scope of the invention as defined in the appended claims.

Claims

1 . An apparatus for carrying, inspecting and selectively releasing successively carried items, the apparatus comprising:

an upper carrier assembly defining an item traveling path, the upper carrier assembly including a vacuum assembly configured to generate a vacuum suction sufficient to capture the successively carried items from above and carry the successively carried items along the item travelling path;

an item control unit tracking a real-time position of each one of the successively carried items carried by the upper carrier assembly along the item traveling path;

an item inspection unit inspecting each one of the successively carried items carried by the upper carrier assembly in order to validate at least one characteristic thereof, each one of the successively carried items being categorized as being a conform item or a nonconform item based on the validation of the at least one characteristic; and

an item ejection mechanism selectively releasing one of the conform items and the non-conform items from the upper carrier assembly.

2. The apparatus of claim 1 , wherein the vacuum assembly comprises a plurality of independent vacuum modules adjacent to one another, each one of the vacuum modules being selectively deactivatable to release the one of the conform items and the non-conform items from the upper carrier assembly.

3. The apparatus of claim 2, wherein each one of the vacuum modules comprises at least one suction cup configured to capture and carry the one of the successively carried items, the successively carried items being engageable with the at least one suction cup when the vacuum module is active.

4. The apparatus of any one of claims 1 to 3, further comprising at least one printing unit configured to print information onto at least one surface of the successively carried items carried by the upper carrier assembly.

5. The apparatus of claim 4, wherein the at least one printing unit is mounted upstream of the item inspection unit along the item travelling path.

6. The apparatus of claim 4 or 5, wherein the at least one printing unit is operatively connected to the item control unit to allow data exchange therebetween, the at least one printing unit being controlled by the item control unit according to the real-time position of each one of the successively carried items carried along the item traveling path, tracked by the item control unit.

7. The apparatus of any one of claims 4 to 6, wherein the at least one characteristic validated by the inspection unit comprises the information printed by the printing unit on the surface of the successively carried items.

8. The apparatus of any one of claims 1 to 7, further comprising at least one seal application unit applying a tamper evidence seal onto a surface of the successively carried items carried by the upper carrier assembly.

9. The apparatus of claim 8, wherein the at least one seal application unit is mounted upstream of the item inspection unit along the item travelling path.

10. The apparatus of claim 8 or 9, wherein the at least one seal application unit is operatively connected to the item control unit to allow data exchange therebetween, the at least one seal application unit being controlled by the item control unit according to the real-time position of each one of the successively carried items carried along the item traveling path, tracked by the item control unit.

1 1 . The apparatus of any one of claims 8 to 10, wherein the at least one characteristic validated by the inspection unit comprises the tamper evidence seal applied by the seal application unit on the surface of the successively carried items.

12. The apparatus of any one of claims 1 to 1 1 , wherein the ejection mechanism releases the conform items at an outfeed end, from a lower surface of the upper carrier assembly, and retains the non-conform items in contact with the upper carrier assembly, the upper carrier assembly carrying the non-conform items to an upper surface thereof.

13. The apparatus of claim 12, further comprising a lateral item ejection assembly comprising at least one of an item diverter, an item pusher, and an air jet, the lateral item ejection assembly being configured to propel laterally the non-conform items from the upper surface of the upper carrier assembly.

14. The apparatus of any one of claims 1 to 13, wherein the item ejection mechanism is mounted downstream of the item inspection unit along the item travelling path.

15. The apparatus of any one of claims 1 to 14, wherein the item ejection mechanism comprises an ejection assembly configurable in an operative configuration to release the one of the conform items and the non-conform items onto an outfeed station and configurable in a non-operative configuration to retain the other one of the conform items and the nonconform items in contact with the upper carrier assembly.

16. The apparatus of claim 15, wherein the item ejection mechanism comprises at least one ejection blade extending progressively outwards from the upper carrier assembly in the operative configuration and positioned inward of the upper carrier assembly in the non-operative configuration.

17. The apparatus of any one of claims 2 to 13, wherein each one of the vacuum modules comprises a valve operative to control a gas flow in the vacuum module and momentarily deactivate the vacuum module to release the one of the conform items and the non-conform items onto an outfeed station.

18. The apparatus of any one of claims 15 to 17, wherein the outfeed station comprises a lower carrier assembly running below the upper carrier assembly.

19. The apparatus of any one of claims 1 to 18, wherein the items are successively carried on a lower carrier assembly towards the apparatus and wherein the upper carrier assembly extends above a section of the lower carrier assembly.

20. The apparatus of any one of claims 1 to 19, wherein at least one of the item inspection unit and the item ejection mechanism is operatively connected to the item control unit to allow data exchange therebetween, the at least one of the item inspection unit and the item ejection mechanism being controlled by the item control unit according to the real-time position of each one of the successively carried items carried along the item traveling path, tracked by the item control unit.

21 . The apparatus of claim 20, wherein the item control unit is operatively connected to the item inspection unit and the item ejection mechanism to allow data exchange therebetween, the item control unit receiving inspection data from the item inspection unit and controlling the item ejection mechanism based on the received inspection data.

22. The apparatus of any one of claims 1 to 21 , wherein the item control unit comprises at least one sensor mounted proximate to an infeed end of the upper carrier assembly, a rotary encoder and a controller, the at least one sensor and the rotary encoder cooperating to track the real-time position of each one of the successively carried items along the item travelling path and being operatively connected to the controller to allow data exchange therebetween.

23. The apparatus of claim 22, wherein the at least one sensor initially senses at least a section of each one of the successively carried items to determine an initial position thereof and the rotary encoder tracks the position of each one of the successively carried items along the item travelling path, according to the initial position thereof.

24. A method for performing the inspection and selective release of successively carried items, the method comprising the steps of:

successively capturing and retaining, from above, each one of the successively carried items along an item travelling path; tracking in real time a position of each one of the successively carried items along the item travelling path;

inspecting each one of the successively carried items being retained from above in order to validate at least one characteristic thereof; categorizing each one of the successively carried items as being a conform item or a non-conform item, based on the validation of the at least one characteristics thereof; and

selectively releasing one of the conform items and the non-conform items onto an outfeed station at a release location along the item travelling path.

25. The method of claim 24, wherein the step of selectively releasing the one of the conform items and the non-conform items onto the outfeed station at the release location along the path comprises deactivating at least one vacuum module corresponding to the one of the conform items and the non-conform items located at the release location.

26. The method of claim 24 or 25, wherein the items are continuously conveyed along the item traveling path.

27. The method of any one of claims 24 to 26, further comprising the step of printing information onto a surface of the successively carried items retained from above.

28. The method of claim 27, wherein the at least one characteristic being validated comprises the information printed onto the surface of the successively carried items.

29. The method of any one of claims 24 to 28, further comprising the step of applying a tamper evidence seal onto a surface of the successively carried items retained from above.

30. The method of claim 29, wherein the at least one characteristic being validated comprises the tamper evidence seal applied onto the surface of the successively carried items.

31 . The method of any one of claims 24 to 30, wherein the step of selectively releasing one of the conform items and the non-conform items onto an outfeed station at a release location along the item travelling path comprises configuring an ejection assembly in an operative configuration to release the one of the conform items and the non-conform items and in a non-operative configuration to retain the other one of the conform items and the non-conform items along the item travelling path.

32. The method of any one of claims 24 to 31 , wherein the step of selectively releasing one of the conform items and the non-conform items onto an outfeed station at a release location along the item travelling path comprises releasing the conform items from a lower surface of an upper carrier assembly, the method further comprising the step of retaining the non-conform items in contact with the upper carrier assembly, the upper carrier assembly carrying the non-conform items to an upper surface thereof.

33. The method of claim 32, further comprising the step of laterally propelling the non-conform items from the upper surface of the upper carrier assembly.

34. The method of any one of claims 24 to 33, wherein the step of successively capturing and retaining, from above, each one of the successively carried items along an item travelling path is performed by an upper carrier assembly extending above a section of a lower carrier assembly, wherein the method further comprises the step of successively carrying the items on the lower carrier assembly towards the upper carrier assembly.

35. The method of any one of claims 24 to 34, wherein the step of tracking in real time a position of each one of the successively carried items along the item travelling path comprises the sub steps of initially sensing at least a section of each one of the successively carried items to determine an initial position thereof and tracking the position of each one of the successively carried items along the item travelling path, according to the initial position thereof.