High speed robotic product collation and loading system

Abstract

A product collation and loading system collates products into a proper pack pattern and loading the product into a load station or container. The system includes a grouping robot for separating group counts and holding incoming product while the sweep arm begins its cycle. The grouping robot may be positioned upstream of the sweeping robot. The sweeping robot pushes groups of product from the loading station and may act as overhead containment where the product is decelerated. The sweeping robot may be positioned between the grouping robot and a dynamic backstop. The dynamic backstop may be used to position the leading product in the correct location for the sweeping robot and may also decelerate the product to reduce impact. The dynamic backstop may be positioned directly downstream of the sweeping robot. The system may also include a reject cylinder for lifting an arm of the dynamic backstop to allow improperly oriented/located product to pass.

1 . A collation and loading system for collating and loading product, the system comprising:
 a grouping robot adapted to group product into predetermined groups;   a sweeping robot adapted to push grouped product into a loading area; and   a dynamic backstop adapted to position the grouped product in a sweep position to be pushed by the sweeping robot.   
     
     
         2 . The system of  claim 1 , further comprising a conveyor for moving the product through the system. 
     
     
         3 . The system of  claim 1 , wherein the grouping robot includes an end effecter adapted to be positioned between products moving on a conveyor to separate the product into product groups. 
     
     
         4 . The system of  claim 3 , wherein the grouping robot includes a system for keeping the end effecter horizontal during movement. 
     
     
         5 . The system of  claim 1 , wherein the sweeper robot includes:
 a sweeper arm adapted to be positioned over the product to act as an overhead containment, the sweeper arm further adapted to push product off a conveyor into the loading area; and   a system for keeping the sweeper arm horizontal during movement.   
     
     
         6 . The system of  claim 1 , wherein the dynamic backstop includes a backstop arm lifted by a cylinder to reject and allow product to continue downstream on a conveyor. 
     
     
         7 . A method for collating and loading product, the method comprising:
 conveying product along a conveyor;   grouping product into predetermined groups with a grouping robot;   positioning the grouped product in a sweep position with a dynamic backstop; and   pushing the grouped product from the sweep position from the loading station.   
     
     
         8 . The method of  claim 7 , further comprising decelerating the product with the dynamic backstop.