Automated small object sorting systems and methods

Abstract

In various embodiments, a small object sorting system includes an object tray cart docking station configured to dock an object tray cart here within. The system additionally includes an automated tray removal and positioning subsystem configured to remove an object tray from the object tray cart, selectively position the tray such that selected small objects can be extracted therefrom, and replace the object tray into the object tray cart. Furthermore, the system includes an automated collection assembly positioning subsystem configured to selectively position a collection assembly such that the selected extracted small objects can be deposited into selected object receptacles, and an automated object extraction subsystem configured to extract the selected small objects and deposit each extracted small object into the selected object receptacles.

What is claimed is: 
     
         1 . An automated method for sorting small objects, said method comprising:
 docking an object tray cart within an object tray cart docking station of an automated small object sorting system;   removing an object tray from the object tray cart utilizing an automated tray removal and positioning subsystem of the automated small object sorting system, wherein the object tray includes a plurality of wells and a plurality of small objects stored within the wells;   selectively positioning the removed tray utilizing the automated tray removal and positioning subsystem such that selected ones of the small objects can be extracted from the removed object tray;   selectively positioning a collection assembly of the automated small object sorting system utilizing an automated collection assembly positioning subsystem of the automated small object sorting system such that the selected one or more small objects extracted from the removed object tray can be deposited into selected one or more of a plurality of object receptacles of the collection assembly; and   extracting the selected one or more small objects from the object tray and depositing each extracted small object into the selected one or more object receptacles utilizing an automated object extraction subsystem of the automated small object sorting system; and   replacing the removed object tray into the object tray cart after the selected small objects have been extracted utilizing the automated tray removal and positioning subsystem.   
     
     
         2 . The method of  claim 1  further comprising verifying that the object extraction subsystem extracted each of the selected small objects from the object tray utilizing an object extraction verification assembly of the automated small object sorting system. 
     
     
         3 . The method of  claim 2 , wherein verifying that the object extraction subsystem extracted each of the selected small objects comprises:
 capturing image data of one or more nozzle heads of the object extraction subsystem utilizing one or more imaging devices of the object extraction verification assembly; and   communicating the image data to a central control system of the automated small object sorting system to verify whether selected ones of a plurality of nozzles of the nozzle head have an extracted small objected retained on a tip of each selected nozzle.   
     
     
         4 . The method of  claim 1 , wherein removing the object tray from the object tray cart comprises:
 removing selected object trays from the docked object tray cart, selectively positioning the removed object tray such that selected ones of the small objects can be extracted from the removed object tray, and reinserting the removed object trays into the docked object tray cart after the selected small objects have been extracted utilizing a tray locating assembly structured and operable of the tray removal and positioning subsystem; and   selectively raising and/or lowering the tray locating assembly utilizing a tray locating assembly lift of the tray removal and positioning subsystem.   
     
     
         5 . The method of  claim 4 , wherein removing the object tray from the object tray cart further comprises read a tray information tag affixed to each object tray stored in the cart utilizing a tray information tag reader of the tray removal and positioning subsystem, each tray information tag including:
 information identifying each respective object tray;   identifying information of each small object stored in each respective object tray; and   a location, within the respective object tray, of the well in which each respective small object is stored.   
     
     
         6 . The method of  claim 1 , wherein extracting the selected one or more small objects from the object tray comprises extracting the selected one or more small objects from the object tray removed by the tray removal and positioning subsystem and depositing each extracted small object into the selected one or more object receptacles of the collection assembly utilizing a pair of opposing object transfer assemblies of the object extraction subsystem, the object transfer assemblies extending between the tray removal and positioning subsystem and the collection assembly positioning subsystem. 
     
     
         7 . The method of  claim 6 , wherein each object transfer assembly comprises a nozzle head removably mounted to a nozzle head carriage mounted to a carriage transporter, and extracting the selected one or more small objects from the object tray comprises moving the nozzle head carriage and nozzle head between the tray removal and positioning subsystem and the collection assembly positioning subsystem utilizing the carriage transporter. 
     
     
         8 . The method of  claim 7 , wherein extracting the selected one or more small objects from the object tray further comprises magnetically mounting the nozzle head to the nozzle head carriage utilizing one or more magnets included in at least one of the nozzle head carriage and the nozzle head comprise. 
     
     
         9 . The method of  claim 7 , wherein extracting the selected one or more small objects from the object tray further comprises selectively providing a vacuum to a tip of each of a plurality of nozzles in a nozzle array of each nozzle head, the vacuum used to extract the selected one or more small objects from the object tray and retain the one or more extracted small objects when the nozzle head is moved from the tray removal and positioning subsystem to the collection assembly positioning subsystem to transport the one or more extracted small objects from the object tray to the collection assembly. 
     
     
         10 . The method of  claim 7 , wherein each carriage transporter comprises a linear motor, and extracting the selected one or more small objects from the object tray further comprises producing a controllable linear force, utilizing the linear motor, to controllably move the nozzle head carriage and nozzle head between the tray removal and positioning subsystem and the collection assembly positioning subsystem. 
     
     
         11 . The method of  claim 9  further comprising controlling operation of the tray removal and positioning subsystem and the object extraction subsystem utilizing a central control system operable to utilize electronically stored data, to position the respective nozzle head and the object tray relative to each other and to stipulate specific ones of the nozzles to which the vacuum is provided such that the selected one or more small objects are extracted from the object tray, wherein the data comprises data identifying particular traits or characteristics of each small object in the object tray and the location of each respective small object within the object tray such that the small objects are extracted based on the traits or characteristics of each respective small object. 
     
     
         12 . The method of  claim 11 , wherein positioning the collection assembly comprises utilizing a single axis stage of the collection assembly positioning subsystem to selectively positioning the collection assembly along a longitudinal axis of the single axis stage. 
     
     
         13 . The method of  claim 12 , wherein the collection assembly comprises a multi-receptacle object receiving fixture including the one or more object receptacles, and a multi-funnel object disposition fixture that includes a plurality of funnels, and wherein positioning the collection assembly further comprises receiving the one or more extracted small objects in selected ones of the funnels whereby the one or more small objects are deposited into the selected one or more object receptacles. 
     
     
         14 . The method of  claim 12 , wherein the single axis stage comprises a linear motor, and positioning the collection assembly further comprises producing a controllable linear force to selectively position the collection assembly along a longitudinal axis of the linear motor such that the selected ones of the funnels are positioned beneath a selected one of the nozzle heads, whereby the one or more extracted small objects can be deposited into the selected one or more object receptacles. 
     
     
         15 . The method of  claim 12  further comprising controlling operation of the object extraction subsystem and the collection assembly positioning subsystem via the central control system utilizing the electronically stored data to position the respective nozzle head and the multi-funnel object disposition fixture relative to each other and to stipulate specific ones of the nozzles for which the vacuum is terminated such that the selected one or more small objects are released from the respective nozzle into a selected one of the funnels such that each small object is deposited into a corresponding selected object receptacle. 
     
     
         16 . The method of  claim 13 , wherein the one or more object receptacles comprises a plurality of containers and the multi-receptacle object receiving fixture is structured to retain and position the containers, and wherein selectively positioning the collection assembly further comprises aligning an open end of each container with a dispensing end of a corresponding one of the funnels such that selected small objects can be deposited into selected containers. 
     
     
         17 . The method of  claim 13 , wherein the one or more object receptacles comprises a plurality of plant-ready cups and the multi-receptacle object receiving fixture includes an alignment platform structured to retain and position the plant-ready cups, and wherein selectively positioning the collection assembly further comprises aligning an open end of each plant-ready cup with a dispensing end of a corresponding one of the funnels such that selected small objects can be deposited into selected plant-ready cups. 
     
     
         18 . The method of  claim 2 , wherein the small objects comprise seeds, the object tray comprises a seed tray, and the object receptacles comprise seed receptacles.