Description:TECHNICAL FIELD
[001] The disclosed subject matter relates generally to the field of food tray handling systems on roller conveyors. More particularly, the present invention introduces a novel automated tray emptying system with an integrated ejector mechanism tailored for efficient operation on roller conveyors.

BACKGROUND
[002] Food tray handling systems are integral components of many food processing and packaging industries. One of their primary functions is to transport and handle food trays containing various food products. An essential process within these systems is the emptying of trays. Emptying the tray ensures that the food content is transferred to the next phase of processing or packaging, and the emptied trays can then be cycled back into the system for reuse.

[003] As industries have evolved, there has been a significant push towards automation, aiming to increase efficiency and reduce manual labor. This transition gave birth to automated tray emptying systems. These automated systems typically utilize a mechanism that holds and flips the food tray, typically by 180°, to ensure the content is emptied completely. With the emptied tray, the next cycle in the food handling process can be initiated without delay.

[004] However, a persistent technical problem plagues many existing automated tray emptying systems. After the tray has been flipped and emptied, it is not uncommon for the tray to remain stuck or not be fully ejected from the gripper mechanism. Such malfunctions not only disrupt the seamless operation of the system but can lead to significant accidents, jeopardizing worker safety, and resulting in substantial production losses. A common underlying cause of this issue is the frictional factor between the gripper and the tray, which can hinder the tray's smooth ejection.

[005] Some modern designs have attempted to rectify this problem by introducing ejector mechanisms within the gripper. The purpose of this ejector is to ensure the tray is pushed out when the gripper releases it. Yet, even with these advancements, ensuring 100% ejection of the tray remains elusive due to persisting challenges like the aforementioned frictional factors.

[006] In light of the aforementioned disadvantages of existing technologies, there exists a need for a more reliable and efficient automated tray emptying system that can consistently and safely eject trays post-emptying.

SUMMARY
[007] The following invention presents a simplified summary of the disclosure in order to provide a basic understanding to the reader. This summary is not an extensive overview of the disclosure and it does not identify key/critical elements of the invention or delineate the scope of the invention. Its sole purpose is to present some concepts disclosed herein in a simplified form as a prelude to the more detailed description that is presented later.

[008] The exemplary embodiments of the present disclosure pertain to an automated tray emptying system with integrated ejector mechanism and method thereof.

[009] The objective of the present disclosure is to provide an improved automated tray emptying system capable of securely holding and flipping a food tray 180°, thereby ensuring that the contents within the tray are thoroughly emptied, making the tray ready for the next cycle.

[0010] Another objective of the present disclosure is to address and mitigate the prevalent issue of trays not being ejected from grippers after release, which has been a primary cause for accidents and substantial production losses in previous systems.

[0011] Another objective of the present disclosure is to overcome the challenges posed by frictional factors, which in known designs hinder the complete ejection of trays.

[0012] Another objective of the present disclosure is to enhance the overall safety of automated tray emptying processes by minimizing the chances of tray jams or mishandlings, which could lead to machine downtime or risks to operating personnel.

[0013] Another objective of the present disclosure is to increase the overall throughput of the food processing line by ensuring faster, more consistent tray emptying and ejection. This leads to reduced wait times and ensures a continuous flow in the production line.

[0014] Yet another objective is to ensure longevity and durability of the system. By employing precision-engineered components and mechanisms, the invention seeks to minimize wear and tear, thus reducing maintenance frequency and extending the system's operational life.

[0015] An additional objective of the present disclosure is to provide flexibility in adapting to various tray sizes or designs. Given the myriad tray designs used across the food industry, a system capable of accommodating different trays without extensive reconfiguration is highly advantageous.

[0016] Yet another objective is to optimize the tray's journey on the roller conveyor, ensuring the food remains on the top side until the precise flipping moment, further enhancing the efficiency and reliability of the tray emptying process.

[0017] In an exemplary embodiment of the present disclosure, the invention introduces a unique gripper system that incorporates an ejector mechanism, tailored to address the prevalent issues of tray ejection post-emptying. This gripper, upon releasing the tray, activates the ejector mechanism to ensure the tray is pushed out of its grasp, thereby enhancing the reliability of the emptying process and minimizing potential disruptions.

[0018] Another exemplary embodiment of the present disclosure focuses on the ejector plate and its operational mechanics. Positioned strategically within the system, the ejector plate is empowered by an ejector spring. When activated, this spring-driven ejector plate provides the necessary force to overcome frictional factors and other challenges, ensuring a consistent and complete ejection of the tray from the gripper system.

[0019] Yet another exemplary embodiment of the present disclosure emphasizes the gripping mechanism's design and functionality. This embodiment employs specially designed gripper fingers, powered by a pneumatic cylinder, to securely grasp the tray. Assisting these gripper fingers are additional components, namely finger clamps and fixed plates, which come together to hold the tray from multiple directions. This multi-directional grip ensures the tray's position is securely maintained during the entire emptying process, from the moment it's grasped till it's flipped, emptied, and ejected.

[0020] A further exemplary embodiment of the present disclosure delves into the coordinated operation of all these elements. This embodiment highlights how the combination of gripper fingers, ejector mechanisms, and associated components work synchronously, optimizing the tray's journey through the system. The intuitive design ensures that the tray is held securely, flipped precisely, emptied completely, and ejected efficiently, realizing the overall objectives of safety, efficiency, and reliability.

BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a schematic representation illustrating a conveyor system, wherein an automated tray emptying system is equipped with an integrated ejector mechanism.
[0022] FIG. 2A and FIG. 2B provide schematic illustrations of the automated tray emptying system, specifically showcasing the system in a condition wherein the tray is not engaged by the gripping mechanism.
[0023] FIG. 3A and FIG. 3B present schematic illustrations detailing the automated tray emptying system, notably illustrating the system while the tray is securely engaged by the gripping mechanism.
[0024] FIG. 4A and FIG. 4B depict schematic illustrations of the automated tray emptying system, specifically demonstrating the system with the tray in a rotated position subsequent to the gripping action.
[0025] FIG. 5A and FIG. 5B display schematic illustrations of the automated tray emptying system, highlighting the system with the tray having completed its rotation, while still being securely held in the gripping condition.
[0026] FIG. 5C presents a schematic illustration of the automated tray emptying system, emphasizing the system with the tray in an ungripped condition following the completion of its rotation.
[0027] FIG. 6 provides a schematic representation of the Automated Tray Emptying System, particularly illustrating the arms of the system returning to their original position following the successful emptying of the tray.
[0028] FIG. 7 presents a schematic depiction of the Automated Tray Emptying System, illustrating the arms of the system having completed their rotation back to the original position, while the tray is concurrently moved away.
[0029] FIG. 8A provides a schematic illustration of the Automated Tray Emptying System, highlighting a detailed view of the system's arm, inclusive of the gripper finger and finger clamp components.
[0030] FIG. 8B depicts a schematic illustration of the Automated Tray Emptying System, specifically highlighting the ejector mechanism, which includes critical components such as the ejector plate and ejector spring, utilized for efficiently ejecting the tray from the system.
[0031] FIG. 9 illustrates a flow diagram, according to an exemplary embodiment, depicting the operational procedure of the Automated Tray Emptying System, showcasing sequential steps from the tray's initial entry to its ejection post-emptying.
[0032] FIG. 10 illustrates a flow diagram according to another exemplary embodiment, detailing an alternative operational procedure of the Automated Tray Emptying System. This diagram systematically visualizes the sequence and interaction of various system components throughout the comprehensive process, from the tray's initial positioning on the conveyor system through to its eventual ejection post-emptying.

DETAILED DESCRIPTION OF EXAMPLE EMBODIMENTS
[0033] It is to be understood that the present disclosure is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. The present disclosure is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting.

[0034] The use of “including”, “comprising” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. The terms “a” and “an” herein do not denote a limitation of quantity, but rather denote the presence of at least one of the referenced item. Further, the use of terms “first”, “second”, and “third”, and so forth, herein do not denote any order, quantity, or importance, but rather are used to distinguish one element from another.

[0035] Referring to FIG. 1, a schematic representation illustrating a conveyor system is provided, wherein an automated tray emptying system is equipped with an integrated ejector mechanism to facilitate the meticulous handling and subsequent ejection of a tray post-its content emptying process. The figure aims to elucidate an overview of the system's integral components and their concerted operation in a typical setup, denoted as the overall image (100).

[0036] The system predominantly comprises a roller conveyor (102), which serves as the principal medium for the tray’s (104) transit across the system. The roller conveyor (102) may be devised to ferry the tray (104) through the various stations of the system where specified actions are performed. Inherent in its design, the roller conveyor (102) may provide a steady and controlled movement of the tray (104) to ensure precision during the emptying and ejecting operations.

[0037] Positioned adjacently to the roller conveyor (102) are the right arm (108A) and left arm (108B) of the Automated Tray Emptying System, which are critically instrumental in manipulating the tray (104) during the emptying process. The arms may be actuated and controlled by a servo motor (106), which ensures their movement is both systematic and accurate to accomplish the intended flipping and ejecting actions with a high degree of reliability.

[0038] Moreover, each arm, namely right arm (108A) and left arm (108B), is equipped with a gripper finger (110), which is intricately designed to grasp, hold, and subsequently release the tray (104) during various stages of the operation. The gripper finger (110) may secure the tray (104) with enough firmness to maintain its position during rotation and enough gentleness to preserve the integrity of the tray (104).

[0039] In this configuration, the automated tray emptying system with an integrated ejector mechanism is portrayed to illustrate a potential operation cycle, where the tray (104) is maneuvered from an upright position to an inverted position to empty its contents, and subsequently, to an upright position again for the ejection process. This systematic operation optimizes the utility of the roller conveyor (102) and ensures that trays (104) are emptied and released with minimal manual intervention and maximal operational efficiency.

[0040] Referring to FIG. 2A and FIG. 2B provide schematic illustrations of the automated tray emptying system, specifically showcasing the system in a condition wherein the tray is not engaged by the gripping mechanism, signifying an initial or preparatory stage of the tray handling process. At this juncture, the system is portrayed in a poised state, ready to commence the successive actions integral to its functionality.

[0041] In FIG. 2A, represented as the overall image (200A), the system’s various components are visibly unengaged, providing a clear visual depiction of the physical state of the automated tray emptying system at the outset. The tray (210) is positioned on the conveyor, yet not engaged— or un-gripped, indicating that the operational cycle concerning the tray emptying and ejection is at a standstill or has not been initiated.

[0042] Transitioning to FIG. 2B, which delivers a more detailed view (200B) of the system, we may delve into a closer examination of the system's componentry and their respective states in this unengaged condition. Notably, the servo motor (202) and cylinder (204) are pivotal in manipulating and controlling the mechanical arms and, consequently, the gripper finger (208). The servo motor (202) may regulate the overall movement of the mechanical arms, ensuring a controlled and stable environment for the tray (210) to be manipulated.

[0043] The gripper finger (208), crucial in holding and releasing the tray (210), is distinctly in an open or inactive state, delineated by the spacing between the fingers. This ensures that the tray (210) remains un-gripped and stationary on the conveyor, awaiting subsequent actions. Associated with the gripper finger (208) is the finger clamp (206), which in this context, may be retracted or disengaged to allow the unimpeded placement of the tray (210) on the conveyor.

[0044] In the apparent condition, wherein the tray (210) remains un-gripped, the system is exemplified to be in a state ready to initiate the sequence of operations that include gripping, flipping, and emptying of the tray (210), before progressing through to the ejection stage. This initial condition assures that the tray (210) is aptly positioned and oriented for the commencement of the operation cycle, underlining the system’s preparedness and capability to undertake the subsequent, critical steps involved in the automated tray emptying process.

[0045] Referring to FIG. 3A and FIG. 3B, these figures present schematic illustrations detailing the automated tray emptying system, notably illustrating the system while the tray is securely engaged by the gripping mechanism, thus marking a pivotal moment in the process where the tray transitions from a static to an active state within the operational cycle.

[0046] FIG. 3A reveals an overall image (300A), thereby affording a broad view of the system during a phase wherein the tray (310) has been actively engaged by the gripping mechanism. In this phase, the gripper finger (308) has transitioned from its previous unengaged state to a securely gripped state, ensuring that the tray (310) is firmly held in place. This secure engagement facilitates the following actions of flipping and emptying the tray (310) in a controlled and precise manner.

[0047] The finger clamp (306), visible in this depiction, may play a critical role in sustaining the position and stability of the gripper finger (308) during the gripping action. It may do so by applying a determined force or pressure to maintain the gripper finger (308) in its designated position, ensuring a firm and steadfast hold on the tray (310) throughout the flipping and emptying actions that are to follow.

[0048] Within FIG. 3B, providing another overall image (300B), a detailed examination of the engaged components may be observed. The servo motor (302), fundamental to the precise and deliberate movements of the system, may initiate and control the motion of the mechanical arms and subsequently the gripper finger (308), enabling the secure engagement of the tray (310) with reliability and consistency.

[0049] Likewise, the cylinder (304), in cooperation with the servo motor (302), may direct and regulate the pressing action of the gripper finger (308) ensuring that the tray (310) is held securely. The collaborative action between the cylinder (304) and the servo motor (302) allows the system to manipulate the tray (310) with a high degree of control and accuracy, ensuring a smooth and stable operation throughout the tray emptying process.

[0050] In this particular stage, the collective components of the automated tray emptying system work in harmony to securely grip the tray (310), setting the stage for the subsequent tray manipulation processes, including the pivotal flipping and emptying stages. This reliable gripping action is paramount to ensuring that the subsequent stages of the process can occur with minimal risk of error or incident, enhancing the overall efficiency and safety of the system.

[0051] Referring to FIG. 4A and FIG. 4B, these figures depict schematic illustrations of the automated tray emptying system, specifically demonstrating the system with the tray in a rotated position subsequent to the gripping action, thereby entering an intermediate phase where the tray contents are being maneuvered towards the discharge position.

[0052] In FIG. 4A, an overall image (400A) showcases a moment where the tray (410), previously securely engaged by the gripper fingers (402), is in the process of rotation, a pivotal action initiated and managed by the servo motor (404). The illustrated right (408A) and left (408B) arms of the automated tray emptying system may possess a symbiotic mechanical relationship, ensuring the tray (410) is rotated with a balanced and steady motion, essential for preventing unwanted spillage or imprecise emptying of the tray contents.

[0053] The gripper fingers (402), still engaged with the tray (410), may retain a firm yet calculated pressure on the tray throughout the rotation, ensuring that the tray (410) remains securely in position while mitigating the risk of unwanted release or misalignment during this crucial phase of the operation.

[0054] Moving on to FIG. 4B, providing another overall image (400B), a further advanced stage of the tray rotation process (410) is captured. The gripper fingers (402), driven by the directive forces from the servo motor (404), maintain a steadfast grip on the tray (410), ensuring its stable rotation and assuring that the contents of the tray (410) are navigated towards the desired emptying position with precision and control. The right (408A) and left (408B) arms of the automated tray emptying system are depicted midway through the rotation process, showcasing a deliberate and controlled rotational movement which is paramount to the accurate and efficient emptying of the tray contents.

[0055] In these stages of operation, illustrated by FIG. 4A and FIG. 4B, it is imperative that the system adheres to a meticulous and precise operation, ensuring that the tray (410) is rotated to the accurate position for optimal emptying of its contents. This is achieved through the harmonious operation of the servomotor (404), the structural integrity of the arms (408A and 408B), and the secure yet flexible gripping of the gripper fingers (402). Thus, the detailed interplay between these components, as illustrated, forms a critical phase in the operational cycle of the automated tray emptying system, allowing it to achieve the desired outcome of a controlled and complete emptying of the tray (410) contents.

[0056] Referring to FIG. 5A and FIG. 5B, these figures display schematic illustrations of the automated tray emptying system, highlighting the system with the tray having completed its rotation, while still being securely held in the gripping condition, and thereby entering a subsequent phase that ensures the accurate and controlled discharge of tray contents.

[0057] In FIG. 5A, the overall image (500A) underscores a scenario where the tray (508) has successfully completed its rotation, owing to the precise mechanical activities of the preceding steps. The gripper fingers (502) continue to maintain a secure hold on the tray (510) ensuring its stability and preventing any inadvertent shifts or movements that could compromise the content emptying process. During this stage, the finger clamps (504) may exhibit a critical role in further stabilizing the tray (510) through engaging with the gripper fingers (502), thereby creating a secure and stable environment for the tray during the emptying process.

[0058] The operational sequence of these elements may be critically coordinated to ensure that the post-rotation holding of the tray (510) is both secure and strategically oriented for optimal content discharge. Despite the completion of the rotation, it is vital that the gripper fingers (502) and finger clamps (504) maintain their structural integrity and positional accuracy to ensure that the contents of the tray (510) are efficiently and thoroughly evacuated.
[0059] Moving on to FIG. 5B, providing another overall image (500B), the system underscores the strategic importance of the tray’s position (510) post-rotation. The tray (508), having completed its rotation, is stationed in a position conducive for content discharge while being steadfastly held by the gripper fingers (502). The ejector plate (506) is also illustrated, hinting at its impending role in the subsequent phase of the operation to ensure the effective ejection of the tray (510) post-emptying.

[0060] At this stage, the unified actions of the gripper fingers (502) and finger clamps (504) are pivotal to maintaining a secure and stable condition for the emptied tray (508). The crucial interplay between the gripper fingers (502), finger clamps (504), and ejector plate (506) during this stage sets the stage for the subsequent ejection phase, ensuring that the tray is not only effectively emptied but also primed for a controlled and effective ejection from the system.

[0061] These visuals provided in FIG. 5A and FIG. 5B reveal the crucial operational moments within the automated tray emptying system, ensuring the tray, having completed its rotation (508), remains in a stable and secure gripped condition (510) prior to and during the emptying of its contents, thereby ensuring a meticulous and spillage-free operation.

[0062] Referring to FIG. 5C, the illustration presents a schematic depiction of the automated tray emptying system, emphasizing the system with the tray in an ungripped condition following the completion of its rotation. The overall system is represented by label 500C, showcasing various components that cooperate to facilitate the sequential operation of tray gripping, rotating, and ultimately, releasing.

[0063] In the context of this condition, the Gripper Finger, labeled as 502, and Finger Clamp, labeled as 504, may have already performed the rotation action and retracted to disengage from the tray. The disengagement from the tray, marked as 512 and showcased in an un-gripped condition, signifies the point in the operation where the contents of the tray would have been emptied owing to the preceding rotation. The coordination between the gripper finger and the finger clamp may be instrumental in providing a secure grip during the rotation and a clear release post-rotation, ensuring that the tray is not inadvertently retained or dropped.

[0064] Moreover, the Ejector Plate, represented by label 506, may be in a position ready to perform the next stage of the operation, which involves pushing the emptied tray forward. The ejector plate may utilize a mechanism, potentially spring-loaded or driven by another form of actuator, to apply a precise amount of force to the tray, ensuring a consistent and controlled ejection that mitigates the risk of jams or misaligned tray travel post ejection.

[0065] The conditions illustrated in FIG. 5C depict a crucial transition from the rotation to the ejection phases of the operation, highlighting how the automated tray emptying system efficiently manages each stage of the process to optimize the continuous flow of trays through the system. It showcases how mechanical precision and well-coordinated actuation may allow for the system to successfully navigate the inherent challenges of automated tray management, ensuring reliability and consistency across numerous cycles of operation.

[0066] Referring to FIG. 6, which provides a schematic representation of the Automated Tray Emptying System, the diagram particularly illustrates the arms of the system returning to their original position following the successful emptying of the tray. In the context of the illustrated state within the overall image, labeled as 600, the various components of the system are showcased, each contributing to the intricate yet efficient operational workflow of the Automated Tray Emptying System.

[0067] The Gripper Finger, denoted as 602, which played a pivotal role in holding and manipulating the tray during the emptying process, may now be in a rest or initial position, having released the tray post-rotation and emptying. Simultaneously, the Cylinder, marked as 604, which might have facilitated the motion of the gripper fingers by providing the necessary linear actuation, returns to its initial state, readying itself for the upcoming cycle.

[0068] In a similar vein, the Servo Motor, labeled as 606, which may have driven the rotational motion of the arms (608A and 608B) to achieve the tray flipping, might have navigated the arms back to their original position. This reversion of the Right and Left Arms of the Automated Tray Emptying System, respectively labeled as 608A and 608B, signifies the completion of one operational cycle and the system’s readiness to initiate the next.

[0069] The arms, notably 608A and 608B, within this system and their precise rotation, possibly enabled by the Servo Motor 606, ensures that the tray is accurately flipped to facilitate thorough emptying. Subsequent to this, their return to the original position is quintessential to maintaining a streamlined, continuous operation of the system, enabling the subsequent tray to be gripped, flipped, emptied, and ejected in a consistent manner, thereby upholding the system’s efficiency and operational throughput.

[0070] In summary, FIG. 6 emphasizes the reversion of the system to its original state post-emptying, highlighting the meticulous mechanical orchestration that enables the system to efficiently manage the trajectory and orientation of the trays throughout the entire operational cycle. This seamless transition between operational phases underscores the Automated Tray Emptying System’s capability in facilitating a high-throughput, reliable tray management process, minimizing the scope for disruptions or delays in a potentially fast-paced industrial setting.

[0071] Referring to FIG. 7, which presents a schematic depiction of the Automated Tray Emptying System, the visual articulation illustrates the arms of the system having completed their rotation back to the original position, while the tray is concurrently moved away, indicating a state of reset and readiness for the subsequent operational cycle.

[0072] Within the overall image, designated as 700, pivotal components are depicted, providing insight into the final phase of an operational cycle of the Automated Tray Emptying System. The Servo Motor, labeled as 702, plays an instrumental role throughout the process and particularly, in this stage, it may have navigated the arms back to their starting position after successful execution of the tray emptying. The precision and controlled movement of the Servo Motor 702 not only ensures that the arms 704A and 704B, which are Right Arm and Left Arm of the Automated Tray Emptying System respectively, revert to their original positions but also guarantees the system is primed for the next cycle.

[0073] The arms 704A and 704B, after successfully engaging, rotating, and disengaging the tray, have now potentially completed their retraction, achieving a position that parallels the initial state before the tray engagement commenced. This resetting of the arms is pivotal to the system's continual, cyclic operation, mitigating downtime and facilitating a seamless transition into the subsequent tray emptying process.

[0074] Simultaneously, the tray, tagged as 706, having been subjected to the emptying process - involving being gripped, rotated, emptied, and subsequently released - is shown to be moved away. This displacement of the tray 706 might signify not only the successful completion of an emptying operation but also the adeptness of the system in managing tray trajectory post-emptying, ensuring that the tray is unobtrusively extricated from the operational zone. This movement away may be vital to ensuring that there are no inadvertent hindrances or blockages in the immediate operational area of the Automated Tray Emptying System.

[0075] In essence, FIG. 7 encapsulates the final transitionary phase between the culmination of one tray emptying operation and the inception of the next, highlighting the Automated Tray Emptying System’s capability to maneuver between these phases with refined control and efficiency. This carefully coordinated repositioning of both the arms and the tray underscores the system’s proficiency in maintaining a continuous, unimpeded operational flow, pivotal to upholding throughput and reliability in an industrial context.

[0076] Referring to FIG. 8A, which provides a schematic illustration of the Automated Tray Emptying System, attention is drawn to a detailed view of the system's arm, inclusive of the gripper finger and finger clamp components, each integral to the functioning and efficacy of the tray handling, emptying, and ejecting procedures within the system's operational sequence.

[0077] Within the delineated overall image (800A), specific components of the system's arm are brought to the fore, offering a closer exploration of their structure and potential functionality in the context of the Automated Tray Emptying System. The Gripper Finger, labeled as 802, is a pivotal component that may be designed with precise specifications to adeptly engage with the trays. It may navigate under the tray, providing a secure and stable grip that not only facilitates the lifting and rotation of the tray but also ensures a maintained hold during the tray emptying phase. This element might cater to both the stability and consistency of the tray handling operation, minimizing potential spillages or misalignments during rotation and emptying.

[0078] Concurrently, the Finger Clamp, designated as 804, may serve as a crucial support and stabilization element to the Gripper Finger 802. This component may provide the necessary counter-force or grip, ensuring that the tray is securely sandwiched between the Gripper Finger 802 and the Finger Clamp 804 during the entire emptying process. The Finger Clamp 804 might also be integral in ensuring that the tray is securely held, especially during the rotation and emptying phases, thereby mitigating the risk of accidental releases or disengagements.

[0079] Together, the Gripper Finger 802 and Finger Clamp 804 potentially synergize to create a robust and reliable gripping mechanism, ensuring that the trays are not only securely gripped but also maneuvered with precision throughout the emptying process. This coordination between the components is crucial to ensuring that the objectives of the Automated Tray Emptying System, pertaining to reliable and consistent tray handling, emptying, and ejection, are accomplished with minimized risk and maximized efficiency.

[0080] In this regard, FIG. 8A affords a focused lens into the mechanical interplay and strategic design of the Automated Tray Emptying System’s arm components, underscoring their potential significance in ensuring a seamless, reliable, and effective operation in the handling and emptying of trays within an industrial context.

[0081] Referring to FIG. 8B, which depicts a schematic illustration of the Automated Tray Emptying System, the focus is particularly directed towards the ejector mechanism, which plays a pivotal role in facilitating the efficient ejection of the tray from the system post-emptying. This mechanism encompasses critical components such as the ejector plate and ejector spring, each instrumental in actualizing a streamlined and effective ejection process, safeguarding both the integrity of the emptied contents and the operational consistency of the system.

[0082] Situated within the overall image (800B), the Ejector Plate, indicated as 806, may be meticulously designed to directly interface with the tray, ensuring that upon activation of the ejection mechanism, it provides a uniform and steady force to effectively displace the tray from its initially secured position to a state of release. The importance of such a mechanism may be underscored by its ability to prevent manual intervention in the tray emptying process, thereby enhancing the automation and reducing potential downtimes or disruptions in a high-throughput industrial setting.

[0083] Conversely, the Ejector Spring, labelled as 812, may be integral in providing the requisite kinetic energy for the ejection process. Initially, it might be in a compressed state, storing potential energy derived from the mechanical actions of the system during the tray emptying phase. Upon reaching a predetermined phase within the operational sequence, this potential energy may be rapidly converted into kinetic energy as the Ejector Spring transitions from its compressed state to a naturally extended state. This dynamic release of stored energy could, in turn, be transferred to the Ejector Plate 806, propelling it forward and thereby effectuating the tray’s ejection.

[0084] The ejector mechanism may be crucial in ensuring that the tray is not only released from the gripping condition but also actively pushed away from the gripping fingers to facilitate a smooth transition back to the conveyor or other collection point. Herein, the ejector plate (806) propels the tray outward, utilizing the force provided by the ejector spring (812). The dynamic of this mechanism may involve an initial compression state of the ejector spring (812), and upon release, it harnesses its stored potential energy to actively push the ejector plate (806), thereby ensuring a reliable ejection of the tray.

[0085] Other components like the Guide Block (808) and Washer Plate (810) may further facilitate the alignment and smooth motion of the ejection mechanism, ensuring that the Ejector Plate 806 and Ejector Spring 812 harmoniously interact while minimizing wear and potential mechanical discrepancies. The Guide Block 808 may provide directional stability to the ejection mechanism, while the Washer Plate 810 may serve to distribute the mechanical load evenly, potentially mitigating localized stress points and enhancing the longevity and reliability of the system.

[0086] In essence, the ensemble of components within the ejector mechanism, each with their designated functionalities and strategic mechanical interplays, collaboratively serve to realize the efficient ejection of the tray, aligning with the overarching objectives of autonomy, reliability, and efficiency within the Automated Tray Emptying System. The detailed view provided in FIG. 8B thus allows for a nuanced appreciation of the design and operational philosophy embedded within the system, wherein every component, from the Ejector Plate 806 to the Ejector Spring 812, collectively orchestrates a seamless and automated tray ejection process.

[0087] Referring to FIG. 9 illustrates a flow diagram, according to an exemplary embodiment, depicting the operational procedure of the Automated Tray Emptying System, showcasing sequential steps from the tray's initial entry to its ejection post-emptying. The step 902 reveals the initiation of the procedure by conveying the tray with food on the roller conveyor toward the automated tray emptying system, effectively setting the stage for the mechanical process to unfold. This commencement is pivotal as it mobilizes the tray into the operational domain of the automated tray emptying system.

[0088] Subsequently, followed by step 904, which involves detecting the tray as it reaches the specified position for gripping. The system may utilize integrated sensors or mechanisms to ascertain the precise location of the tray and determine the optimal moment to instigate the gripping mechanism. Thereupon, the sequence advances to step 906, involving the moving of gripper fingers together via the pneumatic cylinder to secure the tray perpendicularly to conveyor movement. This step underscores the importance of achieving a secure and steadfast hold on the tray to ensure subsequent actions are executed flawlessly.

[0089] Step 908 follows, illustrating the closing of the finger clamp against a fixed plate thereby engaging the tray to stabilize its position and orientation in alignment with the conveyor movement. This step furthers the assurance that the tray remains stationary and secure during the pivotal actions that follow, mitigating any risk of disruption to the process or displacement of the tray. Transitioning into step 910, holding the tray securely in place in all relevant directions ensures a stable and unmoving position, which is imperative to maintain during the forthcoming rotational action. Next, followed by step 912, the process involves rotating the entire finger system by 180° to flip the tray and position the food content to the bottom side. This particular movement is pivotal, allowing the contents of the tray to be entirely evacuated due to the inversion.

[0090] Post-rotation, step 914 is initiated, which involves opening the finger clamp and gripper fingers utilizing the pneumatic cylinder, enabling the physical detachment and subsequent ejection of the tray from the mechanism. The trajectory then advances to step 916, wherein the process introduces the use of the ejector plate and ejector spring, methodically pushing the tray out and thus enabling the controlled expulsion of the now-empty tray from the secure hold of the gripper mechanism. Subsequently, step 918 illustrates the release of the tray into a free state, unencumbered and devoid of its initial contents, now seamlessly travelling along the conveyor for further processing or collection.

[0091] Finally, followed by step 920, reverting the system to its initial position prepares the apparatus for the next cycle, ensuring it is optimally positioned to receive the subsequent tray and repeat the process. This reversion to the starting point is fundamental to ensuring the system is perpetually ready to undertake subsequent cycles of operation, maintaining a consistent and efficient operational tempo. The illustrated steps embody a comprehensive and meticulous breakdown of the system’s operation, ensuring each action is accomplished with precision and in harmonious sequence, to allow for a smooth, uninterrupted, and efficacious tray emptying process.

[0092] Referring to FIG. 10 illustrates a flow diagram according to another exemplary embodiment, detailing an alternative operational procedure of the Automated Tray Emptying System. This diagram systematically visualizes the sequence and interaction of various system components throughout the comprehensive process, from the tray's initial positioning on the conveyor system through to its eventual ejection post-emptying. The step 1002 initiates the outlined process, whereby the tray is positioned onto the conveyor system, serving as the commencement of its journey through the automated emptying mechanism. This initial positioning is paramount as it sets the trajectory for the subsequent mechanized operations. Followed by step 1004, which sees the tray being transported along the conveyor system toward the automated tray emptying system. This motion progresses the tray toward the mechanical apparatus, wherein the automated actions will be performed.

[0093] Progressing to step 1006, the system may then engage its integrated sensors to sense the tray's presence, ensuring it has arrived at the requisite position for the commencement of the automated procedure, thereby maintaining synchronization with the system’s actions. Step 1008 then unfolds, with the initiation of the automated tray emptying system's operational cycle, setting the mechanized sequence into methodical action. Next, followed by step 1010, activating the servo motor to position arms appropriately may ensure precise maneuvering, which is critical to secure and manipulate the tray accurately throughout the procedure.

[0094] Moving to step 1012, the system may deploy the gripper fingers towards the tray, initiating the physical interaction between the mechanism and the tray. Subsequently, step 1014 engages the gripper fingers to securely hold the tray, ensuring a steadfast grip is achieved prior to the implementation of the rotation and emptying phases. Transitioning to step 1016, the system activates the ejector mechanism, comprising the ejector plate and spring, preparing it for the tray's ejection. This is followed by step 1018, which involves compressing the ejector spring and aligning the ejector plate, priming it for the physical expulsion of the tray.
[0095] The sequence then advances to step 1020, wherein it confirms the secure grip and readiness for rotation, safeguarding against any potential mishaps or misalignments during the pivotal rotating phase. Step 1022 then invokes the initiation of tray rotation by actuating servo motors and cylinders, translating the mechanized action into physical movement of the tray.

[0096] Moving forward, step 1024 involves rotating the tray to an inverted position for emptying contents, ensuring that the food content is effectively displaced from the tray. Ensuring the thoroughness of the procedure, step 1026 focuses on ensuring complete emptying of the tray contents while inverted, maintaining the integrity of the emptying process. Step 1028 then sees the releasing of the compressed ejector spring, providing the necessary force for ejection. Thereafter, step 1030 focuses on pushing the tray out of the gripping mechanism via the ejector plate, physically displacing the now-empty tray from the secure confines of the gripper fingers. The process then progresses to step 1032, disengaging the tray completely from the gripping fingers, concluding the physical interaction between the mechanism and tray. Moving to step 1034, the system may retract the gripper fingers and arms to their original position, resetting them in preparation for the next cycle. In step 1036 completes the rotation back to the initial, upright position. In step 1038, monitoring the ejected tray as it continues along the conveyor ensures it is effectively moving away from the operational area. Step 1040 then involves reverting the system to the initial state, ensuring it is ready and optimally positioned for the next operational cycle.

[0097] Finally, at step 1042 closes the depicted sequence by repeating the cycle for subsequent trays entering the system, maintaining a continuous and efficient operational rhythm throughout. The aforementioned steps, as visualized in FIG. 10, offer a methodical and systematic representation of the alternative operational procedure, ensuring each action and interaction within the system is executed with precision, continuity, and reliability. This sequence, while meticulously detailed, reflects the potential procedural variations within the automated tray emptying system, underpinning its adaptability and functionality in various operational contexts.

[0098] The Automated Tray Emptying System, as explored in the preceding figures and descriptions, may find potential applicability across a myriad of contexts within the food production and processing industry, reflecting its versatility and adaptability in handling various substances. For instance, the system may proficiently facilitate the emptying of baked Horlicks powder from trays, ensuring a seamless transition of the powdered product from production trays to subsequent processing or packaging stages. Similarly, it may adeptly manage the emptying of baked Boost powder from trays, demonstrating its capability in handling distinct powder-based substances without compromising integrity or quality. Furthermore, the system may be effectively applied to manage more viscous substances, such as emptying of Tomato Sauce from trays, underscoring its flexibility in dealing with varying consistencies and maintaining hygienic and efficient handling. Additionally, it may also cater to the emptying of Potato chips after seasoning from trays, illustrating its aptness in handling solid and seasoned food items, thus ensuring the undamaged and quality-maintained transfer to subsequent processes or packaging. Consequently, the versatility of the Automated Tray Emptying System allows it to be potentially instrumental across varied applications, ensuring precise, hygienic, and efficient handling of diverse food products.

[0099] Reference throughout this specification to “one embodiment”, “an embodiment”, or similar language means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present disclosure. Thus, appearances of the phrases “in one embodiment”, “in an embodiment” and similar language throughout this specification may, but do not necessarily, all refer to the same embodiment.

[00100] Although the present disclosure has been described in terms of certain preferred embodiments and illustrations thereof, other embodiments and modifications to preferred embodiments may be possible that are within the principles and spirit of the invention. The above descriptions and figures are therefore to be regarded as illustrative and not restrictive.

[00101] Thus the scope of the present disclosure is defined by the appended claims and includes both combinations and sub-combinations of the various features described hereinabove as well as variations and modifications thereof, which would occur to persons skilled in the art upon reading the foregoing description.
, Claims:We Claim:

1. An automated tray emptying system with integrated ejector mechanism comprising:
a right arm and a left arm, each operatively connected to a servo motor, whereby the servo motor is configured to control a synchronous rotational movement of the right and left arms, thereby enabling the arms to engage, rotate, and release a tray within the system during an emptying operation;

a gripper finger associated with each of the right and left arms, adapted to secure a tray therebetween, whereby the secured tray reliably rotated through manipulation of the right and left arms to enable emptying of the contents therein;

a cylinder associated with each of the right and left arms, wherein activation of the cylinder induces movement of the associated gripper finger, thereby ensuring the fingers are capable of secure, adaptable engagement and release of trays of varying sizes and shapes;

a finger clamp associated with the gripper finger, configured to stabilize the tray during the rotational emptying procedure, whereby the content of the tray is comprehensively emptied through strategic orientation and securement thereof;

an ejector plate, guide block, washer plate, and ejector spring collectively forming an ejector mechanism, whereby upon completion of the emptying procedure, the ejector plate is driven by the compressed and subsequently released ejector spring to forcibly disengage the emptied tray from the gripper fingers, thereby ensuring the emptied tray is effectively expelled from the system in preparation for the next operational cycle; and

a roller conveyor, configured to facilitate the guided transport of the tray into and out of engagement with the gripper fingers, whereby the trays are sequentially and automatically introduced to and expelled from the system, thereby promoting a continuous and automated operation of the tray emptying system.

2. The automated tray emptying system of claim 1, wherein the synchronous rotational movement of the right and left arms is adjustable in speed and rotation degree, thereby allowing adaptability to various types and viscosities of contents within the trays to be emptied.

3. The automated tray emptying system of claim 1, wherein the gripper fingers are furnished with a surface material designed to enhance grip on the trays, whereby the securement of the tray during rotation is fortified against slippage and misalignment.

4. The automated tray emptying system of claim 1, wherein the servo motor adjusts the rotational movement of the right and left arms to a first rotational stage, thereby placing the tray in a pre-determined position optimized for the initiation of the emptying process, and wherein the gripper fingers are activated to secure the tray in position, preventing any unintended movement during the upcoming emptying phase.

5. The automated tray emptying system of claim 4, wherein upon reaching the first rotational stage, the finger clamp is further engaged to fortify the hold on the tray, especially designed to oppose any forces or shifts encountered during the subsequent rotation and emptying stages, thereby ensuring the stability of the tray and the integrity of the emptying process.

6. The automated tray emptying system of claim 4, wherein the right and left arms transition the tray from the first rotational stage to a second rotational stage, thereby inverting the tray to facilitate gravity-assisted emptying of the contents, while maintaining the tray in a securely gripped position, ensuring that the entire contents of the tray are effectively evacuated.

7. The automated tray emptying system of claim 6, wherein following the confirmation of complete emptying, the right and left arms are maneuvered from the second rotational stage back to an initial or an intermediate rotational stage, thereby reorienting the tray for the subsequent ejection and ensuring that no residual contents revert into the emptied tray.

8. The automated tray emptying system of claim 1, wherein the gripper fingers and finger clamp are disengaged in a controlled and gradual manner after reaching the intermediate rotational stage, thereby preventing any abrupt or misaligned movement of the tray in preparation for ejection.

9. The automated tray emptying system of claim 7, wherein the disengagement of the gripper fingers and finger clamp is synchronized with the activation of the ejector mechanism, ensuring a smooth and error-free transition of the tray from the emptying mechanism to the ejection mechanism, thereby minimizing any risk of jamming or misalignment.

10. A method for emptying and ejecting a tray in an automated tray emptying system with integrated ejector mechanism comprising:
conveying a tray, laden with food, on a roller conveyor toward the automated tray emptying system;
detecting the tray as it reaches a specified position, suitable for the engagement by a gripping mechanism;
actuating gripper fingers, employing a cylinder, to converge and secure the tray, positioning it perpendicularly to the direction of conveyor movement;
closing finger clamp against fixed plate, thereby engaging the tray to stabilize its position and orientation in alignment with the conveyor movement;
maintaining the tray securely in place, mitigating motion in all pertinent directions, ensuring stability throughout the subsequent steps of the method;
executing a 180° rotation of the integrated finger system, thereby flipping the tray and subsequently orienting the food content toward the bottom side;
retracting the finger clamp and gripper fingers, utilizing the cylinder, upon the completion of the tray-flipping action;
exerting force upon the tray through the activation of an ejector plate and an ejector spring, thereby facilitating the disengagement of the tray from the gripping mechanism;
releasing the tray into a liberated state, now devoid of its initial contents, and ensuring the tray exits the immediate operational zone; and
resetting the automated tray emptying system, including the gripper fingers, finger clamp, and ejector mechanism, to its original position, thereby preparing the system for a subsequent operational cycle.