Automatic Case Sorter

Description

FIELD OF THE INVENTION

The present invention relates to ammunition reloading or case processing and more specifically to a novel and useful case sorter for automatically measuring and sorting ammunition cases.

BACKGROUND OF THE INVENTION

Many professional and amateur shooting competitors and enthusiasts prefer to reload bullets to save money, to improve accuracy, to accommodate specialty ammunition needs, or simply because they enjoy it. Reloading works for most kinds of ammunition, which consists of a cartridge or case, primer, powder, and a bullet. To reload bullets, several pieces of equipment can be desirable including a reloading press or brass processing machine. Reloading bullets requires that the case be first resized to factory specifications, the old primer removed, and then loaded with a new primer and powder. After the case is loaded with powder, a new bullet can be seated on top of the powder.

The types of processing machines and presses suitable for reloading include single stage reloading presses that hold one die at a time, turret presses that hold multiple dies simultaneously, and progressive reloading presses that include multiple stations in its shell plate such that each cycle of the press handle progresses the case from one station to the next. For example, the first station is for sizing and decapping the case, the second station is often used for inserting a new primer, and the third station is usually used for filling a measured charge of powder using a powder dropper. The fourth station can be used for a powder check, which is used to confirm that the amount of powder in the case is roughly correct, and later stations are generally used to place, seat and crimp the bullet. Progressive reloading presses can be manual-index or auto-index and are commonly used by pistol shooters and semi-automatic rifle shooters or anyone with high volume reloading needs.

Some progressive reloading presses include or work with case feeder attachments. Case feeders automatically insert a case into the shell plate for each cycle of the press, which can speed up the reloading process. Case feeders range from simple manually filled tube type feeders to motorized case feeders that automatically refill a tube of cases. While case feeders work especially well for bulk reloading operations, they can suffer from feeding jams and misoriented cases. Additionally, currently available case feeders fail to identify when an incorrect caliber case is present, or a case is not oriented correctly (i.e., oriented base up rather than base down). As a result, reloaders can waste valuable time manually sorting cases, identifying potential problems, and troubleshooting reloading errors.

Because loading a tube of casings correctly and efficiently is very useful when reloading ammunition, it would be desirable to provide an automated system that identifies cases of the wrong caliber, damaged cases, and misoriented cases before they are loaded into the tube of cases for reloading, or into the shell plate. Additionally, it would be desirable to monitor the cases as they load into the tube to prevent overfilling and minimize jams. Such a case sorter would be a notable advance in the firearm and ammunition arts.

BRIEF SUMMARY OF THE INVENTION

In accordance with the present invention a novel and useful case sorter is provided that can be used with case collators or feeders and case processing machines such as ammunition reloading presses. The case sorter receives cases from the collator or feeder and then measures individual cases and sorts them based on their measurements and orientation. Any cases that are undersized, oversized, or turned upside-down are directed to an exit for rejected cases, while acceptable cases are directed to an exit tube that feeds the case processing machine.

The case sorter of the present invention includes a housing that supports a slider assembly, and the slider assembly carries an individual case through several case sorter positions. At a feed position, the slider assembly receives a case from a case inlet, which cooperates with a feed tube containing multiple stacked cases. At a measurement position, the case's height and diameter are measured. At an accept position, an accepted case is directed out a first exit, which cooperates with an exit tube. Alternatively, at a reject position a rejected case is directed out a second exit. In a preferred embodiment, the slider assembly includes upper and lower sliders, which move the case through an additional drop position where the case drops or falls from the upper slider to the lower slider. By using upper and lower sliders, the size of the slider assembly is more compact, and sorting is more efficient because the feed position and accept position can be consolidated.

In addition to supporting the slider assembly, the case sorter housing preferably also houses, supports, or cooperates with additional case sorter components and assemblies including a stepper assembly for driving the slider assembly, a height measurement assembly, a diameter measurement assembly, and one or more controllers or control systems. The stepper assembly includes a stepper motor connected to an output shaft and gears which in turn cooperate with one or more toothed bars on the slider assembly such that when the stepper assembly gears turn, the slider assembly translates from side to side. The height measurement assembly includes a spring-loaded height measurement arm that pivots and displaces vertically relative to the case, a magnet that rotates as the arm pivots and displaces, and a height measurement sensor that measures the change in magnetic field to determine the angular displacement of the height measurement arm and attached magnet. The diameter measurement assembly includes a static rail opposite of a spring-loaded diameter measurement arm where the arm pivots and displaces horizontally relative to the case and static rail. A magnet attached to the diameter measurement arm rotates as the arm pivots and displaces, and a diameter measurement sensor measures the change in magnetic field to determine the angular displacement of the diameter measurement arm and the attached magnet. Both the vertical and horizontal measurements are received and evaluated by components of the controllers or control systems present, and the stepper motor drives the slide assembly accordingly.

Additional optional features of the case sorter include adaptors and fasteners that facilitate attaching feed tubes and exit tubes to the case sorter housing, a spring-loaded latch positioned at the case inlet to prevent multiple shorter cases dispensing simultaneously, and speed inputs and controllers and sensor inputs and controllers that receive input from the user and adjust the operational speed of the case sorter and sensitivity of the height measurement sensor, diameter measurement sensor, and an exit sensor positioned at the first exit that alerts when accepted cases are backed up into the first exit.

To operate the case sorter, an operator or user first attaches a feed tube between the case feeder and case sorter, preferably attaching the feed tube to the case inlet, and an exit tube between the case sorter first exit position and the case processing machine. The operator then connects the power and adjusts any user inputs available as needed such as to adjust the speed at which the case sorter sorts cases or the sensitivity of the measurement sensors. Once the case sorter is powered on, the zero position 502 of the slider assembly is determined, a stepper assembly homing routine is run, and then cases begin being sorted. Where the slider assembly has an upper slider and lower slider, the cases first fall at the case inlet from the feed tube into the upper slider at the feed position. Next, the case is moved by the slider assembly to the drop position, where the case drops from the upper slider to the lower slider. After falling into the lower slider, the case is carried to the measurement position where height and diameter measurements for the case are determined with the height measurement assembly and diameter measurement assembly, respectively. Using programing preferably stored in the controllers or control system, the height and diameter measurements of the case determine whether the case should be accepted or rejected. Preferably, standard height and diameter measurements can be programmed by the operator prior to initiating a sort by running a calibration program to determine the average height and diameter measurements of a set number of standard cases predetermined as good or of a preferred size Accepted cases are carried by the lower slider to the first exit, and a new case to be sorted falls at the case inlet from the feed tube into the upper slider at the feed position. Rejected cases are carried by the lower slider to the second exit, and then the slider assembly returns to the feed position to receive a new case. The process repeats until the operator manually switches off the power to the case sorter or the exit sensor causes the case sorter to alert or stop operating when the exit tube is full or jammed. Other sensors such as a load sensor incorporated into the stepper motor can also shut down the case sorter as needed including if the case inlet is jammed or one of the measurement systems experiences an error. Additionally, the case sorter can run other programs such as an empty program that empties the case sorter and attached feed tube without sorting the cases or a calibration program that measures and averages a sample set of cases to establish parameters for acceptable cases that can be used during the sort program. At its fastest speed, about 4000 cases per hour can be sorted.

The features and advantages of the present invention will be readily apparent to those skilled in the art upon a reading of the description of the exemplary embodiments, which follows.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the case sorter of the present invention positioned between a case feeder and case processor.

FIG. 2 is rear perspective view of the preferred embodiment of the present invention.

FIG. 3 is a front perspective view of the preferred embodiment of the case sorter of the present invention with the front cover removed and a feed tube and exit tube attached.

FIG. 4 is a schematic view of the first side of preferred embodiment of the present invention.

FIG. 5 is a schematic view of the rear of the preferred embodiment of the present invention without the slider assembly present.

FIG. 6 is a schematic view of the preferred embodiment of the present invention as cut along the line marked 6-6 of FIG. 5.

FIG. 7 is a perspective view of the first side of the preferred embodiment of the present invention without the slider assembly present.

FIG. 8 is a perspective view of the preferred embodiment of the present invention as but along the line marked 8-8 of FIG. 4.

FIG. 9 is a front perspective view of some components of the case sorter of the preferred embodiment with the front cover removed.

FIG. 10 is schematic of components of the diameter measurement assembly according to the preferred embodiment of the present invention.

FIG. 11 is a schematic of an acceptable case positioned among components of the diameter measurement assembly and height measurement assembly according to the preferred embodiment of the present invention.

FIG. 12 is a schematic of an unacceptable case positioned among components of the diameter measurement assembly and height measurement assembly according to the preferred embodiment of the present invention.

FIG. 13 is a schematic of a tall case positioned among components of the diameter measurement assembly and height measurement assembly according to the preferred embodiment of the present invention.

FIG. 14 is a schematic of a short case positioned among components of the diameter measurement assembly and height measurement assembly according to the preferred embodiment of the present invention.

FIG. 15A is a schematic view of the case sorter of the present invention according to its preferred embodiment as cut along the line marked 15A-15E-15A-15E of FIG. 4 showing a case in the feed position.

FIG. 15B is a schematic view of the case sorter of the present invention according to its preferred embodiment as cut along the line marked 15A-15E-15A-15E of FIG. 4 showing a case in the drop position.

FIG. 15C is a schematic view of the case sorter of the present invention according to its preferred embodiment as cut along the line marked 15A-15E-15A-15E of FIG. 4 showing a case in the measurement position.

FIG. 15D is a schematic view of the case sorter of the present invention according to its preferred embodiment as cut along the line marked 15A-15E-15A-15E of FIG. 4 showing a case in the accept position.

FIG. 15E is a schematic view of the case sorter of the present invention according to its preferred embodiment as cut along the line marked 15A-15E-15A-15E of FIG. 4 showing a case in the reject position.

FIG. 16 is a flowchart of the sort program according to the preferred embodiment of the present invention.

FIG. 17 is a flowchart of the empty program according to the preferred embodiment of the present invention.

FIG. 18 is a flowchart of the calibrate program according to the preferred embodiment of the present invention.

For a better understanding of the invention reference is made to the following detailed description of the preferred embodiments of the invention which should be taken in conjunction with the above-described drawings.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates to a novel and useful case sorter 10 for use with a case feeder 20 and a case processing machine 30 such as an ammunition reloading press as shown in FIG. 1. Case sorter 10 receives cases 40, 42 from the collator or feeder 20 and then determines measurements for each case 40, 42 individually to sort them as acceptable or unacceptable. Acceptable cases 40 are directed to a first exit 600 where an exit tube 602 connects case sorter 10 to case processing machine 30, and any cases that are undersized, oversized, or misoriented (e.g., turned upside-down) are directed to a second exit 700 for rejected or unacceptable cases 42. FIGS. 2-10 illustrate the assemblies and features of case sorter 10 that carry, measure, and sort the individual cases. FIGS. 11-14 illustrate how measurements are determined for a case 40, 42 to evaluate whether it should be accepted or rejected, FIGS. 15A-15E illustrate how a case 40, 42 is carried by a slider assembly 200 from a feed position 50 to either a reject position 80 or accept position 75 depending on whether the case is acceptable or unacceptable, and FIGS. 16-18 illustrate programs that can be carried out by case sorter 10.

As shown in FIGS. 2-10, the preferred embodiment of case sorter 10 includes a housing 300 that supports a slider assembly 200, which carries an individual case 40, 42 through several case sorter positions. FIGS. 15A-15E illustrate the preferred case sorter positions, which include a pre-load position 45, the feed position 50, a drop position 60, a measurement position 70, the accept position 75, and the rejection position 80. Housing 300 preferably has a floor 302, top 304, front 306, back 309, first side 310, second side 309, and an optional but preferred inner wall 330. Optionally, housing 300 further includes a front cover 307 that attaches to front 306 either permanently or in a removable manner and a back cover (not shown) that attaches to back 309 either permanently or in a removable manner. Defined by housing 300 is a sort chamber 301 and, where inner wall 330 is present, an optional front chamber 308. Sort chamber 301 sits between the back 309 of housing and either front 306 or, when present, inner wall 330. Optional front chamber 308 sits between inner wall 330 and front 306. Slider assembly 200 translates through sort chamber 301 as it moves a case 40, 42 through the case sorter positions. Front chamber 308 preferably houses one or more controllers or control systems for case sorter 10 and components of a height measurement assembly 400 and diameter measurement assembly 500. Housing 300 can be any rigid or semi-rigid material but is preferably plastic.

As shown in FIGS. 2-10, floor 302 of housing 300 defines several openings or slots and supports additional case sorter 10 components. A first opening 302a in floor 302 provides a channel between sort chamber 301 and first exit 600. A second opening 302b in floor 302 provides a channel between sort chamber 301 and second exit 700. A third opening 302c in floor 302 provides a channel between sort chamber 301 and components of a stepper assembly 370, which operates to move the slider assembly from one case sorter position to another. Additional openings (not shown) can be present to accommodate fasteners or provide access for the operator or features as needed. Additionally, grooves or slots 303 may be formed in or through floor 302 to filter out debris such as polishing media and other residue, to reduce friction between floor 302 and cases 40, 42 as they move along floor 302, or to reduce manufacturing costs or the weight of case sorter 10.

FIG. 8 illustrates a preferred embodiment of first exit 600, which attaches to or is integral with floor 302 and in communication with sort chamber 301 through first opening 302a of floor 302. As shown, first exit 600 defines a first exit channel 610 for receiving accepted cases 40. First exit 600 is preferably further configured to accept an exit tube 602 that cooperates with case processing machine 30. For example, as shown in FIG. 8, first exit 600 may include a lip 600a or equivalent features such as notches, flanges, rims, and other protrusions that can rest upon or abut the end of exit tube 602. Preferably, first exit channel 610 is further sloped as shown in FIG. 8 to create a smooth transition for case 40 between exit channel 610 and the inner channel (not labeled) of exit tube 602. First exit 600 preferably further defines a window 612 that accommodates an exit sensor 620 configured to sense when a case 40 can no longer exit through first exit 600, which happens when exit tube 602 is full of stacked cases 40 or when a jam occurs in either exit tube 602 or first exit 600. Exit sensor is preferably an infra-red object detection sensor that attaches to or sits within an exit sensor housing 616 or exit 600. Brass, copper, and other metallic cases will reflect the infra-red light while a non-reflective plastic such as black plastic, which exit 600 is preferably comprised of, will not. Exit sensor 620 operationally connects to exit sensor controller 630, which may be housed wholly or in part in first exit 600, a separate exit sensor housing 616, or within case sorter housing 300, preferably in front chamber 308. Optionally, exit sensor 630 and exit sensor controller 630 also operationally connect to sensor user inputs 342, 344 that allow an operator to adjust the sensitivity of exit sensor 630.

FIG. 8 also illustrates a preferred embodiment of second exit 700, which attaches to or is integral with floor 302 and in fluid communication with sort chamber 301 through second opening 302b of floor 302. As shown, second exit 700 defines a second exit channel (not labeled) for receiving rejected cases 42, which is preferably sloped. Optionally and preferably, second exit 700 further includes a lip (not labeled) for cooperating with additional exit tubes (not shown) if desired.

As shown in FIGS. 2-10, top 304 of housing 300 also defines openings or slots and supports additional case sorter components. A top slot 304a preferably extends along top 304 from first side 310 to second side 312, as shown in FIGS. 2, 3, 7, and 8 to accommodate slider assembly 200 as it operates in sort chamber 301 and carries cases 40, 42. One or more openings 304b also can be defined by top 304 to accommodate fasteners 320 as shown in FIG. 7.

Top 304 of housing 300 further supports case inlet 100, which accommodates cases 40, 42 being fed to case sorter 10. Case inlet 100 preferably is positioned over top slot 304a and attaches to top 304 for quick and easy removal with a thumb screw 130 positioned on an inlet flange 126 as shown in FIG. 3. Case inlet 100 defines an inlet channel 110 and cooperates with a feed tube 102, as shown in FIGS. 3 and 8. Along inlet channel 110, case inlet 100 preferably also defines an inlet lip 100a or equivalent features such as notches, flanges, rims, and other protrusions that are configured to support the dispensing end of feed tube 102 and provide a smooth transition from feed tube 102 to inlet channel 110.

Case inlet 100 preferably is further configured with door opening 100b and cooperating spring-loaded latch 120 as shown in FIG. 3. As cases 40, 42 move from case inlet 100 to the next case sorter position, they move through door opening 100b. While most cases 40, 42 preferably move below latch 120, latch 120 ensures that taller cases can exit case inlet 100 without causing a jam at case inlet 100 and that multiple shorter cases do not exit case inlet 100 simultaneously. Latch 120 preferably cooperates with a latch spring 122 that biases latch 120 in a closed position and latch fastener 124 as shown in FIGS. 2 and 3. When a taller case 40, 42 exits case inlet 100, latch 120 moves aside, and when a short case 40, 42 exits case inlet 100, latch 120 preferably remains closed to prevent multiple cases from exiting simultaneously.

As shown in FIGS. 2, 3, and 7, first side 310, second side 320, and optional front cover 307 of housing 300 also define windows or openings to accommodate slider assembly 200 and other features such as fasteners, user inputs, and status indicators. First side 310 preferably defines a side window 310a through which slider assembly 200 can translate and several side openings 310b to facilitate fasteners. Second side 312 preferably defines input openings 312a for user inputs such as a speed control switch 346, fastener openings 312b, and a power inlet 332 that receives power source 90 and electrically communicates with a central controller 360. Front cover 307 optionally includes openings that provide for accessing or observing status indicators 350, user input 348, and sensor inputs 342, 344. User input 348 can be a multipurpose button such as one that turns on and off power to case sorter 10 and initiates sort program 800 based on a short push, executes a calibrate program with a 3-second push, or executes a third program such as an empty program 820 with a 6-second push. Speed control switch 346 is preferably a slider switch allowing a user to choose to run case sorter 10 at any case processing speed between a predetermined minimum and maximum. For example, in the preferred embodiment, a user can choose case processing speeds of up to 4000 cases per hour.

Slider assembly 200 operates within sort chamber 301 of housing 300 and preferably includes an upper slider 210 and lower slider 240, as shown in FIGS. 2-10, both of which can be any rigid or semi-rigid material but are preferably plastic. A toothed bar 214 extends along and from upper slider 210 at a position that cooperates with a gear 376 on an adjacent stepper assembly 370 as shown in FIG. 2. Upper slider 210 also defines an upper slider drop channel 212 and optional slots or grooves 216. Upper slider drop channel 212 extends through upper slider 210 such that when drop channel 212 is positioned below case inlet 100, case inlet channel 110 and drop channel 212 are in fluid communication allowing a case 40, 42 to move from case inlet 100 to upper slider 210. Further, when slider assembly 200 is positioned at the drop position 60, drop channel 212 is in fluid communication with lower slider 240 allowing a case 40, 42 to drop from upper slider 210 to lower slider 240. Upper slider grooves or slots 216 may be formed in or through upper slider 210 to filter out debris such as polishing media and other residue, to reduce friction between upper slider 210 and cases 40, 42 as upper slider 210 moves below cases 40, 42 positioned in case inlet 100, or to reduce manufacturing costs or the weight of case sorter 10.

Lower slider 240 also includes a toothed bar 244 that extends along and from lower slider 240 at a position that cooperates with a gear 378 on an adjacent stepper assembly 370 as shown in FIG. 2. Lower slider 240 also defines a lower slider drop channel 242 and first and second case guides 246, 248. Lower slider drop channel 242 extends through lower slider 240 such that when drop channel 242 is positioned above floor 302 at first floor opening 302a, lower slider drop channel 242 and first exit 600 are in fluid communication allowing an accepted case 40 to move from lower slider 240 to first exit 600. Likewise, when lower slider drop channel 242 is positioned above floor 302 at second floor opening 302b, lower slider drop channel 242 and second exit 700 are in fluid communication allowing a rejected case 42 to move from lower slider 240 to second exit 700. Additionally, when slider assembly 200 is positioned at the drop position 60, lower slider drop channel 242 is in fluid communication with upper slider drop channel 212 allowing a case 40, 42 to drop from upper slider drop channel 212 to lower slider drop channel 242. Optionally and preferably, lower slider also includes first and second case guides 246, 248 that attach to or are integrally formed with lower slider 240. First and second case guides 246, 248 extend upwards from lower slider 240 toward upper slider 210 at a position near lower slider drop channel 242, which facilitates and guides cases 40, 42 as they drop from upper slider drop channel 212 to lower slider drop channel 242. Preferably first and second case guides 246, 248, extend upwards at a spaced distance from one another such that they can accommodate a height measurement arm 410 moving between them as shown in the FIGS. 4, 8, and 11-14.

A rack and pinion mechanism between stepper assembly 370 with gears 376, 378 and the upper and lower toothed bars 214, 244 on slider assembly 200 cause slider assembly to translate through sort chamber 301 of housing 300 and thereby carry individual cases 40, 42 through the case sorter positions. Stepper assembly 370 is preferably positioned at least partially in housing 300 at sort chamber 301 and near back 309. Stepper assembly includes upper stepper gear 376, lower stepper gear 378, rotatable output shaft 374, a stepper motor 372, and a stepper controller 371. Stepper assembly 370 also preferably includes a driver with sensor-less homing and integrated stall detection such as the TMC2209 driver by TRINAMIC Motion Control GmbH & Co. KG of Hamburg, Germany. Preferably, upper stepper gear 378 and lower stepper gear 378 are attached to output shaft 374 at a spaced distance from one another and such that upper stepper gear 376 aligns with upper slider toothed bar 214 and lower stepper gear 378 aligns with lower slider toothed bar 244 as shown in FIG. 2. Also preferably, output shaft 374 connects to and cooperates with stepper motor 372 such that operation of motor 372 causes output shaft 374, upper stepper gear 376, and lower stepper gear 378 to rotate.

In the preferred embodiment, stepper motor 372 is positioned immediately below housing 300 such output shaft 374 extends into sort chamber 301 of housing 300 through third floor opening 302c of floor 302. Additionally, stepper motor 372 is slightly offset from slider assembly 200 such that an output shaft 374 of motor 372 and gears 376, 378 can be positioned to cooperate with toothed bars 214, 244 of slider assembly 200 as discussed above. Optionally and preferably, output shaft 374 if further anchored to housing top 304 with a fastener 375 that allows for output shaft 374 to rotate as needed. Motor 372 is preferably a NEMA 17 42SHDC3025-24B stepper motor with rated power of 14 W, rated voltage of 3.96V, rated current of 0.9A, rated speed of 1000 rpm, rated torque 0.34 NM, holding torque of 1.4 NM, step angle of 1.8 degrees, and step angle accuracy of ±5%. A power inlet 332 facilitates electrical communication and operational connection between motor 372 and an external power supply 90.

Positioned within housing 300 at measurement position 70 is height measurement assembly 400, which is supported by inner wall 330 of housing 300 in the preferred embodiment as shown in FIGS. 5 and 8. Optionally, height measurement assembly can be supported by top 304 where no inner wall is present. Height measurement assembly 400 includes a height measurement arm 410 that pivotally attaches to or through a support shelf 460. Preferably support shelf 460 also defines a support channel 462 and extends into sort chamber 301 from inner wall 330 of housing 300 such that upper slider 210 can translate along a top surface (not labeled) of support shelf 460. As upper slider 210 translates, an individual case 40, 42 carried by upper slider 210 will also travel along the top surface of support shelf 460 until it reaches support channel 462. Preferably, support channel 462 is positioned such that when slider assembly 200 is positioned at case sorter drop position 60, support shelf 460 sits between upper slider 210 and lower slider 240 such that upper slider drop channel 212, support channel 462, and lower slider drop channel 242 are in fluid communication and a case 40, 42 can drop from upper slider 210 to lower slider 240 traveling through support shelf 460 as shown in FIG. 15B. More preferably, support channel 462 is sloped slightly as shown in FIG. 5 to facilitate dropping of a case 40, 42.

Height measurement arm 410 is positioned on support shelf 460 such that it rotates through the spaced distance between lower slider first and second case guides 246, 248 when a case is present in the measurement position 70 of case sorter 10 and as shown in FIGS. 4, 11, and 12. Additionally, height measurement arm 410 pivotally attaches to support shelf 460 with arm fastener 464 at shaft 412, and arm 410 includes a tip 414 and contact edge 416. A spring 440 attaches to height measurement arm 410, biasing its tip 414 away from support shelf 460 and towards second exit 700 as shown in FIG. 8. Contact edge 416 rests against case 40, 42 when it is at the measurement position 70 of the case sorter 10. Preferably, height measurement arm 410 includes an extension 410a integrally connected with or fixedly secured to arm 410, the arm being positioned in front chamber 308 of housing 300. With this embodiment, extension 410a attaches to spring 440, which in turn attaches to inner wall 330 at a spring anchor 442, which is also positioned in front chamber 308 of housing 300. More preferably, extending from inner wall 330 into front chamber 308 of housing, an arm stopper 418 is positioned to prevent over rotation of arm extension 410a, and thereby arm 410, as shown in FIG. 9.

Height measurement assembly 400 also includes a height measurement magnet 430 attached to arm 410 and positioned at shaft 412 such that as the arm rotates about shaft 412, so does magnet 430. At a spaced distance, preferably in front chamber 308 of housing 300, a height measurement sensor 420 is positioned to cooperate with and sense changes in the magnetic field caused by the rotation of arm 410 and attached magnet 430. While called a height measurement magnet herein, it shall be understood by those skilled in the art that the angular change of the magnetic field of magnet 430 is measured, which is then used to calculate the angular displacement of arm 410 and thereby determine a height measurement or the relative height of case 40 being measured. Preferably, height measurement sensor 420 is a rotary magnetic position sensor capable of measuring the angle that shaft 412 turns. For example, sensor 420 can be an AS56000 sensor and magnet 430 is preferably a diametrically magnetized magnet. Alternatively, height measurement magnet 430 can be an axial magnetized magnet. Height measurement sensor 420 operationally connects to a height measurement controller 450, which includes programming for accessing, determining, or calculating a height measurement for case 40, 42 based on the angle of turn of magnet 420 at shaft 412. Optionally, height measurement sensor 420 and controller 450 also operationally connect to sensor user inputs 342, 344 that allow an operator to adjust the sensitivity of height measurement sensor 420. FIGS. 13-14 illustrate cases having differing heights, which are represented in the Figures by the distances H1 and H2 measured between lower slider 240 and arm tip 414. As shown, H1 corresponds to a taller case and H2 corresponds to a shorter case. In FIG. 13 where the case is taller, arm 410 is positioned closer to support shelf 460 (angle A1). In FIG. 14 where the case is shorter, arm 410 is positioned further from support shelf 460 (angle A2).

Also positioned within housing 300 at measurement position 70 is diameter measurement assembly 500, which operates in a similar manner to height measurement assembly 400 but determines measurements relating to the diameter of correctly oriented case 40 (and of the extractor groove 41) or an incorrectly oriented case 42 (no extractor groove 41) when it is at the measurement position 70 of case sorter 10. Diameter measurement assembly 500 is supported by floor 302 of housing 300 in the preferred embodiment as shown in FIGS. 6, 7, and 10. Diameter measurement assembly 500 includes a diameter measurement arm 520 that pivotally attaches to floor 302 at an arm shaft 521 as shown in FIG. 10. Arm 520 is biased with a spring 550 to extend toward the back 309 of housing 300 and includes an arm blade 522 at its tip 520a as shown in FIG. 7 and an arm stopper section 524 that cooperates with inner wall 330 to prevent over rotation of arm 520. Attached to arm 520 at shaft 521, diameter measurement assembly 500 also includes a magnet 540, which is attached such that as the arm 520 rotates about shaft 521, so does magnet 540.

As shown in FIG. 7, diameter measurement assembly 500 optionally but preferably also includes a static rail 510 attached to floor 302 of housing 300, preferably with fasteners 518 attached through static rail openings 510a. In the preferred embodiment, static rail 510 also has a first stopper end 514 and a second stopper end 416, each of which is configured to prevent case 40, 42 from traveling beyond a desired position, and a rail blade 512. Both rail blade 512 and arm blade 522 of diameter measurement arm 520 are sized and positioned to fit in the extractor groove 41of a correctly oriented case 40 when it is at the measurement position of case sorter 10 as shown in FIG. 11 and to rest on the outer surface of an incorrectly oriented case 42 when it is at the measurement position 70 of case sorter 10 as shown in FIG. 12. While only one blade 512 or 522 is needed to identify when an extractor groove 41 is present (thus a correctly oriented case 40), using two opposing blades 512 and 522 doubles the diameter measurement difference due to the absence of the extractor groove 41 when an incorrectly oriented case 42 is present. Accordingly, two opposing blades 512 and 522 are preferred for greater accuracy and reliability. Preferably arm blade 522 and rail blade 512 are made of a rigid material such as steel, which increases durability and performance.

Diameter measurement assembly 500 also includes a diameter measurement sensor 530, preferably positioned within in front chamber 308 of housing 300 at a spaced distance from diameter measurement magnet 540 such that sensor 530 cooperates with and senses changes in the magnetic field caused by the rotation of arm 520 and attached magnet 540. While called a diameter measurement magnet herein, it shall be understood by those skilled in the art that the angular change of the magnetic field of magnet 540 is measured, which is then used to calculate the angular displacement of arm 520 and thereby determine a diameter measurement or the relative diameter of case 40 being measured. Preferably, diameter measurement sensor 530 is a rotary magnetic position sensor capable of measuring the angle that magnet 540 turns about shaft 521. For example, sensor 530 can be an AS56000 sensor and magnet 540 is preferably a diametrically magnetized magnet. Alternatively, diameter measurement magnet 540 can be an axial magnetized magnet. Diameter measurement sensor 530 operationally connects to diameter measurement controller 560, which includes programming for accessing, determining, or calculating a diameter measurement for of case 40, 42 based on the angle of turn of magnet 530 at shaft 521. Optionally, diameter measurement sensor 530 and controller 560 operationally connect to sensor user inputs 342, 344 that allow an operator to adjust the sensitivity of sensor 530. FIGS. 11 and 12 illustrate cases having differing orientations, which causes the measured diameters to differ. In FIG. 11, arm blade 522 and rail blade 512 fit within the extractor groove 41 of case 40, resulting in a smaller measured diameter D1. In FIG. 12, because case 42 is incorrectly oriented, arm blade 522 and rail blade 512 rest against the outside of case 42, resulting in a larger measured diameter D2. The resulting displacement of arm 520 from its resting position is greater for D2 than it is for D1, which allows diameter measurement assembly to detect whether cases are correctly or incorrectly oriented.

The inputs, inlets, indicators, sensors, switches, stepper assembly, height measurement assembly, diameter measurement assembly, and first exit sensor of case sorter 10 that are discussed above each operationally connect to and electrically communicate with a central controller 360 or parts of a central controller 360, which can be attached to or positioned anywhere in housing 300. Controller 360 also preferably operationally connects to and electrically communicates with any other components as needed. Controller 360 includes any necessary components necessary to process user inputs, operate the stepper motor 372 including to move the slider assembly according to a program of predetermined case sorter positions, receive and process sensor measurements associated with the height measurement magnet 430 and diameter measurement magnet 540, calculate height measurements and diameter measurements, distinguish between acceptable versus nonacceptable cases based on the height and diameter measurements, and deliver output signals. Controller 360 preferably houses together or among connected components any necessary control and processing components such as a processor, memory, input and output components, wireless or wired communication components, or any other feature of a computer or controller system as is well known in the art. Software can be stored on the controller's memory and is preferably executable by the processor to perform many tasks, including, for example, calculating a diameter measurement based on the sensed rotational displacement of the diameter measurement sensor, calculating a height measurement based on the sensed rotational displacement of the height measurement sensor, and comparing the diameter measurements and height measurements to stored diameter and height measurements to determine if a case should be accepted or rejected. Where discussed herein that individual assemblies include dedicated controllers or control systems such as stepper assembly controller 371, height measurement controller 450, diameter measurement controller 560, and exit sensor controller 630, it shall be understood by those skilled in the art that the dedicated controllers or control systems can be parts of or integral with central controller 360 as all are operationally connected and in electrical communication.

In operation, the case sorter 10 of the present invention moves cases 40, 42 through a series of case sorter positions according to programs stored in the memory of controller 360 of case sorter 10 and executable by its processor. For example, after a user initiates a case program 800, cases 40, 42 move through case sorter positions that facilitate measuring individual cases 40, 42 before sorting them as acceptable or unacceptable. With each program, however, before a case 40, 42 begins its journey, the case rests in a pre-load position 45 in case inlet 100 as shown in FIGS. 15B-15D. Preferably, a feed tube 102 sits in case inlet 100 to provide a steady stream of cases to be sorted as shown in the Figures. Once power is connected to the case sorter 10, an operator selects any desired program parameters such as speed and program mode. For example, using a multipurpose input push button 348 that electrically communicates with central controller 360, a user can start or stop case sorter 10 and initiate a sort program 800 with a short push, run a calibrate program with a 3-second push, or run an empty program 820 with a 6-second push. A user can select speed using switch 346, which is preferably a slider switch for selections between a predetermined minimum and maximum speed. In some embodiments, an operator can adjust sensor sensitivity for one or more sensors using optional sensor inputs as well.

When a user wishes to sort cases 40, 42 between those that are acceptable and unacceptable, the user initiates the sort program 800, which is illustrated in FIG. 16. When first initiated, sort program 800 records the zero position of slider assembly 200 and then causes stepper assembly 370 to execute a homing routine 810, which in the preferred embodiment is automatically performed by the stepper assembly driver. Preferably, at the conclusion of the homing routine, slider assembly 200 is positioned at the reject position 80 as shown in FIG. 15D, which corresponds to the point where the slider assembly 200 cannot translate any further causing the stepper motor to recognize an increased load. After the homing routine, stepper assembly 370 causes slider assembly 200 to move in either a first direction DIR-1 or a second direction DIR-2 to the feed position 50 where slider assembly receives a case 40, 42 as shown in FIG. 15A. Preferably, case 40, 42 drops from case inlet 100 into upper slider drop channel 212 of slider assembly 200. Next, stepper assembly 370 causes slider assembly 200 to move in second direction DIR-2 to the drop position 60 where case 40, 42 drops from upper slider drop channel 212 through height measurement support channel 462 and into lower slider drop channel 242 as shown in FIG. 15B. When case 40, 42 reaches lower slider drop channel 242, it rests on floor 302 of housing 300, and then stepper assembly 370 causes slider assembly 200 to again move in first direction DIR-1 until case 40, 42 engages height measurement arm 410 and diameter measurement arm 520 at measurement position 70 as shown in FIG. 15C. At measurement position 70, the outputs of height measurement sensor 420 and diameter measurement sensor 530 are recorded based on the angular displacements of height measurement arm 410 and magnet 430 and diameter measurement arm 520 and magnet 540 by case 40, 42. The sensor outputs are then received by and used by sort program 800 to determine height and diameter measurements for case 40, 42. The height and diameter measurements are then compared to stored parameters of acceptable cases 40 to determine if case 40, 42 is an acceptable case 40 or unacceptable case 42. The stored parameters can be a set of parameters preloaded into the memory of case sorter 10 or an average of example or standard cases previously evaluated and stored in the memory of case sorter 10 using a calibrate program 830 of the case sorter 10 as discussed below. Where case 42 is unacceptable, stepper assembly 370 moves slider assembly 200 in second direction DIR-2 to the reject position 80, which is where case 42 is positioned immediately above second exit 700 as shown in FIG. 15D. Case 42 then drops from lower slider drop channel 242 into second exit 700, after which stepper assembly 370 causes slider assembly 200 to return to feed position 50 as shown in FIG. 15A. Where case 40 is acceptable, stepper assembly 370 moves slider assembly 200 in first direction DIR-1 to the accept position 75, which is where case 40 is positioned immediately above first exit 600 as shown in FIG. 15E. Case 40 then drops from lower slider drop channel 242 into first exit 600, where it passes by exit sensor 620. If case 40 does not successfully pass by exit sensor 620, case program 800 stops and optionally, an alert notifies the operator. If case 40 successfully passes by exit sensor 620, then stepper assembly 370 causes slider assembly to return to the feed position 50 as shown in FIG. 15A and the process repeats itself. In the preferred embodiment and as shown in FIG. 15E, feed position 50 and accept position 75 are the same, which eliminates the extra step of returning to the feed position 50, thereby improving operational efficiency. The sort program continues to repeat until the user manually stops the program or an error such as a jammed first exit 600 occurs.

When a user wishes to empty cases 40, 42 from the case sorter 10 or an attached feed tube 102, the user initiates the empty program 820, which is illustrated in FIG. 17. When first initiated, empty program 820 records the zero position of slider assembly 200 and then causes stepper assembly 370 to execute the homing routine 810. Next, stepper assembly 370 causes slider assembly 200 to move in either a first direction DIR-1 or a second direction DIR-2 to the feed position 50 where slider assembly receives a case 40, 42 as shown in FIG. 15A. Preferably, case 40, 42 drops from case inlet 100 into upper slider drop channel 212 of slider assembly 200. Next, stepper assembly 370 causes slider assembly 200 to reverse or move in a second direction DIR-2 to the drop position 60 where case 40, 42 drops from upper slider drop channel 212 through height measurement support channel 462 and into lower slider drop channel 242 as shown in FIG. 15B. When case 40, 42 reaches lower slider drop channel 242, it rests on floor 302 of housing 300, and then stepper assembly 370 causes slider assembly 200 to again continue moving in second direction DIR-2 until case 40, 42 reaches the reject position 80 where case 40, 42 is positioned directly above second exit 700 as shown in FIG. 15D. Case 42 then drops from lower slider drop channel 242 into second exit 700, after which stepper assembly 370 causes slider assembly 200 to return to feed position 50 as shown in FIG. 15A. The empty program continues to repeat until the user manually stops the program.

Case sorter 10 can include programs in addition to the sort program 800 and empty program 820 as needed. For example, a calibrate program 830, which is illustrated in FIG. 18, can be run where a set number of acceptable or standard cases travel through the feed position 50, drop position 60, and measure position 70 to record height and diameter measurements of the cases and calculate average acceptable height and diameter measurements. The cases can exit out either first exit or second exit, and the calculated average acceptable height and diameter measurements can then be used as a reference when running sort program 800. In the preferred embodiment, case sorter 10 stores in its memory the most recent calibrated average acceptable height and diameter measurements until a new calibrate program is executed, which ensures that the most recent stored averages are not erased if the case sorter 10 is turned off or experiences a stall or jam.

With any program, including sort program 800 and empty program 820, the user can choose to stop the program. Preferably, however, when a user manually initiates the program stop, stepper assembly 370 first moves slider assembly 200 and case 40 to the immediate next case sorter position before actually stopping operation. Additionally, in the preferred embodiment, should case sorter 10 experience a stall or jam as it moves case 40, 42 through case sorter positions while running a program, stepper assembly 370 first causes slider assembly 200 to quickly move pack and forth in an attempt to resolve the stall or jam. If not successful, the stepper assembly 370 pauses or is cut off from power and the status indicator 350 flashes, alerting the user that manual intervention is necessary.

While in the foregoing, embodiments of the present invention have been set forth in considerable detail for the purposes of making a complete disclosure of the invention, it may be apparent to those of skill in the art that numerous changes may be made in such detail without departing from the spirit and principles of the invention.