SYSTEM AND METHODS FOR AUTOMATIC LABELING OF ARTICLES OF ARBITRARY SHAPE, SIZE AND ORIENTATION
20200039676 ยท 2020-02-06
Assignee
Inventors
Cpc classification
G06F7/00
PHYSICS
B65B59/00
PERFORMING OPERATIONS; TRANSPORTING
B65C9/00
PERFORMING OPERATIONS; TRANSPORTING
B65C1/021
PERFORMING OPERATIONS; TRANSPORTING
B65C2009/401
PERFORMING OPERATIONS; TRANSPORTING
B65B15/00
PERFORMING OPERATIONS; TRANSPORTING
B25J9/0093
PERFORMING OPERATIONS; TRANSPORTING
International classification
B65C9/00
PERFORMING OPERATIONS; TRANSPORTING
B67B1/00
PERFORMING OPERATIONS; TRANSPORTING
B65B59/00
PERFORMING OPERATIONS; TRANSPORTING
B65B15/00
PERFORMING OPERATIONS; TRANSPORTING
B25J9/00
PERFORMING OPERATIONS; TRANSPORTING
Abstract
The present disclosure provides an improved system and related methods for automating the sizing and labeling of articles of arbitrary shape, size and orientation, whether still or moving. The system comprises a detection and interrogation zone, one or more proximity sensors, one or more interrogation devices, a processor, a controller, a labeling device, and an electromechanical label applicator arm. Detection of an article by a proximity sensor triggers an interrogation device to interrogate the detection and imaging zone for one or more observable properties when the article is located therein. Analysis of the interrogation data yields the height of the article. Combined with a conveyor rate, article height determines the signals sent to the controller, which commands when and how far a label applicator arm should extend from the labeling apparatus to label the article.
Claims
1. A system for the automatic sizing and labeling of an article of arbitrary size, shape and orientation, whether still or moving, the system comprising: an interrogation system configured for: capturing one or more sets of interrogation data pertaining to the article; and sending the data pertaining to the article to a processor; a processor configured for: receiving the captured data from the interrogation system; calculating physical properties of the article based on the received data; and sending corresponding data pertaining to the article to a labeling system; and a labeling system configured for: receiving the corresponding data pertaining to the article from the processor; and applying a label to the surface of the article.
2. The system of claim 1, wherein the interrogation system further includes: a detection and interrogation zone defined by a predetermined volume; one or more proximity sensors configured for detecting the article at one or more locations in the detection and interrogation zone; and one or more interrogation devices configured for interrogating for physical properties of the detection and imaging zone upon detection of the article; wherein each proximity sensor is configured for detecting the article independent of the other proximity sensors and triggering a respective interrogation device; and wherein each interrogation device is configured for interrogating one or more times for one or more predetermined physical properties of the detection and interrogation zone when the article is located therein.
3. The system of claim 2, wherein the detection and interrogation zone is cuboidal in shape, and its six sides include an entrance side, an exit side and at least one side through which an interrogation device interrogates for observable properties of the detection and imaging zone.
4. The system of claim 2, wherein the at least one proximity sensor is one or more of an electromagnetic sensor, an ultrasonic sensor, a weight sensor, a thermal sensor or a combination thereof.
5. The system of claim 2, wherein the at least one interrogation device is configured to interrogate one or more times for one or more physical properties of the detection and interrogation zone sequentially in time at a predetermined rate, and the at least one interrogation device has temporary data storage capacity.
6. The system of claim 2, wherein at least one of the one or more interrogation devices is positioned above the detection and interrogation zone and is configured for measuring distance, the means of measuring distance being primarily optical in nature, the optical nature being primarily active in character, and the active, optical device enabling distance measurement based on a direct or an indirect measurement of photon time of flight.
7. The system of claim 2, wherein the system further includes one or more data processors incorporated into the one or more interrogation devices.
8. The system of claim 2, wherein the connections between the at least one proximity sensor and the at least one interrogation device are wired connections, wireless connections, or a combination thereof.
9. The system of claim 1, wherein the processor is configured to analyze one or more sets of interrogation data pertaining to the article, calculate one or more physical quantities, including the height of the article, and send a signal to the controller related to the height and rate of motion of the article.
10. The system of claim 1, wherein the labeling system further includes: a controller configured for receiving signals from the processor and sending commands to one or more labeling devices; and one or more labeling devices configured for actuating an electromechanical label applicator arm based on commands receiving from the controller; wherein the label applicator arm is configured to extend at a first specified time and to retract at a second specified time, the first and second specified times being determined by the height and rate of motion of the article.
11. The system of claim 1, wherein the connections between the interrogation system, the processor and the labeling system are wired connections, wireless connections, or a combination thereof.
12. A method for the automatic sizing of an article of arbitrary size, shape and orientation, the method comprising: conveying the article through an entrance side of a detection and interrogation zone; detecting the article in the detection and interrogation zone by one or more proximity sensors; triggering one or more respective interrogation devices by the one or more proximity sensors; interrogating one or more times for one or more predetermined observable properties of the detection and interrogation zone by the one or more interrogation devices; transferring the results of the one or more interrogations to a processor; analyzing the results of the one or more interrogations with the processor; and calculating from the results one or more physical properties pertaining to the article.
13. The method of claim 12, where the article is conveyed to or through the detection and imaging zone by any convenient means.
14. The method of claim 12, wherein one or more of the proximity sensors is one or more of an electromagnetic sensor, an ultrasound sensor, a weight sensor and a heat sensor.
15. The method of claim 12, wherein one or more of the interrogation devices is a three-dimensional time-of-flight camera.
16. The method of claim 12, wherein at least one of the predetermined properties of the detection and interrogation zone to be interrogated is the shortest distance from the interrogation device to the article in the detection and interrogation zone.
17. The method of claim 12, wherein at least one of the calculated physical properties of the article is height in standard units of length.
18. A method for the automatic labeling of an article of arbitrary size, shape and orientation, the method comprising: calculating by a processor a first time point for extending an electromechanical label applicator arm and a second time point for retracting a label applicator arm of a labeling device based on article height and a conveyance speed; sending both time points from the processor to a controller; sending commands from the controller to the labeling device, indicating the time points for extending and retracting the label applicator arm; conveying the article to the labeling device at the conveyance speed; affixing a label for the article to the label applicator arm; extending the label applicator arm at the extension time; applying the label to the article; and retracting the label applicator arm at the retraction time.
19. The method of claim 18, wherein the article can be labeled by any of one or more labeling devices.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] For a fuller understanding of the invention, reference is made to the following detailed description, taken in connection with the accompanying drawings illustrating various embodiments of the present invention, in which:
[0021]
[0022]
[0023]
[0024]
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0025] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. This invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the invention to those skilled in the art. Like numbers refer to like elements throughout.
[0026] Referring to
[0027] In the embodiment of the present invention shown in
[0028] It can be desirable to determine the height of an article 16 on a conveyor 32 for one or more downstream processes, for example, sorting or labeling the article 16 based on height. In the embodiment of the present invention shown in
[0029] In one embodiment of the present invention, the at least one proximity sensor 14 is a reflective electromagnetic sensor, or photon eye. Such sensors are relatively reliable and inexpensive, and they can operate in a convenient wavelength range, for example, a band that includes wavelengths in a region generally known as the near-infrared. Such sensors typically comprise a transmitter, a reflector and a receiver, which together can be used to detect a target (e.g. an article 16) within the range of the detector. In the present context, this range can include a portion of a detection and interrogation zone 12 through which the article 16 will pass. The target is detected when it obstructs the radiation path of the photoelectric sensor and thus reduces the reflected signal and photon flux at the receiver relative to an obstruction-free radiation path.
[0030] Detection of an article 16 by at least one proximity sensor 14 can be used to trigger one or more interrogation devices 18. In one embodiment of the present invention, the one or more interrogation devices 18 can be used to interrogate a detection and imaging zone 12 one or more times for one or more observable properties. The results of the at least one interrogation can be used to determine the height of the article 16. The one or more interrogation devices 18 can be configured for measuring distance. The distance measurement can be primarily optical in nature, and the optical nature can be primarily active in character. One or more of the interrogation devices 18 can be a camera, which can be configured for its optical axis 181 to be perpendicular to the plane of the conveyor 30 and pass through the detection and interrogation zone 12, as in
[0031] In one embodiment of the present invention, one or more of the interrogation devices 18 can be a three-dimensional time-of-flight camera. Each such camera can be configured for its field of view to include a detection and interrogation zone 12, so that when a target (e.g. an article 16) is present, each camera can sample an array of points simultaneously on the target surface. Each such camera can further be configured for collecting data in response to a signal from a proximity sensor 14 that has detected the target (e.g. the article 16). Sampling of points on the target surface involves light pulses emitted by a source, often an array of special light-emitting diodes in an illumination unit of a camera used for sampling. A lens of the camera then gathers reflected light and focuses it onto sensors inside the camera in the focal plane of the lens, e.g. an array of photodiodes. Measurement of the time of flight of the reflected light can be combined with other information to calculate the distance of objects (e.g. the article 16) in the field of view of the camera from its focal plane.
[0032] The time required for a photon to travel from a source to a target will depend on distance. In the embodiment of the present invention shown in
[0033] An interrogation device 18 of the present invention can send the results of one or more interrogations for observable properties of a detection and interrogation zone 12 to a processor 24 for real time or near-real time data analysis. In one embodiment of the present method, the interrogation device 18 can be a three-dimensional time-of-flight camera. The results of the one or more interrogations of the detection and interrogation zone 12 can contain time-of-flight information. The time-of-flight information can pertain to one or more targets in the detection and interrogation zone 12 (e.g. an article 16 and a conveyor 32). The real time or near-real time image processing of the one or more images can result in the determination of the shortest distance between a sensor array of the interrogation device 18 used to interrogate the detection and interrogation zone 12 and a first target (e.g. the article 16, the distance 42) and the shortest distance between the sensor array of the interrogation device 18 and a second target (e.g. the conveyor 32, the sum of the distances 40 and 42). From these data the height of the first article (the distance 40) can be calculated by subtraction. Height data thus determined can be used for diverse purposes, for example, the labeling and/or sorting of the article 16.
[0034] Singulated articles can be sorted in a process based on one or more physical properties of the articles, for example, height. In an embodiment of the present invention, if the height 40 of an article 16 on a conveyor 32 exceeds a predetermined minimum value in a binary sortation process, the article 16 can be diverted from the path of the conveyor 32, whereas if the height 40 of the article 16 on the conveyor 32 does not exceed the predetermined minimum value, the article 16 can remain on the path of the conveyor 32. In an embodiment of the present invention the article 16 can be one of a train of singulated articles of limited width and length but otherwise arbitrary size, shape and orientation. Height-based sortation of such articles can be used to achieve a variety of downstream purposes, for example, increasing the uniformity of mass distribution over a volume of a large container in an automated filling process or improving the utilization of a space in a fixed volume.
[0035] Referring to
[0036] At step 304 of the present method, the proximity sensor 14 triggers a first of one or more interrogation devices 18.
[0037] At step 306, the interrogation device 18 interrogates one or more times for one or more observable properties the detection and interrogation zone 12.
[0038] At Step 308, the Interrogation Device 18 Transfers the Data Acquired in the at Least One Interrogation to a Processor 24.
[0039] At step 310, the processor 24 analyzes the data of the at least one interrogation.
[0040] At step 312, the processor 24 calculates one or more quantities of interest based on the analyzed data, at least one of which is the height 40 of the article 16 in the detection and interrogation zone 12.
[0041] The method then returns to step 302. If the same article 16 is targeted by a second proximity sensor 14, steps 304-310 are repeated. In this case, a second interrogation device 18 interrogates the detection and interrogation zone 12 one or more times, and the results are sent to the processor 24. Otherwise, at step 314, the method ends and the first article 16 leaves the detection and interrogation zone 12. The conveyor 32 can now bring a second article 16 into the detection and interrogation zone 12. The method then begins anew at step 302.
[0042] Accurate article height information can be used to control an article labeling process in the case of a moving article. The process can involve, for instance, a print and apply device, and the labels can be adhesive labels. The process can also require specifying a first time, when an electromechanical label applicator arm (e.g. label applicator arm 38) of a labeling system must be actuated and extended from a location in the vicinity of (e.g. directly above) a conveyor (e.g. conveyor 32), and a second time, when the same label applicator arm should be retracted to its original position, so that the label applicator arm will apply a label to the surface of an article (e.g. the upper side of a cuboidal article 16) on the conveyor (e.g. conveyor 32) as the article is conveyed to the labeling system (e.g. labeling device 36) and the label applicator arm will not become damaged in the process (e.g. by being overextended). Specifying the first and second times for label applicator arm movement will require an accurate measure of the height (e.g. distance 40) of the article (e.g. article 16), the rate of motion of the conveyor (e.g. conveyor 32), and the rate of motion of the label applicator arm (e.g. label applicator arm 38). The article labeling process described here could occur downstream of an article sizing process.
[0043] Referring to the embodiment of the present invention shown in
[0044] A time interval t is required for a conveyor 32 to move an article 16 from a first location x.sub.1 at a time point t.sub.1 to a second location x.sub.2 at a time point t.sub.2, where t.sub.2>t.sub.1. In one embodiment of the present invention, x.sub.1 can correspond to a location in space where one or more proximity sensors 14 are configured to detect an article 16 in relation to a detection and interrogation zone 12, and x.sub.2 can correspond to a location in space where a label applicator arm 38 extends from a labeling device 36 and applies a label to the article 16. It is assumed that both the one or more proximity sensors 14 and the labeling device 36 are at rest in the same reference frame. In
[0045] A value for t.sub.2 can enable calculation of the time point t.sub.a when a label applicator arm 38 should be actuated so that it will make physical contact with the surface of an article 16 in the vicinity of a labeling device 36 and thus enable productive labeling of the article 16. Suppose it is desired to apply a label to the upper side of the article 16, that is, the side that is farthest from a conveyor 32, as in
[0046] Some practical considerations are worth noting. If v.sub.a is time-dependent, as will generally be the case, z/t will be variable. One will in this case need the functional form of z(t) to specify t.sub.a. Further, t.sub.a>t.sub.1+t.sub.d, where the delay time t.sub.d is the minimum time needed to interrogate for one or more properties of the detection and interrogation zone 12 when the one or more proximity sensors 14 detects an article 16 therein, transfer the interrogation data obtained to the processor 24, calculate the height 40 of the article 16, signal the controller 28 to command the labeling device 36 to actuate the label applicator arm 38, and actuate the label applicator arm 38. The present disclosure provides a system and methods for sizing and labeling articles still or moving, regardless of the spacing between singulated articles on a conveyor, provided that the time criteria noted herein are met.
[0047] Referring to
[0048] At step 404, the processor 24 sends the time points to a controller 28.
[0049] At step 406, the controller 28 sends commands to the labeling device 36 on when to extend and retract the label applicator arm 38.
[0050] At step 408, the article 16 is conveyed to the labeling device 36.
[0051] At step 410, the labeling device 36 extends the label applicator arm 38 at the extension time.
[0052] At step 412, the labeling device 36 affixes a label for the article 16 to the label applicator arm 38.
[0053] At step 414, the label applicator arm 38 applies the label to the article 16.
[0054] At step 416, the labeling device 36 retracts the label applicator arm 38 at the retraction time.
[0055] At step 418, the article 16 is conveyed from the labeling device 36.
[0056] A conveyor 32 can be used to convey the article 16 into the vicinity of the labeling device 36 for labeling by the label applicator arm 38, and the conveyor 32 can be used to move the article 16 away from the labeling device 36 after the labeling process is complete.
[0057] As used herein, arbitrary orientation means any attitude of an article relative to a size interrogation device used to image its optical, machine-readable representation of data. The article 16 can be a box, flat, softpack or other type of item.
[0058] Arbitrary shape and size means any volume of any shape, provided that it is at once large enough to accommodate the entire area of a label on which a complete, standard-sized optical, machine-readable representation of data can be printed and small enough for a portion of an entity on which an optical, machine-readable representation of data is displayed to pass through the sensing and imaging zone.
[0059] Height means the highest altitude of an article relative to the altitude of a support on which the article is at rest, measured as the difference between the shortest distance from the interrogation device to the support in the detection and interrogation zone and the shortest distance from the interrogation device to the article in the detection and interrogation zone.
[0060] High-speed camera means a certain kind of optical device that can capture and transfer at least one high-resolution frame in a time interval corresponding to the rate of motion of the article in the field of view of an optical device used to determine the height of an article on a conveyor.
[0061] Interrogate means to assay for a specific type of information.
[0062] Interrogation device means an electronic instrument that provides a specific type of information about a subject, for example, an information retrieval system that displays data about the subject upon inquiry. The interrogation device can be a kind of camera. The subject of the interrogation can be a region of space or an object in the field of view of the camera.
[0063] Label means a small piece of paper, plastic, or similar material attached to an article giving written, printed or graphic information, typically, about the article. The information displayed on a label can comprise a unique article identifier.
[0064] Labeling device means an apparatus for applying a label, usually adhesive, to an article.
[0065] Moving article means an article in motion relative to interrogation devices and proximity sensors.
[0066] Optical device means a device the function of which is based on electromagnetic radiation in the visible range. An optical distance-measuring system is active if it illuminates the target during interrogation. Illumination generally involves some combination of monochromatic, polychromatic, continuous, pulsed, modulated, structured, polarized, coherent or partly-coherent light.
[0067] Processor means one or more components in a computer responsible for receiving input data, executing the instructions of one or more computer programs by performing basic arithmetic logical, control and input/output operations specified by the instructions, and carrying out related functions.
[0068] Proximity sensor means a device that can detect the presence of a nearby article, often within 10 meters of the device. The proximity sensor of the present machine vision method can be an electromagnetic sensor that operates in the IR or some other kind of sensor, for example, an ultrasound sensor.
[0069] Support means a platform, whether still or moving, that bears all of the weight of an article.
[0070] Target means an article detected by a change of signal received by a proximity sensor, for instance, a change in reflected sound waves received in the case of an ultrasonic sensor or a change in reflected electromagnetic waves received in the case of a photonic sensor.
[0071] Three-dimensional means three dimensions of space, for example, length, width and height in a Cartesian coordinate system.
[0072] Time-of-flight camera means a range imaging camera that determines distance for each point of an image captured by the camera based on the known and constant speed of light.
[0073] Unique item identifier (UII) means a unique data string assigned to a single tangible article to distinguish the article from another article that may be of the same make and model. A UII is often encoded in a two-dimensional bar code and physically marked on a tangible article, for example, by means of an adhesive label. The label applied by labeling device 36 can include a UII.
[0074] Many additional modifications and other embodiments of the invention will come to the mind of one skilled in the art having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is understood that the invention is not to be limited to the specific embodiments disclosed, and that modifications and embodiments are intended to be included within.
[0075] The foregoing is provided for illustrative and exemplary purposes; the present invention is not necessarily limited thereto. Rather, those skilled in the art will appreciate that various modifications, as well as adaptations to particular circumstances, are possible within the scope of the invention as herein shown and described.