Vision based conveyor package flow management system

• US 20160221762A1
• Filed: 12/31/2015
• Published: 08/04/2016
• Est. Priority Date: 12/31/2014
• Status: Active Grant

• Current Assignee: Fives Intralogistics Corp.
• Original Assignee: Fives Intralogistics Corp.
• Inventors: Schroader, Steven Vann
• Granted Patent: US 9,771,222 B2
• Time in Patent Office: Days
• US Class Current: 1/1
• CPC Class Codes: B65G 2203/041 Camera
• CPC Class Codes: B65G 2811/0673 Control of conveying operations
• CPC Class Codes: B65G 43/08 Control devices operated by article or material being fed, conveyed or discharged and controlling the discharging devices B65G47/42
• CPC Class Codes: B65G 43/10 Sequence control of conveyors operating in combination
• CPC Class Codes: B65G 47/31 by varying the relative speeds of the conveyors forming the series
• CPC Class Codes: B65G 47/681 from distinct, separate conveyor lanes
• CPC Class Codes: G06V 20/52 Surveillance or monitoring of activities, e.g. for recognising suspicious objects recognising microscopic objects G06V20/69
• CPC Class Codes: G06V 2201/06 Recognition of objects for industrial automation
• CPC Class Codes: G06V 30/424 Postal images, e.g. labels or addresses on parcels or postal envelopes

Abstract

A camera based vision system that recognizes and maximizes belt area utilization. A plurality of cameras are positioned at flow entry points of feed conveyors and at the singulator. The control algorithm recognizes individual items area, the rate at which individual objects are passing, and the area utilization of the collector belt. The video camera and computer based conveyor package management system monitor and control the number and size of the packages present on the infeed conveyors, collector conveyor, singulator conveyor and sorting conveyor in a package handling system wherein the camera data is used to measure the available area or space on the conveyors to maintain a desired density of packages on selected conveyor(s). The conveyor speed is controlled as a function of occupancy on a collector or just prior to a singulator or receiver.

Claims

1. A video based conveyor area utilization system comprising:

a feed conveyor;

a receiving conveyor comprising a receiving conveyor including separate sections of conveyor modules independently driven by individual motors with individual speed controllers;

at least one feed conveyors including at least one section independently driven by individual motors with an independent speed controller;

at least one singulator downstream of said receiving conveyor;

a first video camera monitoring a selected areas of said receiving conveyor providing a field of view to determine a receiving conveyor occupancy percentage (RCO %);

a second video camera monitoring a selected areas of said feed conveyor providing a field of view to determine a feeding conveyor occupancy percentage (FCO %);

a control program within said video computer capable of controlling a rate of receiving conveyor speed of said receiving conveyor and a rate of feed speed of said feed conveyor based on a calculated amount of free space area available on a given receiving section compared to an area of a package conveyed on said feed conveyor;

said feed speed is calculated and controlled based on digital camera data to measure the available area on said receiving conveyor;

said receiver conveyor speed is calculated and controlled based on digital camera data to measure the available area on said singulator;

said feed speed and said receiving conveyor speed controlled to achieve a desired conveyor area utilization on a selected down stream conveyor according to the formula V2=V1×

2×

(DO %)/(RCO %+FCO %) where V is volume, (DO %) is Desired Occupancy, RCO % is Receiving Conveyor Occupancy percent, and FCO % is Feeding Conveyor Occupancy percent; and

said singulator comprising a conveyor mechanism for conveying single-file articles in a forward direction while removing articles traveling laterally adjacent the single-file articles, the conveyor mechanism comprising first and second driven conveyor structures respectively forming first and second conveying lanes disposed in parallel as viewed in plan and situated immediately adjacent one another;

the first and second conveying lanes applying first and second conveying forces, respectively, which are divergent relative to one another;

the first conveying force including a forward directional component;

the second conveying force including a lateral directional component extending away from the first lane to move articles away from the first lane that are out of contact with the first lane.

2. A method of managing bulk parcel flow with a vision management system, comprising the steps of:

selecting a transition zone between a feed conveyor and a receiving conveyor each one having independent drive motors;

selecting a camera field of view of said selected transition zone;

addressing an IP address to each camera;

setting an inline feeding conveyor speed to achieve a desired conveyor area utilization on a down stream receiving conveyor according to the formula V2=V1×

2×

(DO %)/(RCO %+FCO %) where V is volume, DO is Desired Occupancy, RCO is Receiving Conveyor Occupancy, and FCO is Feeding Conveyor Occupancy;

selecting a percentage of camera field of view;

selecting a percentage of the feeding conveyor occupancy defined zone;

selecting a percentage of the receiving conveyor occupancy defined zone;

selecting a percentage of the desired occupancy after the merger;

feeding parcels to the receiving conveyor occupancy defined zone

conveying parcels toward a desired occupancy zone at a selected position

merging the parcels at a transition section between said feeding conveyor and said receiving conveyor

3. A vision based bulk parcel flow management system, comprising:

a feed conveyor and a receiving conveyor each one having independent drive motors;

a transition zone between said feed conveyor and said receiving conveyor;

a camera field of view of said selected transition zone;

an inline feeding conveyor speed to achieve a desired conveyor area utilization on a down stream receiving conveyor according to the formula V2=V1×

2×

(DO %)/(RCO %+FCO %) where V is volume, DO is Desired Occupancy, RCO is Receiving Conveyor Occupancy, and FCO is Feeding Conveyor Occupancy;

a camera providing a selected field of view;

a feeding conveyor having a selected occupancy defined zone;

a receiving conveyor having a selected occupancy defined zone;

a section selected included a percentage of the desired occupancy after the merger;

a receiving conveyor having a selected occupancy defined zone;

a conveyor area including a desired occupancy zone at a selected position;

a transition section between said feeding conveyor and said receiving conveyor for merging the parcels from one to another; and

a computer for controlling said conveyor speed and movement based upon signals received from said cameras identifying gaps between packages on said receiving conveyor of sufficient space for insertion of an additional package from said feeding conveyor.