Inspection system

• US 9,468,948 B2
• Filed: 12/16/2015
• Issued: 10/18/2016
• Est. Priority Date: 06/01/2010
• Status: Active Grant

• Current Assignee: Ackley Machine Corporation
• Original Assignee: Ackley Machine Corporation
• Inventors: Ackley, E. Michael, Ford, Mark
• Primary Examiner(s): MATTHEWS, TERRELL HOWARD
• Application Number:
  US14/970,961
• Publication Number:
  US 20160107198A1
• Time in Patent Office: 307 Days
• Field of Search: 209/938, 209/939, 209/582
• US Class Current: 1/1
• CPC Class Codes: B07C 5/34 Sorting according to other particular properties material testing per se G01N; quality control G07C3/14
• CPC Class Codes: B07C 5/3412 according to a code applied to the object which indicates a property of the object, e.g. quality class, contents or incorrect indication sorting according to size measured by light-responsive means B07C5/10; sorting according to optical properties B07C5/342; for packages B65D79/02; for information carriers G06K7/00
• CPC Class Codes: B07C 5/3422 using video scanning devices, e.g. TV-cameras
• CPC Class Codes: B07C 5/362 Separating or distributor mechanisms switches for postal sorting B07C3/065; particular discharging devices for B65G47/74
• CPC Class Codes: B07C 5/363 by means of air
• CPC Class Codes: G01N 2021/845 Objects on a conveyor
• CPC Class Codes: G01N 2021/8592 Grain or other flowing solid samples
• CPC Class Codes: G01N 21/85 Investigating moving fluids or granular solids
• CPC Class Codes: G01N 21/8806 Specially adapted optical and illumination features
• CPC Class Codes: G01N 21/8851 Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges G01N21/8806 and G01N21/93 - G01N21/95692 take precedence; optical measurement of dimensions G01B11/00; optical scanning G02B26/10; image transformation G06T3/00; computerised image enhancement G06T5/00; image processing per se for flaw detection G06T7/0002
• CPC Class Codes: G01N 21/9508 Capsules; Tablets
• CPC Class Codes: G01N 2201/02 Mechanical
• CPC Class Codes: G01N 2201/062 LED's
• CPC Class Codes: G01N 2201/0621 Supply
• CPC Class Codes: Y10T 29/49826 Assembling or joining

Abstract

An inspection system is configured for use with a conveyer apparatus including carrier bars. Each carrier bar conveys pellet-shaped articles along a predetermined path. The inspection system includes at least one camera unit for sensing a predetermined characteristic of the pellet-shaped articles, a removal unit, and a controller. The removal unit, downstream from the at least one camera unit, removes selected pellet-shaped article(s) from the carrier bar(s) depending on whether the characteristic is sensed by the at least one camera unit. The controller is in communication with the at least one camera unit and the removal unit. The controller provides a signal to the removal unit in accordance with the sensed characteristic. The removal unit includes a rotatable ejection drum having extended vacuum nozzles along its length, equal to the number of articles conveyed in each carrier bar. Each vacuum nozzle selectively removes article(s) from the carrier bar(s) by suction.

Claims

1. An inspection system comprising:

a conveyor to convey a plurality of pellet-shaped articles along a path;

at least one camera unit configured to sense a predetermined characteristic of the plurality of pellet-shaped articles;

a removal unit, downstream from the at least one camera unit, structured to remove at least a selected one of the plurality of pellet-shaped articles from the path depending on whether the predetermined characteristic is sensed by the at least one camera unit; and

processing resources, including at least one processor, the processing resources being operably connected to and in communication with the at least one camera unit and the removal unit, and being configured to at least;

provide a signal to the removal unit in accordance with the predetermined characteristic sensed by the at least one camera unit, the signal representing whether a given pellet-shaped article is to be accepted or rejected;

generate for output to a display device a first display area including real-time video output, including at least a portion of the conveyor, from the at least one camera unit,

calculate inspection statistics based on input relating to the predetermined characteristic sensed by the at least one camera unit; and

generate for output to the display device a second display area including the calculated inspection statistics.

2. The inspection system of claim 1, wherein the input relating to the predetermined characteristic sensed by the at least one camera unit includes numbers of accepted and rejected pellet-shaped articles processed.

3. The inspection system of claim 2, wherein the inspection statistics include counts of the accepted and rejected pellet-shaped articles processed.

4. The inspection system of claim 2, wherein the inspection statistics include a calculated yield equal to the number of accepted pellet-shaped articles processed divided by the sum of the counts of the accepted and rejected pellet-shaped articles processed.

7. The inspection system of claim 1, wherein the conveyor includes at least one row of product receiving pockets, the pockets being structured to convey pellet-shaped articles along the path, and wherein the processing resources are further configured to at least calculate at least some inspection statistics on a pocket-by-pocket basis.

8. The inspection system of claim 1, wherein the processing resources are further configured to at least respond to user input and cause one or more camera units to zoom in and update the first display area accordingly.

9. The inspection system of claim 1, further comprising a plurality of camera units, wherein the camera units are individually controllable.

10. The inspection system of claim 1, wherein the first and second display areas are generated for display on a common display screen.

5. An inspection system comprising:

a conveyor to convey a plurality of pellet-shaped articles along a path;

a plurality of camera units configured to sense a predetermined characteristic of the plurality of pellet-shaped articles;

a removal unit, downstream from the plurality of camera units, structured to remove at least a selected one of the plurality of pellet-shaped articles from the path depending on whether the predetermined characteristic is sensed by the plurality of camera units; and

processing resources, including at least one processor, the processing resources being operably connected to and in communication with the plurality of camera units and the removal unit, and being configured to at least;

provide a signal to the removal unit in accordance with the predetermined characteristic sensed by the plurality of camera units, the signal representing whether a given pellet-shaped article is to be accepted or rejected,

generate for output to a display device a first display area including real-time video output, including at least a portion of the conveyor, from the plurality of camera units, and

calculate at least some inspection statistics on a camera-by-camera basis.

6. An inspection system comprising:

a conveyor to convey a plurality of pellet-shaped articles along a path;

a plurality of camera units configured to sense a predetermined characteristic of the plurality of pellet-shaped articles;

a removal unit, downstream from the plurality of camera units, structured to remove at least a selected one of the plurality of pellet-shaped articles from the path depending on whether the predetermined characteristic is sensed by the plurality of camera units; and

processing resources, including at least one processor, the processing resources being operably connected to and in communication with the plurality of camera units and the removal unit, and being configured to at least;

provide a signal to the removal unit in accordance with the predetermined characteristic sensed by the plurality of camera units, the signal representing whether a given pellet-shaped article is to be accepted or rejected,

generate for output to a display device a first display area including real-time video output, including at least a portion of the conveyor, from the plurality of camera units, and calculate inspection statistics including a system-wide yield of accepted pellet-shaped articles, and yields of accepted pellet-shaped articles on a camera-by-camera basis.

11. An inspection system comprising:

a conveyor to convey a plurality of pellet-shaped articles along a path;

at least one camera unit configured to sense a predetermined characteristic of the plurality of pellet-shaped articles;

a removal unit, downstream from the at least one camera unit, structured to remove at least a selected one of the plurality of pellet-shaped articles from the path depending on whether the predetermined characteristic is sensed by the at least one camera unit and

processing resources, including at least one processor, the processing resources being operably connected to and in communication with the at least one camera unit and the removal unit, and being configured to at least;

provide a signal to the removal unit in accordance with the predetermined characteristic sensed by the at least one camera unit, the signal representing whether a given pellet-shaped article is to be accepted or rejected; and

generate for output to a display device a first display area including real-time video output, including at least a portion of the conveyor, from the at least one camera unit,

wherein the removal unit includes a rotatable drum having a plurality of extended nozzles along its length associated with the number of articles conveyed in each row, each nozzle being structured to selectively remove the article from the conveyor.

12. The inspection system of claim 11, wherein the removal unit is structured to remove articles from the conveyor by suction, the removal unit being configured to selectively release suction applied to the articles to directly deposit the articles into one of an accept bin and a reject bin, depending on whether the articles are deemed acceptable or unacceptable.

13. The inspection system of claim 11, wherein the rotatable drum is a rotatable ejection drum and the extended nozzles are extended vacuum nozzles, the extended vacuum nozzles being structured to selectively remove the articles from the conveyor by suction.

14. A method of operating an inspection system, the method comprising:

conveying a plurality of pellet-shaped articles along a path via a conveyor;

sensing a predetermined characteristic of the plurality of pellet-shaped articles using at least one camera unit;

removing at least a selected one of the plurality of pellet-shaped articles from the path depending on whether the predetermined characteristic is sensed by the at least one camera unit via a removal unit located downstream from the at least one camera unit;

providing a signal to the removal unit in accordance with the predetermined characteristic sensed by the at least one camera unit, the signal representing whether a given pellet-shaped article is to be accepted or rejected;

generating for output to a display device a first display area including real-time video output, including at least a portion of the conveyor, from the at least one camera unit;

calculating inspection statistics based on input relating to the predetermined characteristic sensed by the at least one camera unit; and

generating for output to the display device a second display area including the calculated inspection statistics.

15. The method of claim 14, wherein the input relating to the predetermined characteristic sensed by the at least one camera unit includes numbers of accepted and rejected pellet-shaped articles processed.

16. The method of claim 14, wherein the inspection system comprises a plurality of camera units, and further comprising calculating at least some inspection statistics on a camera-by-camera basis.

17. The method of claim 14, further comprising calculating inspection statistics including a system-wide yield of accepted pellet-shaped articles, and yields of accepted pellet-shaped articles on a camera-by-camera basis.

18. The method of claim 14, wherein the conveyor includes at least one row of product receiving pockets, the pockets being structured to convey pellet-shaped articles along the path, and further comprising calculating at least some inspection statistics on a pocket-by-pocket basis.

19. The method of claim 14, further comprising responding to user input and causing one or more camera units to zoom in and update the first display area accordingly.

20. The method of claim 14, wherein the inspection system comprises a plurality of camera units, and wherein the camera units are individually controllable.

21. The method of claim 14, wherein the first and second display areas are generated for display on a common display screen.

22. The method of claim 14, wherein the removal unit includes a rotatable drum having a plurality of extended nozzles along its length associated with the number of articles conveyed in each row, each nozzle being structured to selectively remove the article from the conveyor.

23. The method of claim 22, wherein the rotatable drum is a rotatable ejection drum and the extended nozzles are extended vacuum nozzles, the extended vacuum nozzles being structured to selectively remove the articles from the conveyor by suction.