Calibration of a dynamic digital imaging system for detecting defects in production stream

• US 9,699,447 B2
• Filed: 03/14/2013
• Issued: 07/04/2017
• Est. Priority Date: 11/26/2012
• Status: Active Grant

• Current Assignee: Frito-Lay North America Incorporated (PepsiCo Incorporated)
• Original Assignee: Frito-Lay North America Incorporated (PepsiCo Incorporated)
• Inventors: Fagan, Scott, Bourg, Jr., Wilfred Marcellien, Lange, Sonchai, Bradley, Kerwin, Bajema, Rick Wendell, Warren, David Ray
• Primary Examiner(s): TRUONG, NGUYEN T
• Application Number:
  US13/803,484
• Publication Number:
  US 20140146164A1
• Time in Patent Office: 1,573 Days
• Field of Search: 348 47
• CPC Class Codes: B07C 5/3422 using video scanning devices, e.g. TV-cameras
• CPC Class Codes: G01J 3/2803 using photoelectric array detector
• CPC Class Codes: G01J 3/50 using electric radiation detectors
• CPC Class Codes: G01J 3/524 Calibration of colorimeters
• CPC Class Codes: G01N 21/93 Detection standards; Calibrating baseline adjustment, drift correction
• CPC Class Codes: H04N 17/002 for television cameras

Abstract

A system and method for calibrating a dynamic digital imaging system for the detection of defects in a moving product stream. The system has an elevated platform above a conveying unit for receiving a reference color tile. The elevated platform allows for the passage of products to be inspected on the below conveying unit surface such that calibration and re-calibration processes during image capturing may be accomplished on a continuous basis without interruption of the product stream.

Claims

1. A method of calibrating a dynamic digital imaging system for detecting defects in a production stream on a conveyor having a plurality of articles of products, wherein the method comprises:

a) placing a calibration color tile having a calibration color on a platform elevated above the conveyor in a field of view of an imaging unit;

b) obtaining light absorption data of the calibration color using the imaging unit;

c) calculating a component color intensity of the light absorption data of the calibration color using a processor;

d) normalizing the component color intensity of the calibration color;

e) removing the platform out of the field of view of the imaging unit; and

f) obtaining light absorption data of the articles using the imaging unit;

wherein the method further comprises;

transporting a continuous flow of the production stream on the conveyor, wherein the platform is elevated above the production stream; and

performing steps a)-f) without interrupting the continuous flow of the product stream on the conveyor.

2. The method of claim 1 further comprising:

g) calculating a component color intensity of the light absorption data of the articles using the processor;

h) normalizing the component color intensity of the articles; and

i) calculating a quality index score of the articles based on the component color intensity of the calibration color and the articles.

3. The method of claim 2 further comprising:

j) recalling defect threshold data stored in a memory; and

k) comparing the quality index score with the defect threshold data.

4. The method of claim 1, wherein the platform is removed out of the field of view of the imaging unit by moving in a direction parallel to a flow of the conveyor.

5. The method of claim 1, wherein the platform is removed out of the field of view of the imaging unit by moving in a direction perpendicular to a flow of the conveyor.

6. The method of claim 1 further comprising adjusting an output intensity of an illumination source.

7. The method of claim 6, wherein the output intensity of the illumination source is adjusted based on light absorption data of the calibration color.

8. The method of claim 6, wherein the output intensity of the illumination source is adjusted based on light absorption data of the articles.

9. The method of claim 1 further comprising adjusting a direction of an illumination source using a reflector.

10. The method of claim 9 wherein the direction of the illumination source is adjusted based on light absorption data of the calibration color.

11. The method of claim 1, wherein step d) comprises normalizing the component color intensity of the calibration color by adjusting the gain of each individual pixel of a sensor of the imagining unit.

12. The method of claim 2, wherein step d) comprises normalizing the component color intensity of the calibration color by adjusting the gain of each individual pixel of a sensor of the imagining unit.

13. The method of claim 2, wherein step d) comprises normalizing the component color intensity of the calibration color by adjusting the gain of each individual pixel of a sensor of the imagining unit;

and

wherein step h) comprises normalizing the component color intensity of the articles by adjusting the gain of each individual pixel of a sensor of the imagining unit.

14. A system for calibrating a dynamic digital imaging system for detecting defects in a production stream of products comprising:

a conveyor unit having a first frame extending along at least a portion of a width of a conveyor unit;

a platform elevated above the conveyor unit by a first support movably coupled to the first frame; and

a reference color tile placed on the platform;

wherein the platform is configured to provide a clearance between the conveyor unit and the platform; and

wherein the platform is configured so that, when the platform is used to calibrate the dynamic digital imaging system, the clearance is sufficiently large that the production stream can pass below the platform without interrupting a continuous flow of the production stream on the conveyor unit.

15. The system of claim 14 wherein the reference color tile comprises a plurality of reference color segments.

16. The system of claim 14 further comprising a second frame positioned directly across the width of the conveyor unit from the first frame, wherein the platform is further supported by a second support removably coupled to a track within the second frame.

17. The system of claim 14 wherein the platform is elevated at least 7 centimeters from an upper surface of the conveyor unit.

18. The system of claim 14 further comprising an imaging unit comprising a camera having a field of view, a camera window, and a control/data line.

19. The system of claim 18 wherein the camera is a linear array of light sensors.

20. The system of claim 14 further comprising a lighting unit comprising a light source and a reflector.

21. The system of claim 14 wherein the first support is movably coupled to a track within the first frame.

22. The system of claim 14 further comprising a control unit comprising a processor, a memory, and a display device wherein further an imaging unit is in communication with the control unit through a control/data line.

23. The system of claim 14 wherein the color tile is on a roller operable to rotate about its longitudinal axis.

24. The system of claim 21 wherein the support is a beam operable to move within the track.

25. The system of claim 14, further comprising:

a slot within the platform for receiving a reference color tile.