Inspection system

• US 9,757,772 B2
• Filed: 09/21/2016
• Issued: 09/12/2017
• 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:
  US15/271,799
• Publication Number:
  US 20170008036A1
• Time in Patent Office: 356 Days
• Field of Search: 209546, 209552, 209580, 209587, 209938, 209939
• 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 oriented towards the conveyor so as to image the pellet-shaped articles being conveyed along the path;

a removal unit, downstream from the at least one camera; and

processing resources, including at least one processor and a memory, the memory including instructions executable by the at least one processor to control the inspection system to at least;

process data received from the at least one camera to determine whether the pellet-shaped articles being imaged have a predetermined characteristic;

responsive to a determination that a given one of the pellet-shaped articles has the predetermined characteristic, control the removal unit to remove the given one of the pellet-shaped articles that has the predetermined characteristic;

generate, for output to a display device, operably connected to the inspection system, at least one display section including video output from the at least one camera, as the pellet-shaped articles are being imaged and as the data received from the at least one camera is being processed;

receive input enabling a user to set a plurality of inspection regions, at least one of the inspection regions corresponding to an area internal to an outer boundary of a representative of the plurality of pellet-shaped articles and being defined by user-specification of a geometric shape superimposed on a displayed representation of the representative; and

generate, for output to the display device, the geometric shape superimposed on the displayed representation of the representative.

2. The inspection system of claim 1, wherein the memory includes further instructions executable by the at least one processor to control the inspection system to at least provide an annotation relevant to the pellet-shaped articles that are being imaged for inclusion in the first display section.

3. The inspection system of claim 2, wherein the annotation includes an indication as to whether the pellet-shaped articles have the predetermined characteristic.

4. The inspection system of claim 2, wherein the annotation includes an indication as to whether the pellet-shaped articles have the predetermined characteristic, and at least one metric related to inspection for the predetermined characteristic.

5. The inspection system of claim 1, wherein the annotation includes a boundary of an image printed on the pellet-shaped articles.

6. The inspection system of claim 1, wherein the first display section includes real-time video output showing a plurality of the pellet-shaped articles.

7. The inspection system of claim 1, wherein a plurality of cameras are oriented towards the conveyor so as to image different areas of the conveyor and the pellet-shaped articles being conveyed along the path in those different areas of the conveyor.

8. The inspection system of claim 7, wherein the memory includes further instructions executable by the at least one processor to control the inspection system to at least generate, for output to the display device, different display sections including video output from the different cameras, as the pellet-shaped articles are being imaged and as the data received from the cameras is being processed, each display section corresponding to a different one of the plurality of cameras.

9. The inspection system of claim 8, wherein the different display sections are visible simultaneously on one display screen.

10. The inspection system of claim 8, wherein the display sections are enlargeable.

11. The inspection system of claim 1, wherein the memory includes further instructions executable by the at least one processor to control the inspection system to at least:

calculate inspection statistics based on input relating to the predetermined characteristic; and

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

12. The inspection system of claim 11, wherein the input relating to the predetermined characteristic sensed by the at least one camera includes numbers of accepted and rejected pellet-shaped articles processed.

13. The inspection system of claim 11, wherein the inspection statistics include counts of the accepted and rejected pellet-shaped articles processed.

14. The inspection system of claim 11, 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.

16. The inspection system of claim 11, further comprising a plurality of cameras, wherein at least some inspection statistics include a system-wide yield of accepted pellet-shaped articles, and yields of accepted pellet-shaped articles on a camera-by-camera basis.

18. The inspection system of claim 1, wherein the removal unit includes a rotatable drum having a plurality of nozzles along its length, each nozzle being structured to selectively remove from the conveyor one article at a time, based at least in part on a signal received from the processing resources.

19. The inspection system of claim 18, wherein the removal unit is structured to remove articles from the conveyor by suction.

15. An inspection system, comprising:

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

a plurality of cameras oriented towards the conveyor so as to image the pellet-shaped articles being conveyed along the path;

a removal unit, downstream from the plurality of cameras; and

processing resources, including at least one processor and a memory, the memory including instructions executable by the at least one processor to control the inspection system to at least;

process data received from the plurality of cameras to determine whether the pellet-shaped articles being imaged have a predetermined characteristic;

responsive to a determination that a given one of the pellet-shaped articles has the predetermined characteristic, control the removal unit to remove the given one of the pellet-shaped articles that has the predetermined characteristic;

generate, for output to a display device, operably connected to the inspection system, at least one display section including video output from the plurality of cameras, as the pellet-shaped articles are being imaged and as the data received from the at least one camera is being processed;

calculate inspection statistics based on input relating to the predetermined characteristic; and

generate for output to the display device a second display section including the calculated inspection statistics,

wherein at least some inspection statistics are calculated on a camera-by-camera basis.

17. An inspection system, comprising:

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

at least one camera oriented towards the conveyor so as to image the pellet-shaped articles being conveyed along the path;

a removal unit, downstream from the at least one camera; and

processing resources, including at least one processor and a memory, the memory including instructions executable by the at least one processor to control the inspection system to at least;

process data received from the at least one camera to determine whether the pellet-shaped articles being imaged have a predetermined characteristic;

responsive to a determination that a given one of the pellet-shaped articles has the predetermined characteristic, control the removal unit to remove the given one of the pellet-shaped articles that has the predetermined characteristic; and

generate, for output to a display device, operably connected to the inspection system, at least one display section including video output from the at least one camera, as the pellet-shaped articles are being imaged and as the data received from the at least one camera is being processed,

wherein the conveyor includes at least one row of product receiving pockets, the pockets being structured to convey the pellet-shaped articles along the path, and wherein the memory includes further instructions executable by the at least one processor to control the inspection system to at least calculate at least some inspection statistics on a pocket-by-pocket basis.

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

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

imaging the pellet-shaped articles being conveyed along the path, using at least one camera oriented towards the conveyor;

processing data received from the at least one camera to determine whether the pellet-shaped articles being imaged have a predetermined characteristic;

responsive to a determination that a given one of the pellet-shaped articles has the predetermined characteristic, controlling a removal unit to remove the given one of the pellet-shaped articles that has the predetermined characteristic, the removal unit being located downstream from the at least one camera;

generating, for output to a display device operably connected to the inspection system, at least one display section including video output from the at least one camera, as the pellet-shaped articles are being imaged and as the data received from the at least one camera is being processed;

receiving input enabling a user to set a plurality of inspection regions, at least one of the inspection regions corresponding to an area internal to an outer boundary of a representative of the plurality of pellet-shaped articles and being defined by user-specification of a geometric shape superimposed on a displayed representation of the representative; and

generating, for output to the display device, the geometric shape superimposed on the displayed representation of the representative.

21. The method of claim 20, further comprising providing, for inclusion in the first display section, an annotation relevant to the pellet-shaped articles that are being imaged, the annotation including an indication as to whether the pellet-shaped articles have the predetermined characteristic, at least one metric related to inspection for the predetermined characteristic, and/or a boundary of an image printed on the pellet-shaped articles.

22. The method of claim 20, wherein a plurality of cameras are oriented towards the conveyor so as to image different areas of the conveyor and the pellet-shaped articles being conveyed along the path in those different areas of the conveyor.

23. The method of claim 22, further comprising generating, for output to the display device, different display sections including video output from the different cameras, as the pellet-shaped articles are being imaged and as the data received from the cameras is being processed, each display section corresponding to a different one of the plurality of cameras.

24. The method of claim 23, wherein the different display sections are visible simultaneously on one display screen.

25. The method of claim 20, further comprising:

calculating inspection statistics based on input relating to the predetermined characteristic; and

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