Perception systems and methods for identifying and processing a variety of objects

• US 9,937,532 B2
• Filed: 08/04/2016
• Issued: 04/10/2018
• Est. Priority Date: 12/18/2015
• Status: Active Grant

• Current Assignee: Berkshire Grey Operating Co., Inc. (SoftBank Group Corp.)
• Original Assignee: Berkshire Grey, Inc. (SoftBank Group Corp.)
• Inventors: Wagner, Thomas, Ahearn, Kevin, Cohen, Benjamin, Dawson-Haggerty, Michael, Geyer, Christopher, Koletschka, Thomas, Maroney, Kyle, Mason, Matthew T., Price, Gene Temple, Romano, Joseph, Smith, Daniel, Srinivasa, Siddhartha, Velagapudi, Prasanna, Allen, Thomas
• Primary Examiner(s): MATTHEWS, TERRELL HOWARD
• Application Number:
  US15/228,692
• Publication Number:
  US 20170173638A1
• Time in Patent Office: 614 Days
• Field of Search: 209547, 209552, 209583, 209938
• CPC Class Codes: B07C 2301/0016 RFID-tags
• 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: G01B 11/245 using a plurality of fixed, simultaneously operating transducers G01B11/2408 - G01B11/2425, G01B11/255 take precedence
• CPC Class Codes: G05B 19/4183 characterised by data acquisition, e.g. workpiece identification
• CPC Class Codes: G05B 2219/36371 Barcode reader
• CPC Class Codes: G05B 2219/45045 Maintenance, automatic storage and retrieval system
• CPC Class Codes: G05B 2219/45047 Sorting
• CPC Class Codes: G06K 19/06028 using bar codes
• CPC Class Codes: G06K 7/10693 for omnidirectional scanning
• CPC Class Codes: G06K 7/10732 Light sources
• CPC Class Codes: G06K 7/10881 constructional details of hand-held scanners
• CPC Class Codes: G06K 7/1413 1D bar codes
• CPC Class Codes: G06V 20/80 Recognising image objects characterised by unique random patterns
• CPC Class Codes: G06V 2201/06 Recognition of objects for industrial automation
• CPC Class Codes: H04N 23/56 provided with illuminating means
• CPC Class Codes: H04N 23/90 Arrangement of cameras or camera modules, e.g. multiple cameras in TV studios or sports stadiums
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A drop perception system is disclosed that includes an open housing structure having an internal volume, an open top and an open bottom, and a plurality of perception units positioned to capture perception data within the internal volume at a plurality of locations between the open top and the open bottom of the open housing.

Claims

1. A drop perception system comprising:

an open housing structure having an internal volume, an open top into which an object may be dropped and an open bottom from which the object may fall;

a plurality of perception units positioned within the open structure to capture perception data within the internal volume, said plurality of perception units being positioned at a plurality of locations between the open top and the open bottom of the open housing structure, and each perception unit being associated with a plurality of illumination sources that are positioned to direct illumination into the internal volume, the plurality of perception units acquiring the perception data such that all surfaces of the object traveling within the open housing structure are analyzed by the drop perception system; and

direction routing means for receiving the object from the open housing structure, and for direction routing the object toward one of a plurality of routes responsive to the perception data received from the perception units.

2. The drop perception system as claimed in claim 1, wherein the plurality of perception units includes a plurality of cameras and wherein the perception data includes image data.

3. The drop perception system as claimed in claim 1, wherein the plurality of perception units includes a plurality of scanners and the perception data includes scanner data.

4. The drop perception system as claimed in claim 3, wherein the plurality of scanners are radio frequency ID scanners.

5. The drop perception system as claimed in claim 3, wherein the plurality of scanners are barcode scanners.

6. The drop perception system as claimed in claim 5 wherein each of the plurality of scanners is a laser reflectivity scanner.

7. The drop perception system as claimed in claim 1, wherein the plurality of illumination sources are mounted on opposing sides of each perception unit.

8. The drop perception system as claimed in claim 7, wherein the plurality of illumination sources include a plurality of LEDs.

9. The drop perception system as claimed in claim 1, wherein the perception system further includes an interrupter element that is engageable by an object falling through the perception system for altering a position or orientation of the falling object.

26. The drop perception system as claimed in claim 1, wherein the plurality of illumination sources associated with each perception unit, are mounted on four sides of each respective perception unit.

27. The drop perception system as claimed in claim 1, wherein the direction routing means routes the object toward the one of the plurality of routes, and wherein the plurality of routes include mutually opposing directions.

28. The drop perception system as claimed in claim 1, wherein the direction routing device includes at least one conveyor.

10. A perception system for assisting in identifying and routing an object, said perception system comprising an open structure including a plurality of perception units within the open structure, each of the perception units including a front perception portion that is directed toward an internal volume of the open structure, and the plurality of perception units being positioned to acquire perception data regarding all surfaces of an object as the object travels through the open structure without assistance by any mechanical conveyance system in contact with the object, a plurality of illumination sources for illuminating all surfaces of the object, and direction routing means for receiving the object from the open structure and for direction routing the object toward one of a plurality of routes responsive to perception data from the perception units.

11. The perception system as claimed in claim 10, wherein the plurality of perception units include a plurality of cameras and wherein the perception data includes image data.

12. The perception system as claimed in claim 10, wherein the plurality of perception units include a plurality of scanners and wherein the perception data includes scanner data.

13. The perception system as claimed in claim 10, wherein the drop perception system includes at least one sensor system for detecting whether an object has enter the open structure.

14. The perception system as claimed in claim 10, wherein the plurality of perception units are provided at least at the bottom and central regions of the open structure.

15. The perception system as claimed in claim 10, wherein the plurality of perception units includes at least one perception unit that includes a mirror positioned to permit the at least one perception unit to effectively be directed substantially along the object path.

16. The perception system as claimed in claim 10, wherein the direction routing means includes a controller for assigning a routing path for the object responsive to perception data provided by the perception units.

29. The perception system as claimed in claim 10, wherein the illumination system illuminates all surfaces of the object at over a period of time as the object travels through the open structure.

30. The perception system as claimed in claim 10, wherein the direction routing means routes the object toward the one of the plurality of routes, and wherein the plurality of routes include mutually opposing directions.

31. The perception system as claimed in claim 10, wherein the direction routing means includes at least one conveyor.

17. A drop perception system for identifying an object, said drop perception system comprising an open structure including a top portion into which an object may be dropped and a bottom portion from which an object may fall, a plurality of perception units within the open structure proximate the top portion of the open structure, proximate the bottom portion of the open structure, and positioned between the top portion and the bottom portion of the open structure, said plurality of perception units providing perception data regarding all surfaces of the object, each perception unit being associated with at least one illumination source, and a direction routing device for receiving the object from the open structure and for direction routing the object toward one of a plurality of routes responsive to the perception date.

18. The drop perception system as claimed in claim 17, wherein the direction routing means initially routes the object in one of two opposing directions.

19. The drop perception system as claim in claim 17, wherein the direction routing means includes a conveyor that is adapted to move the object to one of a plurality of locations.

20. The drop perception system as claimed in claim 17, wherein said perception system includes multiple-object detection means for detecting whether multiple objects are dropped through the drop perception system at the same time.

32. The drop perception system as claimed in claim 17, wherein the plurality of illumination sources associated with each perception unit, are mounted on four sides of each respective perception unit.

33. The drop perception system as claimed in claim 17, wherein the direction routing means routes the object toward the one of the plurality of routes, and wherein the plurality of routes include mutually opposing directions.

34. The drop perception system as claimed in claim 17, wherein the direction routing means includes at least one conveyor.

21. A method of sorting objects, said method comprising the steps of:

dropping an object into a perception system that includes a plurality of perception units that are each positioned to be directed toward different directions within the perception system;

illuminating the object with at least one of a plurality of illumination sources;

capturing perception data associated with all surfaces of the object using the perception units as the object falls through the perception system; and

diverting the object received from the perception system toward one of a plurality of routes responsive to the captured perception data.

22. The method as claimed in claim 21, wherein step of illumination the object includes providing illumination with the plurality of illumination sources within the perception system.

23. The method as claimed in claim 21, wherein the step of capturing perception data and the step of illuminating the object, are provided such that different perception units are engaged at discrete times, and different illumination sources provide illumination at the discrete times associated with the different perception units.

24. The method as claimed in claim 23, wherein the discrete times provide that successive sets of perceived data are captured from perception units around the interior of the perception system as the object falls through the perception system.

25. The method as claimed in claim 21, wherein the step of diverting the object toward one of the plurality of routes responsive to the captured perception data of the object further includes the steps of:

receiving the object from the perception system at a sortation conveyance unit; and

moving the object by the sortation conveyance unit to one of the plurality of directions.

35. The method as claimed in claim 21, wherein the step of diverting the object received from the perception system toward the one of the plurality of routes involves moving the object in one of two mutually opposing directions.