Vision based item typing and separation system

• US 10,226,795 B2
• Filed: 05/05/2017
• Issued: 03/12/2019
• Est. Priority Date: 12/31/2015
• Status: Active Grant

• Current Assignee: Fives Intralogistics Corp.
• Original Assignee: Fives Intralogistics Corp.
• Inventors: Schroader, Steven Vann
• Primary Examiner(s): Crawford, Gene O
• Assistant Examiner(s): Rushin, Lester III
• Application Number:
  US15/588,230
• Publication Number:
  US 20170312789A1
• Time in Patent Office: 676 Days
• Field of Search: 198443, 198444, 198448, 700228, 700229, 700230
• CPC Class Codes: B07C 5/10 measured by light-responsive means sorting according to colour B07C5/342
• 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 5/362 Separating or distributor mechanisms switches for postal sorting B07C3/065; particular discharging devices for B65G47/74
• CPC Class Codes: B65G 2201/0285 Postal items, e.g. letters, parcels
• 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 47/54 at least one of which is a roller-way
• CPC Class Codes: B65G 47/681 from distinct, separate conveyor lanes

Abstract

A typing tunnel off-loading and sorting system includes an off-loading conveyor, cameras and photoelectric eye. The overhead cameras detect the item size and whether it is cubic in nature and type and size of its footprint. An in-line slide sorter having alternating conveyor rollers and pop-up belts pass through to, or divert articles from, a downstream conveyor. The vision based system may also be used to detect space between articles and insert articles in the unoccupied space.

Claims

1. A typing tunnel off-loading and sorting system comprising:

an off-loading collector feed conveyor having an independent drive motor in flow communication with a transport loaded with parcels;

a transition zone selected on said off-loading collector feed conveyor;

at least one camera having a field of view of said transition zone;

controller means for maintaining an off-loading collector feed conveyor speed to achieve a desired conveyor area utilization on a down stream receiving conveyor based on said at least one camera field view of said transition zone, a down stream receiving conveyor occupancy defined zone, a feeding conveyor occupancy defined zone and a desired occupancy after the merger;

a slide sorter conveyor speed control system, comprising a first conveyor positioned to carry articles in the direction of a longitudinal axis of said conveyor, a slide sorter pop-up conveyor positioned across said longitudinal axis of said conveyor including means operative to move said pop-up conveyor between a home position in which a pass-through element receives articles from said conveyor and transfers them along the direction of said longitudinal axis, and a diverting position in which a pop-up element receives said articles from said conveyor and transfers selected articles away from the direction of said longitudinal axis, a multiplexed light screen to detect the full length of said articles, a photocell over said conveyor surface to detect a portions of said articles that can be engaged by said pop-up conveyor, and a computer control means for controlling actuation of said pop-up conveyor in response to data transmitted from said multiplexed light screen and said photocell;

wherein said selected articles can be diverted upon decreasing the speed of the conveyor prior to diverting said selected articles with said pop-up conveyor and said articles are moving forward as said pop-up conveyor is rising, and the speed of said conveyor is reduced prior to the transfer of said selected articles to said pop-up conveyor as a function of the length of said articles or the length of a first portion of said articles falling within close proximity to a conveying surface that is close enough that said pop-up conveyor can be expected to engage and impart a transverse force to discharge selected articles.

2. The typing tunnel off-loading and sorting system of claim 1, further comprising:

an off-loading collector or feed conveyor including an independent drive motor in flow communication with a transport loaded with parcels;

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.

3. The typing tunnel off-loading and sorting system of claim 1, further including sensors detecting areas of the item resting on the conveyor to effect cooperative engagement with the pop-up conveyor.

4. The typing tunnel off-loading and sorting system of claim 1, including a diverter conveyor in flow communication with said slide sorter conveyor connecting at one end thereof and extending away from said pass-through conveyor.

5. The typing tunnel off-loading and sorting system of claim 1, wherein said diverting element comprises a roller conveyor.

6. The typing tunnel off-loading and sorting system of claim 1, further comprising a tilted receiving conveyor positioned on an opposite side of said slide sorter.

7. The typing tunnel off-loading and sorting system of claim 1 including a take-off roller extending above a portion of said pop-up conveyor and an tilted receiving conveyor for receiving diverted articles.

8. The typing tunnel off-loading and sorting system of claim 7, said tilted receiving conveyor for receiving diverted articles is positioned having an edge adjacent said take-off roller with a skewed offset roller conveyor surface disposed below a top surface of said take-off roller and said tilted receiving conveyor being tilted upward and outward at a selected angle of from 1-35°

with respect to said feed conveyor for receiving articles from said take-off roller and limiting lateral movement of said articles over the width of said tilted receiving conveyor pulling said articles into a center region of said tilted receiver conveyor due to the forward and lateral forces of said skewed offset rollers.

9. A typing tunnel off-loading and sorting system comprising:

a) vision based bulk package conveyor flow management system, comprising;

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

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

at least one camera providing a selected field of view of said selected transition zone, a selected occupancy zone, or said selected transition zone and said selected occupancy zone;

said feed conveyor, said receiver conveyor, or both said feed conveyor and said receiver conveyor conveying at a selected speed or time to achieve a desired conveyor area utilization on a down stream receiving conveyor based on said at least one camera providing a selected field of view of said selected transition zone, a down stream receiving conveyor occupancy defined zone, a feeding conveyor occupancy defined zone and a desired occupancy after the merger;

said feed conveyor having a selected occupancy defined zone;

said receiving conveyor having a selected occupancy defined zone;

a transition section between said feed conveyor and said receiving conveyor for merging a plurality of packages from one to the other;

said selected transition section including a percentage of the desired occupancy of said receiving conveyor after the merger of said packages from said feed conveyor to said receiving conveyor;

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

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

b) a slide sorter conveyor speed control apparatus in flow communication with said vision based bulk package conveyor flow management system, comprising;

a first upstream conveyor conveying a first group of articles of a selected size, shape, irregular base, marking, or other characteristic and a second group of articles of a selected different size, shape of characteristic along a longitudinal axis of said first upstream conveyor;

a second downstream conveyor conveying said first group of articles along a longitudinal axis of said second downstream conveyor;

a pop-up conveyor disposed between and in flow communication with said first upstream conveyor which passes through said first group of articles, said pop-up conveyor diverting and conveying said second group of articles in a direction away from said second downstream conveyor;

said pop-up conveyor comprising;

i) a frame including a plurality of spaced apart parallel conveyor rollers disposed normal to and at about the same height as said first upstream conveyor and said second downstream conveyor for receiving and conveying and passing through said first group of articles from said first upstream conveyor to said second downstream conveyor, including a motor and drive means for rotating said conveyor rollers;

ii) at least one pop-up belt disposed between said spaced apart conveyor rollers, said at least one pop-up belt spaced apart from and in parallel alignment with said conveyor rollers including a motor and drive means for rotating said at least one pop-up belt;

iii) said at least one pop-up belt resting a selected distance below said conveyor rollers in an inactive position during conveying said first group of articles from said first upstream conveyor passing over and through said conveyor rollers of said pop-up conveyor to said second downstream conveyor;

iv) said pop-up conveyor including cam means for raising said at least one pop-up belt a selected distance above said conveyor rollers conveying and diverting said second group of articles from said second downstream conveyor;

at least one multiplex light screen sensor detecting a full length of said first group of articles and said second group of articles;

at least one photocell including a transmitter projecting at least a single beam a selected distance over a surface of said first upstream conveyor and a receiver for receiving said at least a single beam detecting portions of articles of said first group of articles resting on a surface of said first upstream conveyor surface and detecting portions of articles of said second group of articles resting on a surface of said first upstream conveyor surface engageable by said at least one pop-up belt;

variable speed control means for controlling a conveying speed of said first up-stream conveyor;

computer control means in electrical communication with said variable speed control means and said pop-up conveyor motor and at least said first upstream conveyor for controlling actuation of said at least one pop-up belt of said pop-up conveyor in response to data transmitted from said at least one multiplex light screen sensor and said at least one photocell allowing said first group of articles to pass over said conveyor rollers and through said pop-up conveyor to said second downstream conveyor, and activating said cam means raising said at least one pop-up belt diverting said second group of articles away from said second downstream conveyor without stopping said first upstream conveyor and said second downstream conveyor;

said computer receiving input from at least one multiplex light screen sensor and controlling the optimal speed of said first up-stream conveyor based upon said full length of said article of said first group of articles and said portions of said second group of articles resting on said surface of said first up-stream conveyor for slowing said first up-stream conveyor and activating said pop-up conveyor raising said at least one belt of said pop-up conveyor to engage said portion of said selected article of said second group of articles to be diverted from said first group of articles, and said computer controls a duration said at least one belt remains activated based on said full length of said article to be diverted; and

said computer controlling the speed of said first upstream conveyor and slowing said speed of said first upstream conveyor prior to said article of said second group of articles engaging said pop-up conveyor as a function of the length of the item or the length of a first portion of said selected article falls within a selected proximity to said pop-up conveyor for imparting a transverse force diverting said article of said second group of articles.

10. A method of off-loading, typing, and sorting articles from a bulk package conveyor flow with a vision management system and pop-up slide sorter, comprising the steps of:

identifying and sorting selected packages from an off-loading feed conveyor using a slide sorter pop-up conveyor includes the steps of conveying a selected group of articles of a selected size, shape, irregular base, ID marking, or other characteristic along a longitudinal axis of a first upstream off-loading feed conveyor, by a at least one photo eye device and/or at least one multiplex light screen sensor device identifying and sorting articles to be passed through to a downstream conveyor or diverted from said downstream conveyor;

positioning a pop-up or slide sorter conveyor between and in flow communication with the first upstream conveyor for passing selected articles over a plurality of rollers and through the pop-up conveyor to a second downstream conveyor;

diverting said selected articles with pop-up conveyor in a direction away from said second downstream conveyor by a plurality of driven belts of a pop-up conveyor which are raised above the surface of the rollers to contact the surface of the conveyed article;

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

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

setting a speed or movement of said feed conveyor, said receiving conveyor, or both said feed conveyor and said receiving conveyor to achieve a desired conveyor area utilization on a down stream receiving conveyor based on said at least one camera field view of said transition zone, a down stream receiving conveyor occupancy defined zone, a feeding conveyor occupancy defined zone and a desired occupancy after the merger;

determining a percentage of said feed conveyor occupancy defined zone;

determining a percentage of said receiving conveyor occupancy defined zone;

selecting a percentage of a desired occupancy of said receiving conveyor after a merger of said packages from said feeding conveyor to said receiving conveyor;

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

feeding said packages from said feed conveyor to said receiving conveyor occupancy defined zone at a selected rate;

conveying said packages toward said desired occupancy zone of said conveyor area at a selected position; and

merging said packages at said conveyor area of said transition section between said feed conveyor and said receiving conveyor.