U.S. patent application number 16/527735 was filed with the patent office on 2020-02-13 for systems and methods for high throughput cutting of sealing elements on packages.
The applicant listed for this patent is Walmart Apollo, LLC. Invention is credited to Joseph David Blackner, Santos Cerda, JR., Bryan Hawkins, John Marshall Jones, Geoffrey Michael Miller.
Application Number | 20200047364 16/527735 |
Document ID | / |
Family ID | 69405413 |
Filed Date | 2020-02-13 |
![](/patent/app/20200047364/US20200047364A1-20200213-D00000.png)
![](/patent/app/20200047364/US20200047364A1-20200213-D00001.png)
![](/patent/app/20200047364/US20200047364A1-20200213-D00002.png)
![](/patent/app/20200047364/US20200047364A1-20200213-D00003.png)
![](/patent/app/20200047364/US20200047364A1-20200213-D00004.png)
![](/patent/app/20200047364/US20200047364A1-20200213-D00005.png)
![](/patent/app/20200047364/US20200047364A1-20200213-D00006.png)
![](/patent/app/20200047364/US20200047364A1-20200213-D00007.png)
![](/patent/app/20200047364/US20200047364A1-20200213-D00008.png)
![](/patent/app/20200047364/US20200047364A1-20200213-D00009.png)
![](/patent/app/20200047364/US20200047364A1-20200213-D00010.png)
View All Diagrams
United States Patent
Application |
20200047364 |
Kind Code |
A1 |
Hawkins; Bryan ; et
al. |
February 13, 2020 |
SYSTEMS AND METHODS FOR HIGH THROUGHPUT CUTTING OF SEALING ELEMENTS
ON PACKAGES
Abstract
Systems and methods described herein are optimized for cutting
sealing elements on packages using optical radiation. Packages can
pass through a cutting device that applies the optical radiation to
damage, vaporize, or cut the sealing element (e.g., tape) on the
package. The systems and methods control several aspects of the
cutting process to adjust throughput, improve efficiency, and
reduce line stoppages. Systems can include an in-feed conveyor that
orients packages and rejects packages that are out of
specification, which can lead to issues such as jamming or damage
to the equipment. Systems can include a variable-speed cut conveyor
controlled by a computing system to dynamically adjust the speed of
packages based upon historical cut quality, environmental
measurement data, and height data related to a vertical dimension
of the package.
Inventors: |
Hawkins; Bryan;
(Bentonville, AR) ; Blackner; Joseph David; (Bella
Vista, AR) ; Jones; John Marshall; (Fayetteville,
AR) ; Cerda, JR.; Santos; (Bentonville, AR) ;
Miller; Geoffrey Michael; (Rogers, AR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Walmart Apollo, LLC |
Bentonville |
AR |
US |
|
|
Family ID: |
69405413 |
Appl. No.: |
16/527735 |
Filed: |
July 31, 2019 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
62717179 |
Aug 10, 2018 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65B 69/0033 20130101;
B26D 7/0625 20130101; B65G 13/04 20130101 |
International
Class: |
B26D 7/06 20060101
B26D007/06; B65G 13/04 20060101 B65G013/04; B65B 69/00 20060101
B65B069/00 |
Claims
1. A cutting system comprising: a cutting device, including: an
optical radiation source that focuses at a focal point, a
translation system to adjust a location of the focal point in
three-dimensional space, and a cut conveyor to convey a package
past the optical radiation source; an in-feed conveyor system to
convey the package to the cutting device, the in-feed conveyor
system including: a skew conveyor having one or more skewing
elements to laterally adjust a position of the package in the
in-feed conveyor system, one or more conveyor belts disposed
between the skew conveyor and the cutting device, the one or more
conveyor belts configured to convey packages in a direction of
travel or counter to the direction of travel of the in-feed
conveyor system, one or more photodetectors to detect data related
to a position or horizontal dimension of the package, a height
dimensioner to detect height data related to a vertical dimension
of the package, a diverter to divert the package away from the
cutting device, and an entrance gate to prevent passage of the
package when the vertical dimension of the package exceeds a
threshold value; and a computing system including one or more
processors communicatively coupled to the cutting device and the
in-feed conveyor system and configured to execute instructions to:
receive height data related to the vertical dimension of the
package from the height dimensioner, upon a determination that the
vertical dimension of the package exceeds the threshold value,
activate the diverter to divert the package, receive data related
to the position or horizontal dimension from the one or more
photodetectors, align the focal point of the optical radiation
source to a sealing element of the package based on the data
related to the position or horizontal dimension using the
translation system, and apply radiation from the optical radiation
source to the sealing element.
2. The system of claim 1, wherein the in-feed conveyor system
further comprises an accumulation conveyor coupled to the diverter
to receive the diverted package.
3. The system of claim 1, where the package is a first package and
the computing system is further configured to execute instructions
to: receive data related to a position of a second package from the
one or more photodetectors; determine a gap between the first
package and the second package based upon the data related to the
position of the second package and the data related to the position
of the first package; and upon determining that the gap is below a
threshold value, convey the first package or the second package
using the one or more conveyor belts such that the gap is
increased.
4. The system of claim 1, wherein the diverter conveys the package
at 90 degrees with respect to the direction of travel.
5. The system of claim 1, wherein the skewing elements center the
package with respect to the skew conveyor.
6. The system of claim 1, wherein the skewing elements dispose the
package along an outside edge of the skew conveyor.
7. The system of claim 1, wherein the skewing elements form
packages into a single-file line.
8. The system of claim 1, wherein the skewing elements include
skewed rollers.
9. The system of claim 1, wherein the skewing elements include one
or more angled protrusions that urge the package in a lateral
direction as the package passes.
10. A method for cutting, comprising: adjusting a position of a
package laterally using a skew conveyor of an in-feed conveyor
system, the skew conveyor including one or more skewing elements;
detecting height data related to a vertical dimension of the
package using a height dimensioner; detecting data related to a
position or horizontal dimension of the package using one or more
photodetectors; upon determining that the vertical dimension of the
package exceeds a threshold value, activating a diverter to divert
the package away from a cutting device, the cutting device
including an optical radiation source that focuses at a focal
point, a translation system to adjust the location of the focal
point in three-dimensional space, and a cut conveyor to convey the
package past the optical radiation source; aligning the focal point
of the optical radiation source to a sealing element of the package
based on the data related to the position or horizontal dimension
using the translation system; and applying radiation from the
optical radiation source to the sealing element.
11. The method of claim 10, wherein activating the diverter diverts
the package to an accumulation conveyor coupled to the diverter
that receives the diverted package.
12. The method of claim 10, where the package is a first package
and the method further comprises: detecting data related to a
position of a second package from the one or more photodetectors;
determining a gap between the first package and the second package
based upon the data related to the position of the second package
and the data related to the position of the first package; and upon
determining that the gap is below a threshold value, conveying the
first package or the second package using one or more conveyor
belts disposed between the skew conveyor and the cutting device
such that the gap is increased, the one or more conveyor belts
configured to convey packages in a direction of travel or counter
to the direction of travel.
13. The method of claim 10, wherein diverting the package includes
conveying the package at 90 degrees with respect to a direction of
travel of the package.
14. The method of claim 10, wherein adjusting the position of the
package laterally includes using the skewing elements to center the
package with respect to the in-feed conveyor system.
15. The method of claim 10, wherein adjusting the position of the
package laterally includes using the skewing elements to dispose
the package along an outside edge of the in-feed conveyor
system.
16. The method of claim 10, further comprising forming packages
into a single-file line using the skewing elements.
17. The method of claim 10, wherein the skewing elements include
skewed rollers.
18. The method of claim 10, wherein the skewing elements include
one or more angled protrusions that urge the package in a direction
as the package passes.
Description
RELATED APPLICATIONS
[0001] This application claims the benefit of, and priority to,
U.S. Provisional Application No. 62/717,179, filed Aug. 10, 2018,
the entire contents of the above application being incorporated
herein by reference.
BACKGROUND
[0002] Warehouse facilities may receive a high volume of sealed
packages that must be opened so that the package contents can be
examined, removed, and/or transferred. Manual opening of each
package is burdensome as it requires each facility worker to carry
a cutting tool. Opening each package manually is time-consuming,
inefficient, and presents an injury risk.
BRIEF DESCRIPTION OF DRAWINGS
[0003] Illustrative embodiments are shown by way of example in the
accompanying drawings and should not be considered as a limitation
of the present disclosure.
[0004] FIG. 1 illustrates a cutting system in accordance with
various embodiments of the present disclosure.
[0005] FIGS. 2A and 2B illustrate an end view and a side view,
respectively, of a cutting device for use with cutting systems in
accordance with various embodiments of the present disclosure.
[0006] FIG. 3A illustrates a portion of a conveying system of the
cutting system including a skew conveyor with skewing elements in
the form of skewed rollers in accordance with various embodiments
described herein.
[0007] FIG. 3B illustrates a portion of a conveying system of the
cutting system including a skew conveyor with skewing elements in
the form of protrusions in accordance with various embodiments
described herein.
[0008] FIG. 4 illustrates a side view of a portion of the in-feed
conveyor system 130 in accordance with various embodiments of the
present disclosure.
[0009] FIG. 5 illustrates a side view of the cutting device in
accordance with various embodiments described herein.
[0010] FIG. 6A illustrates a cut pattern formed on a sealing
element of a package in some embodiments of the present
disclosure.
[0011] FIG. 6B illustrates the cut pattern formed over
substantially the entire sealing element of the package in
accordance with some embodiments described herein.
[0012] FIG. 6C illustrates the cut pattern formed over only a
portion of the sealing element of the package in accordance with
some embodiments described herein.
[0013] FIGS. 7A-7E illustrate different cut patterns that are
applied using systems and methods described herein.
[0014] FIG. 8 is a block diagram of an example computing system for
implementing exemplary embodiments of the present disclosure.
[0015] FIG. 9 illustrates a block diagram of an exemplary
distributed computing environment in accordance with exemplary
embodiments of the present disclosure.
[0016] FIG. 10 illustrates a flowchart for a method for cutting in
accordance with various embodiments described herein.
[0017] FIG. 11 illustrates a flowchart for a method for cutting in
accordance with various embodiments described herein.
DETAILED DESCRIPTION
[0018] Described in detail herein are systems and methods for
cutting sealing elements on packages using optical radiation.
Packages can pass through a cutting device that applies the optical
radiation to cut, damage, ablate, remove, pierce or burn the
sealing element (e.g., tape) on the package. The systems and
methods control several aspects of the cutting process to adjust
throughput, improve efficiency, reduce or limit wear on the cutting
device, and reduce line stoppages. Systems can include an in-feed
conveyor that orients packages and rejects packages that are out of
specification, which can lead to issues such as jamming or damage
to the equipment (e.g., the optical radiation source of the cutting
device).
[0019] The cutting device adjusts the position of an optical
radiation source to align with the sealing element of each package
and/or adjusts the intensity and/or cutting pattern or patterns of
the optical radiation source to adjust cutting parameters. The time
to adjust the position can set a rate limit on how fast packages
can be processed by the device. By aligning the packages in a
consistent way (whether to a side or in the middle), the source
translates over a small distance between packages thus leading to
higher throughput.
[0020] Systems and methods described herein can include feedback
from multiple sources to dynamically determine whether to speed up
or slow down the cutting process, whether to adjust the intensity
of the optical radiation emitted by the optical radiation source,
and/or whether to adjust the cutting pattern of the optical
radiation source. Cut quality, the sizes, shapes, or orientations
of incoming packages, whether there is a string of similar
packages, and environmental measurement data can be processed by a
computing system that subsequently controls an in-feed conveyor
system or a cut conveyor to speed up or slow down package
processing and/or adjust the intensity and/or cutting patterns of
the optical radiation source.
[0021] Systems and methods described herein can utilize alternative
cut patterns that reduce the total wear on the optical radiation
source and other replaceable components such as air filters. In
addition, alternative cut patterns that cut only a portion of the
sealing element can allow for faster processing as the time to cut
each package is reduced.
[0022] FIG. 1 illustrates a cutting system 100 in accordance with
various embodiments described herein. The cutting system 100
includes a cutting device 120, an in-feed conveyor system 130, and
a computing system 150. The cutting device 120 includes an optical
radiation source 122, a translation system 124, and a cut conveyor
126. The in-feed conveyor system includes a skew conveyor 132, one
or more conveyor belts 134, one or more photodetectors 135, a
height dimensioner 136, a diverter 137, and an entrance gate 138.
The in-feed conveyor system 130 conveys a package 101 to the
cutting device 120. The cut conveyor 126 of the cutting device 120
conveys the package past the optical radiation source 122. The
optical radiation source 122 applies radiation to a sealing element
102 of the package 101 to cut, damage, ablate, remove, or pierce
the sealing element 102. By irradiating the sealing element 102,
the sealing element 102 is weakened so that a user downstream of
the cutting system 100 can easily open the package 101 by hand
without needing to use a tool such as a box-cutter. The in-feed
conveyor system 130 organizes and conveys packages to the cutting
device 120 to allow fast, continuous processing of packages 101
without slowdowns or stoppages created by disorganized or improper
entry of packages into the cutting device 120. In some embodiments,
the cutting system 100 can process a number of packages per hour,
for example, in a range of about 400 packages per hour to about
2000 packages per hour.
[0023] The optical radiation source 122 focuses optical radiation
at a focal point 123 as depicted in FIGS. 2A and 2B. The optical
radiation source 122 can include a laser in some embodiments. The
optical radiation source 122 can include lenses, mirrors, gratings,
optical filters, optical fibers, waveguides, and/or other optical
or focusing elements as appropriate to manipulate the optical beam
and apply it to the sealing element 102 of the package 101. The
translation system 124 adjusts a location of the focal point in
three-dimensional space. In some embodiments, the translation
system 124 is coupled to the entire optical radiation source 122 or
at least a portion of the optical radiation source 122. That is,
the entire optical radiation source 122 can be mounted to the
translation system 124 in some embodiments. In other embodiments,
only a portion (e.g., a lens or an end of an optical fiber) of the
optical radiation source 122 can be mounted to the translation
system 124. The translation system 124 can include translation
elements that move independently in three orthogonal directions
(e.g., X, Y, and Z directions). In some embodiments, the
translation system 124 can include an X-Y plotter attached to a
gantry that spans over the cut conveyor 126. Different packages 101
can have different vertical dimensions 103 or horizontal dimensions
104 that can cause the sealing element 102 of each package 101 to
be located at a different position in three-dimensional space. The
translation system 124 can raise or lower the location of the focal
point vertically to accommodate packages of different heights. The
translation system 124 can adjust the focal point across a width of
the cut conveyor to position the focal point at the sealing element
102 of the package 101. In some embodiments, the translation system
124 may only position the focal point of the optical radiation in
two-dimensions (e.g., vertically and horizontally across the width
of the cut conveyor).
[0024] The skew conveyor 132 of the in-feed conveyor system 130 can
adjust the position of the package 101 laterally with respect to a
direction of travel 105 of the packages 101. In conventional
systems, packages enter the cutting device 120 at random lateral
positions thereby necessitating adjustment of the location of the
focal point over large distances to place the focal point at the
sealing element of each of the packages. Movement of the focal
point over large distances requires allotment of extra time between
packages to allow the translation system time to move the focal
point and introduces excess wear on the translation system
components. In contrast, the skew conveyor 132 can adjust the
lateral position of each package 101 to align all of the packages
101 at a same position on the conveyor to reduce the distance that
the focal point travels between adjacent packages. In some
embodiments, the skew conveyor 132 can include one or more skewing
elements 141. In some embodiments, skewing elements 141 of the skew
conveyor 132 can dispose the package 101 along an outside edge of
the skew conveyor 132. For example, the skewing elements 141 can
dispose packages 101 along the left edge or right edge of the skew
conveyor 132. In some embodiments, the skewing elements 141 can
center the package with respect to the skew conveyor 132.
[0025] As shown in FIG. 3A, the skewing elements 141 can include a
plurality of skewed rollers in some embodiments. The skewed rollers
can be powered in some embodiments. In some embodiments, the
skewing rollers are skewed or tilted with respect to the direction
of travel 105. The section 133 of skewed rollers can have a length
143. The skewed rollers can be skewed at a skew angle a with
respect to the direction of travel 105. In some embodiments, the
skew angle a can be selected based on the impact on the motor
driving the skewing elements 141. In some embodiments, the skew
angle a is in a range between about 6.degree. and about 10 .degree.
inclusive. The skew conveyor 132 can include more than one section
133 of skewed rollers in some embodiments. In some embodiments, the
skew conveyor 132 can include a belted section.
[0026] The length 143 of the section 133 that includes the skewing
elements 141 can be selected based upon a distance 142 between the
package 101 and an edge of the skew conveyor 132. In other words,
the distance 142 can be defined as the displacement through which
the package 101 is to be moved laterally by the skew conveyor 132.
The greater the distance 142, the longer the section 133 of the
skew conveyor 132 needs to be to effectively transport the packages
laterally to the desired position.
[0027] A width 144 of the skew conveyor 132 can be selected based
upon a measured or anticipated width and/or length 107 of the
packages 101 to be positioned using the skew conveyor 132. To avoid
jamming the skew conveyor 132 by a package 101, the width 144 of
the skew conveyor 132 can be chosen to be greater than the width
and/or length 107 of the packages 101. Similarly, the skew angle a
can be selected to prevent or reduce jamming of packages. Larger
skew angles can only accommodate smaller maximum lengths 107 of the
packages 101 that can be placed on the skew conveyor 132 to avoid
jamming. As a result, the width 144 of the conveyor and skew angle
a can be specified based on the maximum width and/or length 107 of
the packages to be conveyed.
[0028] FIG. 3B illustrates the skew conveyor with skewing elements
141 in the form of angled protrusions in accordance with various
embodiments described herein. In some embodiments, the skewing
elements 141 can include one or more angled protrusions that urge
the package in the lateral direction as the package passes. As
shown in FIG. 3B, the skewing elements 141 can be used to urge the
package in a first lateral direction (e.g., to the left) and then
in a second lateral direction (e.g., to the right). Such a
configuration can be used, for example, to center the package 101
with respect to the skew conveyor 132. In other embodiments, the
skewing elements can include a single angled protrusion to urge the
packages only in a first lateral direction.
[0029] In some embodiments, the skewing elements 141 can arrange
packages 101 into a single-file line. In some environments,
packages may be loaded onto the in-feed conveyor system 130 in a
side-by-side orientation. This orientation is disadvantageous at
the cutting device 120 because the single optical radiation source
can generally only be aligned with a single package and not two
packages passing through the cutting device 120. In such an event,
only a single package may be cut while the other package remains
uncut. To avoid this problem, the skew conveyor 132 can form
packages into a single-file line. For example, angled protrusions
can be used to form "gates" that stop packages from passing through
in a side-by-side configuration.
[0030] In some embodiments, the skewing elements 141 in the form of
angled protrusions can physically stop and push packages into a
single file line. For example, as two packages come to the angled
protrusion in a side-by-side configuration, the package 101 to the
exterior of the skew conveyor 132 can contact the angle protrusion
and its motion on the conveyor will slow down and even stop. The
package 101 to the interior (center) of the skew conveyor 132
continues to move until it has passed beyond the package 101 to the
exterior at which point the package to the exterior can begin to
move again.
[0031] FIG. 4 illustrates a side view of a portion of the in-feed
conveyor system 130 in accordance with various embodiments of the
present disclosure. The one or more conveyor belts 134 can include
continuous belts or rollers in various embodiments. In some
embodiments, the conveyor belts 134 are disposed between the skew
conveyor 132 and the cutting device 120. In some embodiments, the
conveyor belts 134 are disposed between the diverter 137 and the
cutting device 120. The conveyor belts 134 can receive packages 101
from the skew conveyor 132 or the diverter 137 and convey packages
in the direction of travel 105 or counter to the direction of
travel 105 of the in-feed conveyor system 130.
[0032] Because the focal point 123 of the optical radiation can be
adjusted for each package passing through the cutting device 120,
it can be desirable to have a gap 108 between adjacent packages to
allow time for the translation system 124 to adjust the position of
the focal point 123 for each package 101. As packages 101 arrive at
the conveyor belts 134, the gap 108 between adjacent packages 101
may be insufficient and the translation system 124 can fail to
adjust the position of the focal point 123 in time. This can result
in failure to cut the sealing element 102 of a package or
incomplete cutting of the sealing element 102. Another result can
be a collision between a package 101 and the optical radiation
source 122 or translation system 124 if the translation system 124
is not able to move out of the way fast enough. In some
embodiments, the gap 108 between packages can be proportional to
the differential in vertical dimension 103 between the packages.
For example, the operating speed in some embodiments is such that
positioning of the focal point 123 by the translation system 124
determines that the gap 108 between packages is at least 2 inches
(5.08 cm) if there is no differential in vertical dimension 103
between packages 101. In another embodiment, a differential in
vertical dimension 103 between packages of 12 inches (30.5 cm)
means that the translation system 124 needs more time between
packages to move the focal point 123. In such an embodiment, the
gap 108 between packages can be 8 inches (20.3 cm).
[0033] The computing system 150 can receive the detected data
related to a position of a first package and a second package. In
some embodiments, the computing system 150 receives data related to
a position or horizontal dimension 104 of the package 101 from the
one or more photodetectors 135. In some embodiments, the computing
system 150 can use the one or more photodetectors 135 to monitor
the gap 108 between packages 101. For example, the photodetector
135 can detect data such as the time between a first package
leaving view of the photodetector 135 and a subsequent package 101
arriving at the photodetector 135. The computing system 150 can
determine a gap between the first package and the second package
based upon the data related to the position of the second package
and the data related to the position of the first package. For
example, the computing system 150 can combine this measured time
and a predetermined speed of the conveyor belts 134 to determine
the gap 108.
[0034] In some embodiments, the computing system 150 can select the
gap 108 to maintain between subsequent packages as a function of
package dimension or location of the sealing element 102 on the
package 101. For example, if a number of similar packages approach
the cutting device 120, the translation system 124 may not need to
make a large adjustment (or any adjustment) to the position of the
focal point 123 between cutting subsequent packages. In some
embodiments, the computing system 150 can reduce or select the gap
108 based upon a detected property of the package such as package
length, width, or height or based upon a detected position of the
sealing element 102.
[0035] The computing system 150 can determine whether the gap 108
is below a threshold value. Upon determining that the gap 108 is
below the threshold value, the computing system 150 can convey the
first package or the second package using the conveyor belts 134
such that the gap 108 is increased. For example, the computer 150
can control one of the conveyor belts 134 to convey the first
package in the direction of travel 105 or to convey the subsequent
package counter to the direction of travel 105. The computer system
150 can control the conveyor belts 134 to convey the first package
in the direction of travel 105 while holding the subsequent package
still (e.g., stopping the conveyor upon which the subsequent
package rests).
[0036] In some embodiments, the computing system 150 can receive
data related to the position or horizontal dimension 104 of the
package 101 from the one or more photodetectors 135. For example,
the position of the package 101 can include a distance from the
outside edge of the conveyor belts 134. The computing system 150
can then align the focal point of the optical radiation source 122
to the sealing element 102 of the package 101 based on the data
related to the position or horizontal dimension 104 using the
translation system 124.
[0037] Returning to FIG. 1, the height dimensioner 136 can be
disposed adjacent to the diverter 137 or the skew conveyor 132 in
various embodiments. The height dimensioner 136 can measure the
vertical dimension 103 of the package 101 as the package passes by
and produces height data related to the vertical measurement 103.
In some embodiments, the height dimensioner 136 includes an imaging
device and/or an electronic photoeye and/or a laser rangefinder.
The height dimensioner 136 can determine the vertical dimension 103
of the package 101 by looking down at the top of the package 101
from a predetermined fixed position. The height dimensioner 136
then measures the distance from itself to the top of the case. The
vertical dimension 103 is the difference between the predetermined
fixed position and the measured distance to the top of the case. In
some embodiments, the height dimensioner 136 is in communication
with the computing system 150. Height data related to the vertical
dimension 103 of the package 101 can be transmitted from the height
dimensioner 136 to the computing system 150. In some embodiments,
the computing system 150 can adjust the focal point 123 of the
optical radiation in anticipation of the arrival of a package 101
using the height data obtained from the height dimensioner 136.
[0038] In some embodiments, the computing system 150 can compare
the height data related to the vertical dimension 103 of the
package 101 received from the height dimensioner 136 to a threshold
value. If the vertical dimension 103 exceeds the threshold value,
the package may be too large to safely pass through the cutting
device 120. Upon making a determination that the vertical dimension
103 of the package 101 exceeds the threshold value, the computing
system 150 can activate the diverter 137 to divert the package, for
example, to an accumulation conveyor 139. The accumulation conveyor
139 can receive the diverted package and hold the diverted package
until a user can manually assess the package 101. If the package
101 is too large to safely pass through the cutting device 120, the
user can transfer the package to a manual opening area. In some
embodiments, the user may reorient the package 101 and place it
back on the in-feed conveyor system 130 in a different orientation.
In some embodiments, the accumulation conveyor 139 can include
rollers or belts. The rollers or belts can be powered or passive
(i.e., gravity-operated).
[0039] The diverter 137 can convey the package at 90 degrees with
respect to the direction of travel 105 of the package 101 in some
embodiments. The diverter 137 can comprise at least two sets of
rollers in some embodiments. For example, a first set of rollers
can convey packages in the direction of travel 105 and a second set
of rollers can convey packages 101 at an angle (e.g., 90 degrees)
with respect to the direction of travel 105. In some embodiments,
the first and second sets of rollers can be interleaved and the
second set of rollers can be disposed below the first set of
rollers. When the diverter 137 is controlled to divert a package
101, the second set of rollers can rise through the first set of
rollers and assume the role of supporting the package 101 and
conveying the package to the accumulation conveyor 139.
[0040] In some embodiments, the in-feed conveyor system 130 can
include the entrance gate 138. The entrance gate 138 can prevent
passage of the package 101 when the vertical dimension 103 of the
package 101 exceeds the threshold value. In effect, the entrance
gate 138 can act as a final impediment to oversized packages. That
is, if an oversized package 101 is not properly diverted at the
diverter 137, the entrance gate 138 can physically block the
package 101 from entering the cutting device 120. In general, the
inconvenience of having to clear an oversized package from the
entrance gate 138 is more desirable than having to perform costly
repairs to the cutting device 120 or components thereof because of
a collision with an oversized package. In some embodiments, the
entrance gate 138 can be disposed at one of the conveyor belts 134.
Although the entrance gate 138 is shown in FIG. 1 as restricting
packages 101 in both the horizontal dimension 104 and the vertical
dimension 103, the entrance gate 138 can operate to restrict only
one dimension in some embodiments.
[0041] FIG. 5 illustrates a side view of the cutting device 120 in
accordance with various embodiments described herein. The cutting
device 120 can include the optical radiation source 122, the
translation system 124, and the cut conveyor 126. In some
embodiments, the cutting device 120 can include one or more imaging
devices 162 and one or more environmental sensors 164. The imaging
devices 162 are configured to image the sealing element 102 of the
package 101 after the package passes the optical radiation source
122. The imaging devices 162 and environmental sensors 164 are
communicatively coupled to the computing system 150. The elements
of the cutting device 120 can be enclosed within a housing 121 in
some embodiments.
[0042] In some embodiments, the environmental sensors 164 can
include at least one of a smoke detection system, a temperature
detector, a gas detection system, or a fire detection system. As
optical radiation is applied to the sealing element 102 of the
package 101, the sealing element is cut, damaged, ablated, removed,
or pierced. In some instances, the process of cutting the sealing
element 102 can create smoke or fire. This can occur under
circumstances where the intensity of the optical radiation source
122 is too high, the focal point 123 is misaligned, and/or the
package 101 is moving too slowly through the cutting device 120
leading to the deposition of too much energy in the sealing element
102. The environmental sensors 164 can measure environmental
measurement data related to conditions within the cutting device
120 in some embodiments. For example, the environmental measurement
data can be indicative of excessive smoke production or fire within
the cutting device 120. In some embodiments, the computing system
150 can alert a user to dangerous conditions (e.g., fire, smoke, or
gas emissions such as carbon monoxide or carbon dioxide) based upon
an analysis of the environmental measurement data. In some
embodiments, the computing system 150 can activate safety measures
(e.g., power cut-off or fire suppression systems) based upon an
analysis of the environmental measurement data.
[0043] The imaging devices 162 can image the sealing element 102 of
the package 101 after the application of optical radiation to
determine the cut quality (e.g., a measure of whether the cut was
successful). Images can be transmitted from the imaging devices 162
to the computing system 150 for processing. In some embodiments,
the success of the cut can be measured by analyzing the image of
the package 101 to determine a cut success ratio. In some
embodiments, the cutting device 120 applies a discrete number of
physically separated cuts to the sealing element 102. The cut
success ratio is defined as the proportion of successful cuts
(e.g., cuts that fully punctured or pierced the sealing element
102) to total attempted cuts. In some embodiments, cut quality can
be measured by analyzing the image of the package 101 to determine
a surface area of the package 101 that is singed or discolored.
Singeing of the sealing element 102 can indicate the need for
adjustments in the optical radiation source 122 (e.g., intensity or
focus adjustments) or can indicate that the package is moving too
slowly through the cutting device 120. In some embodiments, the
computing system 150 can store the assessed cut quality for a
package 101 in the memory 151 of the computing system 150 as a
historical cut quality. In some embodiments, the cut quality can be
determined by the system by measuring the upper and lower bounds of
a package and referencing the actual cut in the acquired image to
determine the distance off from a centerline 106 of the sealing
element 102. In some embodiments, the image of the cut sealing
element 102 can be compared to an image of an "ideal" cut pattern
to determine inconsistencies between the actual cut and a
successful cut. In some embodiments, the imaging devices 162 can be
located before and after the focal point 123 of the system at which
the sealing element 102 is cut. The imaging devices 162 can acquire
a reflectivity value for the sealing element 102 before the cut
occurs and a reflectivity value for the sealing element 102 after
the cut occurs. In the case of a successful cut, the reflectivity
value of the sealing element 102 will be different from before to
after the cut.
[0044] A speed of the cut conveyor 126 can be varied in some
embodiments. In some embodiments, the variable-speed cut conveyor
126 can include a variable-speed drive or a servo motor. In some
embodiments, the computing system 150 can adjust the speed of the
cut conveyor 126 based upon height data from the height dimensioner
136, historical cut quality retrieved from the memory 151, and/or
environmental measurement data received from the environmental
sensors 164. For example, the computing system 150 can compare the
cut success ratio to a pre-determined value for cut success ratio.
Upon determining that the cut success ratio is below the
pre-determined value, the computing system 150 can decrease the
speed of the variable-speed cut conveyor 126 in some embodiments.
In similar embodiments, the computing system 150 can increase the
speed of the variable-speed cut conveyor 126 upon determining that
the cut success ratio is above the pre-determined value. In some
embodiments, the cut success ratio can be about 50%, 60%, 70%, 80%,
90%, 95%, or 99% as appropriate for a given application. In other
words, the computing system 150 can adjust the speed of the cut
conveyor 126 to slow the conveyor down to allow more time for the
system to make cuts before the package passes out of the cutting
device 120 when the historical cut quality is low. Conversely, the
computing system 150 can speed up the cut conveyor 126 in some
embodiments if cuts are uniformly of high quality (i.e., the
historical cut quality is high). Likewise, the computing system 150
can speed up the cut conveyor 126 for subsequent packages if
packages are burning based upon measurements of smoke or fire
received from the environmental sensors 164 (i.e., if packages are
spending too much time under the optical radiation source and are
catching fire). Similarly, the computing system 150 can slow down
or stop the cut conveyor 126 upon detection of fire or smoke,
disable the optical radiation source, and activate fire suppression
systems.
[0045] As mentioned, the computing system 150 can adjust the speed
of the cut conveyor 126 based upon height data related to the
vertical dimension 103 of the package 101. For example, the height
data can be received from the height dimensioner 136. If the
vertical dimension 103 of the package is such that the translation
system 124 will not have to adjust the position of the focal point
123 over a large distance, the cut conveyor 126 can be sped up to
bring the package 101 past the optical radiation source 122 more
quickly. Because there is no need to leave time for adjustment when
the focal point 123 is already in the correct position, the
throughput of packages can be raised. For example, the computing
system 150 can determine a difference between the vertical
dimension 103 of the package 101 and a vertical position of the
focal point 123. Upon determining that the difference is below a
threshold value, the computing system 150 can increase the speed of
the cut conveyor 126 to convey packages to or past the optical
radiation source 122 more rapidly. This effect is multiplied when
there are many packages of the same size and shape approaching the
cutting device 120. If a series of packages all have the same
dimensions, the translation system 124 will have to move the
optical radiation source 122 very little between packages and the
overall throughput of the cutting system 100 can be increased by
increasing the speed of the cut conveyor 126 Similarly, the gap 108
between packages can be reduced to allow faster conveyance of
packages through the cutting device 120. In some embodiments, the
computing system 150 can receive package dimension information from
the photodetectors 135 or an imaging device 162 of the in-feed
conveyor system 130 to predict or forecast adjustments to the speed
of the cut conveyor 126 in advance of the package 101 arriving at
the cutting device 120. In some embodiments, the cutting device 120
can include four photodetectors 135 wherein two photodetectors 135
are located before the focal point 123 and two photodetectors 135
are located after the focal point 123.
[0046] In some embodiments, the computing system 150 can execute
instructions to adjust an intensity of the optical radiation source
122 based on the historical cut quality or the environmental
measurement data. For example, environmental measurement data
indicating that a fire or smoke is present within the housing 121
of the cutting device 120 may mean that the intensity is too high.
The computing system 150 can reduce the intensity of the optical
radiation source 122 to reduce the likelihood of burning the
package 101. Reducing the intensity can include lowering the
intensity emitted from the optical radiation source 122 (e.g.,
turning down current or voltage in a laser source) or altering the
intensity of the beam of optical radiation itself (e.g., using
adjustable filters such as neutral density filters).
[0047] FIG. 6A illustrates a cut pattern 170 formed on the sealing
element of the package in some embodiments of the present
disclosure. In the illustrated embodiment, the cut pattern 170
includes chevron-shaped cuts. The cut pattern 170 is oriented over
a centerline 106 that represents the location where two flaps or
sides of the top of the package come together and are sealed using
the sealing element 102. In some embodiments, the sealing element
102 is tape or glue.
[0048] FIG. 6B illustrates the cut pattern 170 formed over
substantially the entire sealing element 102 of the package 101 in
accordance with some embodiments described herein. By extending the
cut pattern 170 over substantially the entire sealing element 102,
the system 100 can ensure that the sealing element 102 has been
fully cut or damaged so that the box can be readily opened by a
user. However, application of the cut pattern 170 to substantially
all of the sealing element 102 also introduces disadvantages
including increasing the wear and decreasing lifetime for the
optical radiation source 122, introducing a greater quantity of
particulates into the environment inside the housing 121 which can
necessitate more frequent replacement of air filters in the cutting
device 120, and slower processing of packages as greater care is
used to cut the entire sealing element 102. In particular, the
cutting device 120 may slow down in some embodiments while the
optical radiation source 122 is active and speed up at other times
to more quickly process packages. When using the cutting device 120
to cut substantially the entire sealing element 102, the total cut
time may be longer as the package travels at a slower rate for a
longer time.
[0049] FIG. 6C illustrates a cut pattern formed over only portion
185 of the sealing element 102 of the package 101 in accordance
with some embodiments described herein. By applying the cut pattern
170 to only portions 185 of the sealing element 102, one or more
uncut regions 180 of the sealing element 102 remain. By reducing
the total area of the sealing element 102 that receives the cut
pattern 170, the lifetime of the optical radiation source 122
and/or air filters in the housing 121 can be extended. The package
may still be opened easily even though the amount of the sealing
element that is vaporized is reduced. In addition, ongoing
maintenance costs can be reduced and the speed of conveyor lines
can be increased. In some embodiments, the portion 185 of the
sealing element 102 along the centerline 106 having the cut pattern
can have a linear dimension in a range from 5 cm to 25 cm. In some
embodiments, the portion 185 of the sealing element 102 along the
centerline 106 having the cut pattern can be a percentage of the
total length of the sealing element along the centerline 106. For
example, the portion 185 can represent between 25% and 75% of the
total length. The portion 185 can represent about 50% of the total
length in some embodiments. In some embodiments, the uncut portions
180 together can represent between about 0% and about 50% of the
total length of the sealing element 102 along the centerline 106.
In some embodiments, the portion 185 of the sealing element 102
along the centerline 106 having the cut pattern can be disposed at
a distance from a leading edge or a trailing edge of package 101.
The portion 185 can be offset from an end of the centerline 106 of
the sealing element 102 by about 25% of the total length of the
sealing element 102.
[0050] FIGS. 7A-7E illustrate different cut patterns that are
applied using systems and methods described herein. In some
embodiments, the cut pattern 171 can include chevrons that are
oriented at 90 degrees with respect to the center line 106 or with
respect to the direction of travel 105 of the package 101 through
the cutting device 120 as shown in FIG. 7A. In some embodiments,
the cut pattern 172 can include a zig-zag shape as shown in FIG.
7B. Note that the cut pattern 172 includes connected cuts rather
than discrete and disconnected cuts. Cut patterns in accordance
with various aspects of this disclosure can include connected or
disconnected cut forms. In some embodiments, the cut pattern 173
can include curlicues as shown in FIG. 7C. In some embodiments, the
cut pattern 174 can include X-shaped cuts as shown in FIG. 7D. In
some embodiments, the cut pattern 175 can include cross-cuts that
run perpendicular or substantially perpendicular to the centerline
106 or the direction of motion 105 of the package 101 as shown in
FIG. 7E. In other embodiments, the angle between the centerline 106
and the cross-cuts of the cut pattern 175 can be any angle in a
range from 5.degree. to 90.degree.. Choice of cut pattern can be
based on factors such as toughness of the material in the sealing
element 102 or package 101, desired throughput of the device, and
other factors. In some embodiments, the choice of cut pattern 175
can be made based upon the type of sealing element 102 (i.e., tape
or glue), type of material for the package 101 (e.g., cardboard or
plastic), type of package 101 (e.g., box or bag), the desire to
limit or control exposure of the internal contents of the package
101 to the optical radiation source 122, the desire to extend the
lifetime of the optical radiation source. In some embodiments, the
computing device 150 can control the optical radiation source to
change the cut pattern 175 used upon detection of poor cut quality
or other conditions. For example, the computing device 150 can
change to a cut pattern 175 that reduces the duty cycle of the
optical radiation source 122 (i.e., the amount of time during the
cut that the optical radiation source 122 is actively cutting)
based upon detection of environmental factors such as smoke as
described above.
[0051] FIG. 8 is a block diagram of an example computing system for
implementing exemplary embodiments of the present disclosure. The
computing system 150 may be, but is not limited to, a smartphone,
laptop, tablet, desktop computer, server, or network appliance. In
various embodiments, the computing system 150 can be integrated
into a single unit or can include distributed components that are
connected by a network. For example, the computing system 150 can
include a processor provided as part of the cutting device 120 and
a separate processor or processors provided as part of the in-feed
conveyor system 130. The computing system 150 includes one or more
non-transitory computer-readable media for storing one or more
computer-executable instructions or software for implementing
exemplary embodiments. The non-transitory computer-readable media
may include, but are not limited to, one or more types of hardware
memory, non-transitory tangible media (for example, one or more
magnetic storage disks, one or more optical disks, one or more
flash drives, one or more solid state disks), and the like. For
example, memory 606 included in the computing system 150 may store
computer-readable and computer-executable instructions or software
(e.g., applications 630) for implementing exemplary operations of
the computing system 150. The computing system 150 also includes
configurable and/or programmable processor 602 and associated
core(s) 604, and optionally, one or more additional configurable
and/or programmable processor(s) 602' and associated core(s) 604'
(for example, in the case of computer systems having multiple
processors/cores), for executing computer-readable and
computer-executable instructions or software stored in the memory
606 and other programs for implementing exemplary embodiments of
the present disclosure. Processor 602 and processor(s) 602' may
each be a single core processor or multiple core (604 and 604')
processor. Either or both of processor 602 and processor(s) 602'
may be configured to execute one or more of the instructions
described in connection with computing system 150.
[0052] Virtualization may be employed in the computing system 150
so that infrastructure and resources in the computing system 150
may be shared dynamically. A virtual machine 612 may be provided to
handle a process running on multiple processors so that the process
appears to be using only one computing resource rather than
multiple computing resources. Multiple virtual machines may also be
used with one processor.
[0053] Memory 606 may include a computer system memory or random
access memory, such as DRAM, SRAM, EDO RAM, and the like. Memory
606 may include other types of memory as well, or combinations
thereof.
[0054] A user may interact with the computing system 150 through a
visual display device 152, such as a computer monitor, which may
display one or more graphical user interfaces 616. The user may
interact with the computing system 150 using a multi-point touch
interface 620, a pointing device 618, an image capturing device
634, or a reader 632.
[0055] The computing system 150 may also include one or more
computer storage devices 626, such as a hard-drive, CD-ROM, or
other computer readable media, for storing data and
computer-readable instructions and/or software that implement
exemplary embodiments of the present disclosure (e.g.,
applications). For example, exemplary storage device 626 can
include one or more databases 605 for storing cut quality
information or physical parameters related to elements of the
system. The databases 605 may be updated manually or automatically
at any suitable time to add, delete, and/or update one or more data
items in the databases.
[0056] The computing system 150 can include a network interface 608
configured to interface via one or more network devices 624 with
one or more networks, for example, Local Area Network (LAN), Wide
Area Network (WAN) or the Internet through a variety of connections
including, but not limited to, standard telephone lines, LAN or WAN
links (for example, 802.11, T1, T3, 56 kb, X.25), broadband
connections (for example, ISDN, Frame Relay, ATM), wireless
connections, controller area network (CAN), or some combination of
any or all of the above. In exemplary embodiments, the computing
system can include one or more antennas 622 to facilitate wireless
communication (e.g., via the network interface) between the
computing system 150 and a network and/or between the computing
system 150 and other computing systems. The network interface 608
may include a built-in network adapter, network interface card,
PCMCIA network card, card bus network adapter, wireless network
adapter, USB network adapter, modem or any other device suitable
for interfacing the computing system 150 to any type of network
capable of communication and performing the operations described
herein.
[0057] The computing system 150 may run any operating system 610,
such as versions of the Microsoft.RTM. Windows.RTM. operating
systems, different releases of the Unix.RTM. and Linux.RTM.
operating systems, versions of the MacOS.RTM. for Macintosh
computers, embedded operating systems, real-time operating systems,
open source operating systems, proprietary operating systems, or
any other operating system capable of running on the computing
system 150 and performing the operations described herein. In
exemplary embodiments, the operating system 610 may be run in
native mode or emulated mode. In an exemplary embodiment, the
operating system 610 may be run on one or more cloud machine
instances.
[0058] FIG. 9 illustrates a block diagram of an exemplary
distributed computing environment 550 in accordance with exemplary
embodiments of the present disclosure. The environment 550 can
include computing systems 150 configured to be in communication
with the cutting device 120 or the in-feed conveyor system 130 via
a communication network 615, which can be any network over which
information can be transmitted between devices communicatively
coupled to the network. For example, the communication network 615
can be the Internet, Intranet, virtual private network (VPN), wide
area network (WAN), local area network (LAN), and the like. In some
embodiments, the communication network 615 can be part of a cloud
environment. In some embodiments, one or more computing systems 150
in the distributed computing environment 550 can be mobile
computing devices that are in communication with other computing
systems 150, the in-feed conveyor system 130, or the cutting device
120 via the communication network 615. The environment 550 can
include at least one repository or database 605, which can be in
communication with the computing systems 150, the in-feed conveyor
system 130, or the cutting device 120 via the communications
network 615.
[0059] FIG. 10 illustrates a flowchart for a method 1000 for
cutting in accordance with various embodiments described herein.
The method 1000 includes adjusting a position of a package 101
laterally using a skew conveyor 132 of an in-feed conveyor system
130 (step 1002). The skew conveyor 132 includes one or more skewing
elements 141. The method 1000 includes detecting height data
related to a vertical dimension 103 of the package 101 using a
height dimensioner 136 (step 1004).
[0060] The method 1000 includes detecting data related to a
position or horizontal dimension 104 of the package 101 using one
or more photodetectors 135 (step 1006). The method 1000 includes
activating a diverter 137 to divert the package away from a cutting
device 120 upon determining that the vertical dimension 103 of the
package 101 exceeds a threshold value (step 1008). The cutting
device 120 includes an optical radiation source 122 that focuses at
a focal point 123, a translation system 124 to adjust the location
of the focal point 123 in three-dimensional space, and a cut
conveyor 126 to convey the package 101 past the optical radiation
source 122.
[0061] The method 1000 includes aligning the focal point 123 of the
optical radiation source 122 to a sealing element 102 of the
package 101 based on the data related to the position or horizontal
dimension 104 using the translation system 124 (step 1100). The
method 1000 includes applying radiation from the optical radiation
source 122 to the sealing element 102 (step 1012).
[0062] FIG. 11 illustrates a flowchart for a method 1100 for
cutting in accordance with various embodiments described herein.
The method 1100 includes receiving height data related to a
vertical dimension 103 of a package 101 from a height dimensioner
136 (step 1102). The method 1100 includes retrieving historical cut
quality for at least one previous package from a memory 151 of a
computing system 150 communicatively coupled to a cutting device
120 (step 1104). The cutting device 120 includes an optical
radiation source 122 that focuses at a focal point 123, a
translation system 124 to adjust the location of the focal point
123 in three-dimensional space, and a variable-speed cut conveyor
126 to convey the package 101 through the cutting device 120.
[0063] The method 1100 includes receiving environmental measurement
data from one or more environmental sensors 164 of the cutting
device 120 (step 1106). The method 1100 includes adjusting a speed
of the variable speed cut conveyor 126 based upon the height data,
the historical cut quality, or the environmental measurement data
(step 1108).
[0064] The method 1100 includes aligning the focal point 123 of the
optical radiation source 122 to a sealing element 102 of the
package 101 using the translation system 124 (step 1100). The
method 1100 includes applying radiation from the optical radiation
source 122 to cut the sealing element 102 (step 1112).
[0065] The method 1100 includes determining a cut quality for the
package 101 based on image data from one or more imaging devices
162 configured to image the sealing element of the package after
the package passes the optical radiation source (step 1114). The
method 1100 includes storing the cut quality for the package in the
memory (step 1116).
[0066] In describing exemplary embodiments, specific terminology is
used for the sake of clarity. For purposes of description, each
specific term is intended to at least include all technical and
functional equivalents that operate in a similar manner to
accomplish a similar purpose. Additionally, in some instances where
a particular exemplary embodiment includes a plurality of system
elements, device components or method steps, those elements,
components or steps may be replaced with a single element,
component, or step. Likewise, a single element, component, or step
may be replaced with a plurality of elements, components, or steps
that serve the same purpose. Moreover, while exemplary embodiments
have been shown and described with references to particular
embodiments thereof, those of ordinary skill in the art will
understand that various substitutions and alterations in form and
detail may be made therein without departing from the scope of the
present disclosure. Further still, other aspects, functions, and
advantages are also within the scope of the present disclosure.
[0067] Exemplary flowcharts are provided herein for illustrative
purposes and are non-limiting examples of methods. One of ordinary
skill in the art will recognize that exemplary methods may include
more or fewer steps than those illustrated in the exemplary
flowcharts, and that the steps in the exemplary flowcharts may be
performed in a different order than the order shown in the
illustrative flowcharts.
* * * * *