U.S. patent application number 16/854427 was filed with the patent office on 2020-10-29 for system and method for opening containers.
The applicant listed for this patent is Walmart Apollo, LLC. Invention is credited to Paul E. Durkee, James Benjamin Edwards.
Application Number | 20200339298 16/854427 |
Document ID | / |
Family ID | 1000004810126 |
Filed Date | 2020-10-29 |
United States Patent
Application |
20200339298 |
Kind Code |
A1 |
Edwards; James Benjamin ; et
al. |
October 29, 2020 |
SYSTEM AND METHOD FOR OPENING CONTAINERS
Abstract
Features are applied to a mathematical model to produce a
cutting pattern for opening a container. The cutting pattern
specifies which of one or more cutting tools is to be used and the
location of where cuts are to be made on the container. The cutting
pattern is sent to a container opening machine. The container
opening machine is operated and the container cut and opened by the
container opening machine according to the cutting pattern.
Inventors: |
Edwards; James Benjamin;
(Fayetteville, AR) ; Durkee; Paul E.; (Centerton,
AR) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Walmart Apollo, LLC |
Bentonville |
AR |
US |
|
|
Family ID: |
1000004810126 |
Appl. No.: |
16/854427 |
Filed: |
April 21, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62837261 |
Apr 23, 2019 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
G06K 7/10297 20130101;
G06N 3/04 20130101; G06K 9/46 20130101; B23K 26/0626 20130101; B65B
69/0033 20130101; B23D 59/001 20130101; B26D 5/007 20130101; B23K
26/38 20130101 |
International
Class: |
B65B 69/00 20060101
B65B069/00; B23D 59/00 20060101 B23D059/00; B23K 26/38 20060101
B23K026/38; B23K 26/06 20060101 B23K026/06; G06N 3/04 20060101
G06N003/04; G06K 9/46 20060101 G06K009/46 |
Claims
1. A system for opening a container, the system comprising: a
scanning surface; a plurality of containers that arrive and are
sequentially placed on the scanning surface; a scanning device; a
sensor; a database that stores a mathematical model; a container
opening machine including at least one cutting tool, the at least
one cutting tool being one or more of a saw blade or a laser,
wherein the at least one cutting tool is applied to each of the
plurality of containers arriving on the scanning surface to open
the container; a control circuit coupled to the database, the
scanning device, the sensor, and the container opening machine,
wherein the control circuit is configured to: receive sensor data
from the sensor, the sensor data identifying the contents of the
container; receive scanned images from the scanning device, the
scanned images being of the contents of the interior of the
container; analyze the sensor data and the scanned images to obtain
features of the contents of the container; apply the features to
the mathematical model to produce a cutting pattern, the cutting
pattern specifying which of the one or more cutting tools to be
used and the location of where cuts are to be made; send the
cutting pattern to the container opening machine; wherein the
container opening machine is operated and the container cut and
opened by the container opening machine according to the cutting
pattern.
2. The system of claim 1, wherein the cutting pattern further
includes the depth of the cuts into the container.
3. The system of claim 1, wherein the cutting pattern further
includes the speed of the cutting tool.
4. The system of claim 1, wherein the features of the contents
include one or more of the dimensions of the contents, the spacing
of the contents, the shape of the contents, the size of the
contents, the number of contents in the container, the monetary
value of the contents, and the orientation of the contents.
5. The system of claim 1, wherein the container includes a label or
tag that is scanned and the sensor data is sensed from the label or
tag.
6. The system of claim 1, wherein the containers include the same
type of items.
7. The system of claim 1, wherein the cutting pattern species that
cutting tool selected is a laser and that the intensity of the
laser is adjusted to a predetermined value.
8. The system of claim 1, wherein the mathematical model is a
convolutional neural network (CNN).
9. The system of claim 1, wherein the scanning surface is a
conveyor belt.
10. A method for opening a container, the method comprising:
providing a scanning surface, a plurality of containers that arrive
and are sequentially placed on the scanning surface, a scanning
device, a sensor and a database that stores a mathematical model;
providing a container opening machine that includes at least one
cutting tool, the at least one cutting tool being one or more of a
saw blade or a laser, wherein the at least one cutting tool is
applied to each of the plurality of containers arriving on the
scanning surface to open the container; at a control circuit,
receiving sensor data from the sensor, the sensor data identifying
the contents of the container; at the control circuit, receiving
scanned images from the scanning device, the scanned images being
of the contents of the interior of the container; at the control
circuit, analyzing the sensor data and the scanned images to obtain
features of the contents of the container; at the control circuit,
applying the features to the mathematical model to produce a
cutting pattern, the cutting pattern specifying which of the one or
more cutting tools to be used and the location of where cuts are to
be made; by the control circuit, sending the cutting pattern to the
container opening machine; wherein the container opening machine is
operated and the container cut and opened by the container opening
machine according to the cutting pattern.
11. The method of claim 10, wherein the cutting pattern further
includes the depth of the cuts into the container.
12. The method of claim 10, wherein the cutting pattern further
includes the speed of the cutting tool.
13. The method of claim 10, wherein the features of the contents
include one or more of the dimensions of the contents, the spacing
of the contents, the shape of the contents, the size of the
contents, the number of contents in the container, the monetary
value of the contents, and the orientation of the contents.
14. The method of claim 10, wherein the container includes a label
or tag that is scanned and the sensor data is sensed from the label
or tag.
15. The method of claim 10, wherein the containers include the same
type of items.
16. The method of claim 10, wherein the cutting pattern species
that cutting tool selected is a laser and that the intensity of the
laser is adjusted to a predetermined value.
17. The method of claim 10, wherein the mathematical model is a
convolutional neural network (CNN).
18. The method of claim 10, wherein the scanning surface is a
conveyor belt.
Description
CROSS REFERENCES TO RELATED APPLICATION
[0001] This application claims the benefit of U.S. Provisional
Application No. 62/837,261, filed Apr. 23, 2019, which is
incorporated herein by reference in its entirety.
TECHNICAL FIELD
[0002] These teachings relate to approaches for opening containers
such as boxes without damaging the contents of the container.
BACKGROUND
[0003] Boxes, crates, cases, and other types of containers are used
to ship various types of products. The containers may arrive at a
warehouse, distribution center, or retail store and need to be
opened. In one example, the containers are opened manually.
However, in other examples and when large number of containers are
shipped and received, a cutting or opening machine is used to
remove the top of the container (or otherwise open the container).
Once opened, the contents of the container can be removed, for
example, by a robot or by a human.
[0004] The containers are typically opaque and, consequently, the
contents are not visible either to a human or machine opening the
container. Since the cutting or opening machine is unaware of the
contents or how the contents are arranged, the cutting or opening
process may result in damage to the contents of the container. For
example, a cutting machine that removes the top of a shipping case
may also cut off a portion of an item that is being shipped in the
shipping case.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The above needs are at least partially met through the
provision of approaches that opens containers, wherein:
[0006] FIG. 1 comprises a diagram of a system as configured in
accordance with various embodiments of these teachings;
[0007] FIG. 2 comprises a flowchart as configured in accordance
with various embodiments of these teachings;
[0008] FIGS. 3A, 3B, 3C, and 3D comprise diagrams of an approach as
configured in accordance with various embodiments of these
teachings;
[0009] FIG. 4 comprises a diagram of a system as configured in
accordance with various embodiments of these teachings;
[0010] FIG. 5 comprises a diagram of a system as configured in
accordance with various embodiments of these teachings.
DETAILED DESCRIPTION
[0011] Generally speaking, the present approaches use millimeter
wave (or other wavelength) technology to scan an opaque container
to see the contents of the container and determine how and where to
make cuts to remove the top (or other portions) of the container
allowing robotic pickers (or other devices or humans) to easily
access the container and/or remove these contents. For example,
based on a scan, the system determines what type of cutting tool to
use, the amount of force the tool should use, the locations of cuts
and/or the depths of cuts. In aspects, the approaches described
herein are directed to scanning the container before the contents
of the container are removed (and before the container is cut
and/or opened), and then selecting appropriate cut settings (e.g.,
appropriate cutter (blade, laser, etc.) and appropriate location,
penetration depth, force, shape, etc. of the cut) based upon an
analysis of scanned images of the internal contents of the
container and potentially other information.
[0012] In some aspects, the approaches provided herein use
millimeter wave technology to identify the shape and orientation of
the products in an opaque container before opened. Once the
internal geometry of the contents of the container is determined,
various actions may be taken such as determining how to open the
container and remove the contents.
[0013] In one example, the case-opening cut parameters may be
determined such that the cut does not protrude far enough into the
container to damage products in the container, but does protrude
far enough into the container to cut fully through the container
wall. In another example, the cut location(s) may be placed in
location where the product surface is farthest from the inner
container wall, such that the likelihood of product damage is
minimized.
[0014] In aspects, at least some part of the approaches provided
herein occur during the case opening part of a decantation process
(where the container is opened and its contents removed). The
automated case cutting process includes stored parameters for the
cut action that took place. Such parameters include: the type of
cutter used (e.g., knife blade, reciprocal saw blade, circular saw
blade, laser), a blade penetration depth, a blade traversal speed,
a saw reciprocation or circulation rate, a saw reciprocation
distance (how far back and forth when sawing), laser intensity, and
laser distance from surface. Other examples are possible.
[0015] In many of these embodiments, a system for opening a
container includes a scanning surface; a plurality of containers
that arrive and are sequentially placed on the scanning surface; a
scanning device; a sensor; a database that stores a mathematical
model; and a container opening machine that includes at least one
cutting tool. The cutting tool is one or more of a saw blade or a
laser, and the cutting tool is applied to each of the plurality of
containers arriving on the scanning surface to open the container.
The system also includes a control circuit that is coupled to the
database, the scanning device, the sensor, and the container
opening machine.
[0016] The control circuit is configured to: receive sensor data
from the sensor, the sensor data identifying the contents of the
container; receive scanned images from the scanning device, the
scanned images being of the contents of the interior of the
container; analyze the sensor data and the scanned images to obtain
features of the contents of the container; apply the features to
the mathematical model to produce a cutting pattern, the cutting
pattern specifying which of the one or more cutting tools to be
used and the location of where cuts are to be made; and send the
cutting pattern to the container opening machine. The container
opening machine is operated and the container cut and opened by the
container opening machine according to the cutting pattern.
[0017] In other aspects the cutting pattern further includes the
depth of the cuts into the container. In still other examples, the
cutting pattern further includes the speed of the cutting tool.
[0018] In examples, the features of the contents include one or
more of the dimensions of the contents, the spacing of the
contents, the shape of the contents, the size of the contents, the
number of contents in the container, the monetary value of the
contents, and the orientation of the contents. Other examples are
possible.
[0019] In other aspects, the container includes a label or tag that
is scanned and the sensor data is sensed from the label or tag. In
still other aspects, the containers include the same type of items.
In yet other examples, the containers contain different types of
items.
[0020] In another example, the cutting pattern species that the
cutting tool selected is a laser and that the intensity of the
laser is adjusted to a predetermined value.
[0021] In aspects, the mathematical model is a convolutional neural
network (CNN). Other examples are possible.
[0022] In other examples, the scanning surface is a conveyor belt.
Other examples are possible.
[0023] In others of these embodiments, a scanning surface, a
plurality of containers that arrive and are sequentially placed on
the scanning surface, a scanning device, a sensor and a database
that stores a mathematical model are provided. A container opening
machine that includes at least one cutting tool is also provided.
The cutting tool is one or more of a saw blade or a laser. The
cutting tool is applied to each of the plurality of containers
arriving on the scanning surface to open the container.
[0024] At a control circuit, sensor data is received from the
sensor, the sensor data identifying the contents of the container.
At the control circuit, scanned images are received from the
scanning device. The scanned images are of the contents of the
interior of the container.
[0025] At the control circuit, the sensor data and the scanned
images are analyzed to obtain features of the contents of the
container. At the control circuit, the features are applied to the
mathematical model to produce a cutting pattern. The cutting
pattern specifies which of the one or more cutting tools is to be
used and the location of where cuts are to be made. The control
circuit sends the cutting pattern to the container opening machine.
The container opening machine is operated and the container cut and
opened by the container opening machine according to the cutting
pattern.
[0026] Referring now to FIG. 1, a system 100 is configured to open
one or more containers. The system 100 includes a container opening
machine 102, a control circuit 104, a database 106, sensors 108, a
scanning device 110, a content removal device 112, a first
container 114, a second container 116, and a scanning surface 118.
Some or all of these elements may be disposed at a warehouse,
retail store, or discount center. Other examples of locations are
possible. In one particular example, the elements are all disposed
at a warehouse so that large amounts of data do not have to be
moved to or between networks (e.g., the cloud).
[0027] The container opening machine 102 is any type of device or
combination of devices that are effective to open (e.g., cut,
slash, pierce, and/or remove portions of) the containers 114 and
116. The container opening machine 102 includes one or more cutting
tools (e.g., lasers, circular saws, reciprocating saws, other saws,
drills, blades, knives, or other types of tools). The cutting tools
may be disposed on a robotic arm that moves about the container.
The operation of the container opening machine 102 may be
controlled by parameters stored at the container opening machine
102. For example, the container opening machine 102 may itself have
a control circuit that is operated according to stored parameters
or values. One stored value (parameter) may represent the cutting
tool (or tools used), another value (parameter) may relate to the
depth of a cut, other parameters may specify the shape of a cut,
and still other parameters may describe other details of the cut or
how to obtain the cut. These parameters may be stored at a memory
at the container opening machine 102 in any type of data storage
format. It will be appreciated that the container opening machine
102 may have its parameters reset upon the opening of each
different container.
[0028] In other examples, a model (e.g., a convolutional neural
network (CNN) model) may represent containers and the cutting
patterns. The CNN model may be stored in the database 106. In
aspects, the CNN model is first trained with training data from
various containers. The training alters the layers, weights, and
other parameters of the model. After the training process is
completed, a particular container is scanned to obtain images of
its contents, and a label (or other identifier) on the particular
container is scanned (e.g., to obtain information that may not be
determined by image analysis such as the monetary value of items in
the container). Information obtained from the images and/or the
label is applied to the CNN model to obtain a pattern that can be
used by the container opening machine 102 to open the particular
container. One or more CNN models can be used. In other examples,
the model may be a series of equations, a flowchart (implemented as
computer code), or other elements.
[0029] In aspects, when the containers 114 and 116 are opened, a
cutting pattern is used to perform or make the opening. By pattern,
it is meant one or more of: the location of cuts in or at the
container, the dimensions (length, width, depth) of the cuts, the
amount of force applied to the cuts (e.g., when the tool is a saw),
the intensity of the laser beam (when the cutting tool is a laser),
and the amount of time the tool is used. In other aspects, the
pattern also includes the identity of the tool (or tools used),
when these tools are used, and how these tools are used (e.g., one
tool may be used to open one portion of a container and another
tool used to open another portion of a container). Other examples
are possible.
[0030] It will be appreciated that as used herein the term "control
circuit" refers broadly to any microcontroller, computer, or
processor-based device with processor, memory, and programmable
input/output peripherals, which is generally designed to govern the
operation of other components and devices. It is further understood
to include common accompanying accessory devices, including memory,
transceivers for communication with other components and devices,
etc. These architectural options are well known and understood in
the art and require no further description here. The control
circuit 104 may be configured (for example, by using corresponding
programming stored in a memory as will be well understood by those
skilled in the art) to carry out one or more of the steps, actions,
and/or functions described herein.
[0031] The database 106 is any type of electronic memory storage
device or computer memory. The sensors 108 are any type of sensors
that read information from the containers 114 and 116. For example,
the sensors 108 may be RFID (or label) sensors that read RFID tags
(or labels such as barcodes) on the containers 114 and 116. The
tags or labels have associated with the containers 114 and 116 have
associated information. For example, a label may be encoded with
information including the type of items in a container, the value
of items in a container, the number of items in a container, the
dimensions of items in a container, or any other characteristic of
items in a container. The information may also uniquely identify
the container (e.g., the label may be a barcode with a container
ID). This information may be of the type difficult or impossible to
obtain via image analysis (e.g., information such as a precise
monetary value of the items in a container).
[0032] The scanning device 110 is any type of scanning device that
obtains images of the contents of the container 114 and container
116. In aspects, the scanning device 110 obtains images using
millimeter wave technology (obtaining images to identify the shape
and orientation of the products or items in the container 114 and
116). Other examples (e.g., that obtain images in other radiation
frequencies) such as x-rays may also be use. In examples, the
scanning device 110 transmits millimeter waves from antennas. The
wave energy reflected back from the container and the contents of
the containers 114 and 116 is used to construct images, which can
be analyzed by the control circuit 104.
[0033] In other examples, different types of scanning technology
and devices can be used for different purposes (e.g., obtain images
or information about different aspects and/or contents of a
container). In other words, multiple scanning devices using
different types of scanning technology can be deployed. In one
example, a camera (a first scanning device) obtains images in the
visible light spectrum of the outside of the container, while a
second scanning device (using a different scanning technology) such
as millimeter wave technology is used to obtain images of the
contents of the container. In this example, a first analysis can be
undertaken of the visible light camera images, while a second
analysis can be performed on images (or other obtained information)
obtained from the scans made by the millimeter technology. In this
way, information about the container itself (e.g., damage) and
information about the contents of the container is obtained. It
will be appreciated that different types of technology including
millimeter, x-ray, acoustic, ultrasound, visible light and
combinations of these can be used.
[0034] In still other examples, more than two types of technology
can be used to obtain information concerning the container and/or
contents of the container. For example a first scanning device is
used to obtain visible light images of the exterior of the
container. A second scanning device utilizes millimeter scanning
technology to obtain images concerning the contents of the
container. A third scanning device utilizes a different type of
scanning technology such as x-rays either to obtain additional
information about the contents and/or confirm information obtained
by the first and/or scanning devices.
[0035] The content removal device 112 is any type of device or
combination of devices that can removed the contents of the
containers 114 and 116. In examples, the content removal device 112
may be a robot with arms, levers, and grips that are operated to
remove the contents of the containers 114 and 116 once the
containers are opened.
[0036] The first container 114 and the second container 116 are any
type of structure that holds items, for example, as the items are
shipped from a first location to a second location. The containers
114 and 116 may have walls that are opaque in that humans or
machines cannot see into the containers and cannot ascertain the
contents of the containers. In other words, the contents of the
containers are ordinarily hidden without using images obtained by
the canning device 110. In examples, the containers may be
cardboard container, constructed of metal, or constructed of
plastic. Other examples are possible. Various types of items may be
shipped in the containers. For example, bottles, cans, other boxes,
and various other items may be placed in the containers 114 and
116.
[0037] The scanning surface 118 may be any type of surface such as
a flat surface where the containers 114 and 116 can be disposed as
the containers are opened. In other aspects, the scanning surface
118 is a conveyor belt that sequentially moves the containers 114
and 116 over time. For example, the conveyor belt first moves the
container 114 to a first position, and the scanning device 110
obtains an image of the contents. The sensors 108 also scan a label
on the container 114 to obtain product information. Based upon the
images and the information from the scanning device 110, a pattern
is selected by the control circuit 104. The container opening
machine 102 then opens the container 114 according to the pattern
from the same location or after the conveyor moves the container to
a new location. Then, the container 114 is moved to the content
removal machine 112 where the contents of the container 114 are
removed from the container 114. Alternatively, the container 114
may stay at the same location. The same procedure is followed for
the container 116 as the container 116 follows the container 114
sequentially in time on the conveyor belt.
[0038] In examples, the various factors applied to the model can be
weighted in importance. For example, the cost of items may be
viewed as more important than the tool to be used to do the
cutting. The weights can then be used to influence the selection of
the pattern.
[0039] In one example of the operation of the system of FIG. 1, the
control circuit 104 receives sensor data from the sensors 108. The
sensor data identifies the contents of the containers 114 and 116
and may also include identifiers that uniquely identify the
containers 114 and 116. At the control circuit 104, scanned images
are received from the scanning device 110. The scanned images are
of the contents of the interior of the containers 114 and 116 and
may also identify the container.
[0040] At the control circuit 104, the sensor data and the scanned
images are analyzed to obtain features of the contents of the
containers 114 and 116. The analysis may include any technique
known to those skilled in the art to obtain the features (e.g., the
shape of an item in a container, the material a container is
constructed, the amount of empty space in the container). For
instance, obtained images can be compared to images of known shapes
to determine the specific shapes of items in a particular
container.
[0041] At the control circuit 104, the features are applied to the
mathematical model to produce a cutting pattern. The cutting
pattern specifies which of the one or more cutting tools is to be
used and the location of where cuts are to be made. The control
circuit 104 sends the cutting pattern to the container opening
machine 102. The container opening machine 102 is operated and the
container cut and opened by the container opening machine 102
according to the cutting pattern.
[0042] Referring now to FIG. 2, one example of an approach for
opening and removing the contents of containers is described. At
step 202, a scanning surface, a plurality of containers (that
arrive and are sequentially placed on the scanning surface), a
scanning device, a sensor and a database that stores a mathematical
model are provided. At step 204, a container opening machine that
includes at least one cutting tool is also provided. The cutting
tool is one or more of a saw blade or a laser. The cutting tool is
applied to each of the plurality of containers arriving on the
scanning surface to open the container.
[0043] At step 206 and at a control circuit, sensor data is
received from the sensor. The sensor data identifies the contents
of the container and/or uniquely identifies the container. At step
208 and at the control circuit, scanned images are received from
the scanning device. The scanned images are of the contents of the
interior of the container. In one example, the scanned images are
obtained using millimeter sensing technology.
[0044] At step 210 and at the control circuit, the sensor data and
the scanned images are analyzed to obtain features of the contents
of the container. Image processing techniques know to those skilled
in the art can be used to discern from the images features of the
container and/or items in the container. These features may include
one or more of: the dimensions of the contents, the spacing of the
contents, the shape of the contents, the size of the contents, the
number of contents in the container, the monetary value of the
contents, the orientation of the contents, the material from which
the container or contents is constructed, or other characteristics
of the contents and/or the container.
[0045] At step 212 and at the control circuit, the features are
applied to the mathematical model to produce a cutting pattern. In
one example, the model is a CNN model. In other examples, the model
is an algorithm implemented as computer code that is executed by a
control circuit. Other examples of models are possible. In aspects,
the cutting pattern specifies which of the one or more cutting
tools is to be used and the location of where cuts are to be made.
Other types of information and parameters can also be supplied by
the pattern.
[0046] At step 214, the control circuit sends or transmits the
cutting pattern to the container opening machine. The sending may
be accomplished across any wired and/or wireless communication
link.
[0047] At step 216, the container opening machine is operated and
the container cut and opened by the container opening machine
according to the cutting pattern.
[0048] Referring now to FIG. 3, one example of a decantation
process (how the contents are opened and removed from a container)
is described. It will be appreciated that the cut method is the
method used for cutting or opening as case such as annual, a
robotic arm with a blade, or a laser to mention a few examples. It
will be understood that the cut type is the type of cut applied to
the case such as a window-type cut (e.g., such as a window opening
on any structure for case replenishment, or a 4-sided cut). "Decant
method" refers to how the contents of the case are removed from the
case such as dumping. Further, it will be appreciated that the
terms "container" and "case" are used interchangeably herein. It
will be additionally be understood that the various ones of these
steps may be performed by a control circuit that is analyzing
images or processing other inputs. Furthermore, the contents of
cases may be disposed in product totes, which are containers that
can be used to store, transport, and/or display products to
customers in retail stores.
[0049] At step 302, the case or container is identified. In one
example, a label on the container is read and in another example,
an RFID tag is read. The information read may include information
that identifies the container (e.g., has a container number or
other identifier that uniquely identifies the container and other
information such as the contents of the container or the monetary
value of the contents).
[0050] At step 304, a computer vison scan of the case or container
is made. The scan obtains images (e.g., in visible light) that
shows damage to the case.
[0051] At step 306 and based, for example on the scan of step 304,
it is determined if the case is damaged. If the answer is
affirmative, execution continues at step 308 where the case is
physically routed and moved to a damage processing area, where, for
example, a determination can be made as to whether to dispose of
the case. Execution then ends.
[0052] If the answer at step 306 is negative, at step 310 a scanner
obtains images using millimeter sensing technology to scan through
the opaque walls of the container to identify, for example, the
shape, disposition, and other information regarding the contents of
the case or container.
[0053] At step 312 and based, for example on the scan of step 310,
it is determined if the contents of the case are damaged. If the
answer is affirmative, execution continues at step 308 as described
above. If the answer is negative, then execution continues with
step 314.
[0054] At step 314, it is determined if the case associated with a
new case identifier (a case not processed before). If the answer is
affirmative, execution continues at step 326. If the answer is
negative, execution continues at step 316.
[0055] At step 316, it is determined whether the contents appear to
be the same as they were at a previous time. If the answer is
negative, execution continues with step 326. If the answer is
affirmative, execution continues with step 318.
[0056] At step 318, it is determined whether the decant settings
(e.g., all inputs for decanting a case, for instance the type of
tote the contents were placed) appear to be the same as they were
at a previous time. If the answer is negative, execution continues
with step 326. If the answer is affirmative, execution continues
with step 320.
[0057] At step 320, it is determined whether the previous decant
(removal of the contents) at a previous time was successful. If the
answer is negative, execution continues with step 322. If the
answer is affirmative, execution continues with step 324.
[0058] At step 322, it is determined if the cause for the
unsuccessful decant was identified and the settings adjusted. If
the answer is negative, then execution continues at step 326. If
the answer is affirmative, then execution continues at step
324.
[0059] At step 324, the cutting of the container is made with the
previous settings. Execution continues at step 364.
[0060] At step 326, it is determined if the material of the case is
compatible with the tools used to remove or cut the case. If the
answer is negative, execution continues at step 328 and if the
answer is affirmative, execution continues with step 330.
[0061] At step 328, the case is routed to be manually cut and
decanted. Execution then ends.
[0062] At step 330, it is determined if the position of the
contents is compatible with the cutting tools, cutting pattern, or
other cutting parameter to be used. If the answer is negative,
then, step 328 is executed as described above. If the answer is
affirmative, step 332 is executed.
[0063] At step 332, it is determined if the case or its contents is
of high value (e.g., each of the contents or all of the contents
together have a monetary value above a threshold). If the answer is
affirmative, step 328 is executed as described above. If the answer
is negative, execution continues with step 334.
[0064] At step 334, it is determined if the case or contents have a
medium value (e.g., each of the contents or all of the contents
together have a monetary value between a first and a second
threshold). If the answer is affirmative, step 336 is executed. If
the answer is negative, execution continues with step 338.
[0065] At step 336, the cutting depth is reduced. At step 338, the
destination type is determined. The destination type specifies
whether the case is being replenished as a full case or whether the
contents are being removed to be placed in a tote. If the
destination is a tote, step 342 is executed. If the destination is
not a tote, but to simply use the case as a full case to display or
present the products, then step 340 is executed. At step 340, a
window cut (to show the products) is made to the container with a
blade. Execution then ends.
[0066] At step 342, a determination is made if the case or items in
the case are fragile. If the answer is affirmative, then execution
continues with step 350. If the answer is negative, execution
continues with step 344. This information can come from analyzing
container images, human input, or from label information from the
container.
[0067] At step 344, a determination is made as to whether the items
in the case need to be rearranged. If the answer is affirmative,
execution continues with step 350. If the answer is negative,
execution continues with step 346.
[0068] At step 346, a determination is made as to whether the items
in the case need to be reoriented. If the answer is affirmative,
execution continues with step 350. If the answer is negative,
execution continues with step 348.
[0069] At step 348, the contents of the case can dumped into a tote
(by a human or a robot) without a special procedure. Next, at step
352, a determination is made as to whether there is empty space in
the container for the cut path of a cutting tool. If the answer is
empty space exists at the top of the container (above), step 354 is
executed where a cut from above is selected; if the answer is there
is empty space at the bottom of the container, at step 356 a cut
from below is used is used. Execution continues at step 364.
[0070] At step 350, the contents of the case are dumped (by a human
or a robot) into a tote individually in a specified manner. At step
358, a determination is made as to whether there is empty space in
the container for the cut path of the cutting tool. If the answer
is negative, step 360 is executed where a default blade cut reduced
depth is used; if the answer is affirmative, at step 362 a
four-sided cut with a blade at a height within the empty space is
used. Execution continues at step 364.
[0071] At step 364, a millimeter wave scan is made of the case and
the contents is made. At step 366, it is determined if damage to
the case or contents exists. If the answer is negative, execution
continues with step 368. If the answer is affirmative, execution
continues with step 374.
[0072] At step 368, it is determined if the case is compatible with
dumping the contents (by a human or a robot) into a tote. If the
answer is affirmative, at step 370, the entire contents of the case
are dumped into the tote. If the answer is negative, at step 372,
the contents of the case are put (decanted) into the tote
individually, one-by-one.
[0073] At step 374, the case is routed to a damage processing area.
Next, at step 376, a determination is made if empty space exists in
the case. If the answer is negative, at step 378, the case is
flagged for manually decanting and execution ends.
[0074] If the answer is affirmative at step 376, at step 380 a
determination is made as to whether to cut along the empty space.
If the answer is affirmative, cut depth is reduced and execution
ends. If the answer is negative, the height of the cut is adjusted
and execution ends.
[0075] Referring now to FIG. 4, one example of determining a
cutting pattern is described. The example of FIG. 4 is, in aspects,
a model implemented as an algorithm (or a lookup table) but it will
be appreciated that it could also be implemented as a CNN
model.
[0076] At step 402, image analysis determines that a shape of an
item is a non-bottle shape 404 or a bottle shape 406. Image
analysis also indicates locations 408 and 410 of the items in a
container as being near the top of the container (labeled as 412
and 416) or distant from the top of the container (by a
predetermined distance and labeled as 414 and 418). Based upon the
item shape and location, specific cutting patterns (labeled as 420,
422, 424, and 426) are selected.
[0077] In one example, a non-bottle shape near the top selects
pattern 420 (pattern 1). In another example, a non-bottle shape
distant from the top selects pattern 422 (pattern 2). In yet
another example, bottle shape near the top selects pattern 424
(pattern 3). In still another example, a bottle shape distant from
the top selects pattern 426 (pattern 2). The patterns 1, 2, and 3
are unique combination of parameters that set the operation of the
container opening machine (e.g., the container opening machine 102)
as described elsewhere herein.
[0078] Referring now to FIG. 5, one example of mapping a pattern to
parameters on a container opening machine is described. A control
circuit 502 generates a cutting pattern 504. The cutting pattern
504 has first feature 506 (specifying the cutting tool or tools
used, e.g., a saw), a second feature 508 (specifying a cutting
depth); and a third feature 510 (specifying a cutting shape).
[0079] The features 506, 508, and 510 are mapped to container
opening machine 512. More specifically, the first feature 506 maps
to a first parameter 514; the second feature 508 maps to a second
parameter 516; and the third feature 510 maps to a third parameter
518. In examples, the parameters 514, 516, and 518 are implemented
as memory locations that have values that are set (and are changed
as the patterns change). In operation, the container opening
machine 512 utilizes these values to use, direct, and control a
cutting tool that opens a container.
[0080] In some embodiments, one or more of the exemplary
embodiments include one or more localized IoT devices and
controllers (e.g., included with or associated with the various
scanners, sensors, cameras, or robots described herein). In another
aspect, the sensors, cameras, or robots may be seen as an IoT
device. As a result, in an exemplary embodiment, the localized IoT
devices and controllers can perform most, if not all, of the
computational load and associated monitoring and then later
asynchronous uploading of data can be performed by a designated one
of the IoT devices to a remote server. In this manner, the
computational effort of the overall system may be reduced
significantly. For example, whenever localized monitoring allows
remote transmission, secondary utilization of controllers keeps
securing data for other IoT devices and permits periodic
asynchronous uploading of the summary data to the remote server. In
addition, in an exemplary embodiment, the periodic asynchronous
uploading of data may include a key kernel index summary of the
data as created under nominal conditions. In an exemplary
embodiment, the kernel encodes relatively recently acquired
intermittent data ("KRI"). As a result, in an exemplary embodiment,
KM includes a continuously utilized near term source of data, but
KM may be discarded depending upon the degree to which such KM has
any value based on local processing and evaluation of such KM. In
an exemplary embodiment, KRI may not even be utilized in any form
if it is determined that KM is transient and may be considered as
signal noise. Furthermore, in an exemplary embodiment, the kernel
rejects generic data ("KRG") by filtering incoming raw data using a
stochastic filter that provides a predictive model of one or more
future states of the system and can thereby filter out data that is
not consistent with the modeled future states which may, for
example, reflect generic background data. In an exemplary
embodiment, KRG incrementally sequences all future undefined cached
kernels of data in order to filter out data that may reflect
generic background data. In an exemplary embodiment, KRG
incrementally sequences all future undefined cached kernels having
encoded asynchronous data in order to filter out data that may
reflect generic background data. In a further exemplary embodiment,
the kernel will filter out noisy data ("KRN"). In an exemplary
embodiment, KRN, like KM, includes substantially a continuously
utilized near term source of data, but KRN may be retained in order
to provide a predictive model of noisy data. In an exemplary
embodiment, KRN and KRI, also incrementally sequences all future
undefined cached kernels having encoded asynchronous data in order
to filter out data that may reflect generic background data.
[0081] Those skilled in the art will recognize that a wide variety
of modifications, alterations, and combinations can be made with
respect to the above described embodiments without departing from
the scope of the invention, and that such modifications,
alterations, and combinations are to be viewed as being within the
ambit of the inventive concept.
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