WO2023201248A1

WO2023201248A1 - Systems, methods and apparatus for picking and sorting products

Info

Publication number: WO2023201248A1
Application number: PCT/US2023/065657
Authority: WO
Inventors: Éric BOUCHARD; Martin Morin; Joey FOURNIER
Original assignee: Premier Tech Prairie, Inc.
Priority date: 2022-04-13
Filing date: 2023-04-12
Publication date: 2023-10-19

Abstract

There is described a pick-and-sort tool for a robotic vacuum sorting system arranged to pick and sort units of product being conveyed in a conveying area. There is also described systems and methods that use the pick-and-sort tool. The pick-and-sort tool comprises a sorting hub including a plurality of outlet tubes each having an opening. The pick-and-sort tool also comprises a picking head having a suction nozzle configured to remove a unit of product form a conveying area and allow the removed unit of product to pass through the picking head to one of the plurality of outlet tube openings. The picking head and the sorting hub are movable relative to each other such that the suction nozzle can be selectively aligned with any of the plurality of outlet tube openings, resulting in a significant increase in pick-and-sort efficiency.

Description

SYSTEMS, METHODS AND APPARATUS FOR PICKING AND SORTING PRODUCTS

CROSS-REFERENCE TO RELATED APPLICATIONS

[0001] The present disclosure claims priority to U.S. Provisional Application number 63/330,440 filed on April 13, 2022, which is hereby incorporated by reference in its entirety.

FIELD

[0002] The present disclosure is directed towards the field of systems, methods, and apparatus for automated picking and sorting. In particular, the present disclosure is directed to systems, methods, and apparatus for vacuum picking and sorting of graded units of product.

INTRODUCTION

[0003] Food grading is the process by which comestibles, such as fruits, nuts and seeds, are inspected, assessed, and sorted based on quality, freshness, shape, size, colour and/or an extent of physical damage, for example. The industrialization of food grading has led to the development of machines, such as robotic sorting machine, that can perform simple food grading tasks, such as, for example, the removal of damaged units of product from a conveyor. More complex tasks however, such as, for example, the grading of units of product into three or more different categories (or “grades”), have typically been carried out by human food graders.

[0004] As the capabilities of digital imaging systems have increased, sorting systems have been developed that include imaging components capable of assessing such grades with greater speed and precision than human food graders. Such systems have however generally relied on robotic components designed to “pick-and-place” units of product based on assessed grades. Pick-and-place systems generally comprise robotically controlled tools capable of removing a unit of product from a conveyor (i.e., “picking”) and transporting the unit of product to one of a plurality of locations (i.e., “placing”) based on the grade associated to the unit of product by the imaging system. The locations to which the pick-and-place systems can bring units of product can include different receptacles, different conveyors, and the entrances to different tubes arranged to receive units of product and convey these to separate locations, such as containers or bins. [0005] One significant disadvantage with pick-and-place systems is the time required by the robotically controlled pick-and-place tool to travel from a “picking” location to a “placing” location, and then back to the next “picking” location. This disadvantage inherently limits the speed and efficiency of automated sorting systems and increases their complexity. There is therefore a clear need for improved systems, methods and apparatus for picking and sorting products.

SUMMARY

[0006] The following summary is intended to introduce the reader to the more detailed description that follows, and not to define or limit the claimed subject matter.

[0007] The present disclosure generally relates to an automated sorting system comprising a pick-and-sort tool capable of both picking a unit of product from a plurality of units of products on, for example, a conveyor, and sorting the unit of product into one of a plurality of separate physical locations.

[0008] The claimed subject matter provides the advantages of allowing users of the systems and methods described herein to avoid the need to travel to and from placing/sorting locations and to overlap the picking and sorting steps such that the sorting of a first unit of product can be performed by the tool whilst the tool is moved towards the picking location of a second subsequent unit of product that is to be picked and sorted. This significantly increases the efficiency of pick-and-sort methods and systems.

[0009] According to one aspect of the present disclosure, there is provided a robotic vacuum sorting system for picking and sorting units of product being conveyed in a conveying area. The robotic vacuum sorting system comprises an imaging device configured to generate image information relating to the units of product. The robotic vacuum sorting system also comprises a processor configured to use the image information to identify and locate the units of product in the conveying area and to assign one of a plurality of product categories to at least one of the units of product. The robotic vacuum sorting system also comprises a robotic sorting device comprising a pick-and-sort tool and one or more robotic arms configured to move the pick-and-sort tool over the conveying area. The pick-and-sort tool comprises a sorting hub including a plurality of outlet tubes. Each outlet tube is associated with one of the plurality of product categories and having an opening. Each opening is configured to receive a unit of product therethrough. The pick-and-sort tool also comprises a picking head having a suction nozzle. The suction nozzle is configured to remove a unit of product from the conveying area and allow the removed unit of product to pass through the picking head to one of the plurality of outlet tube openings. The picking head and the sorting hub are movable relative to each other such that the suction nozzle can be selectively aligned with any of the plurality of outlet tube openings. The processor is further configured to control the movement and action of the robotic sorting device to remove individual units of product from the conveying area and selectively convey each removed unit into the outlet tube associated with its assigned product category.

[0010] According to another aspect of the present disclosure, there is provided a computer-implemented method of controlling a robotic vacuum sorting system including a robotic sorting device. The robotic sorting device is operable to remove a unit of product from a conveying area and inject the unit of product into one of a plurality of outlet tubes extending from the robotic sorting device. The method comprises generating image information of the conveying area and identifying units of product in the conveying area using the image information. The method also comprises categorizing at least one of one or more of the units of product in the conveying area into one of a plurality of product categories, wherein each product category is associated with one of the plurality of outlet tubes. The method also comprises determining the position of the categorized units of product in the conveying area using the image information. The method also comprises moving the robotic sorting device to a location of a categorized unit of product. The method also comprises removing the categorized unit of product from the conveying area using the robotic sorting device. The method also comprises injecting the categorized unit of product into the outlet tube associated with the product category of the unit of product.

[0011] According to yet another aspect of the present disclosure, there is provided a pick-and-sort tool for a robotic vacuum sorting system arranged to pick and sort units of product being conveyed in a conveying area. The pick-and-sort tool comprises a sorting hub including a plurality of outlet tubes each having an opening, each opening being configured to receive a unit of product therethrough. The pick-and-sort tool also comprises a picking head having a suction nozzle. The suction nozzle is configured to remove a unit of product form a conveying area and allow the removed unit of product to pass through the picking head to one of the plurality of outlet tube openings. The picking head and the sorting hub are movable relative to each other such that the suction nozzle can be selectively aligned with any of the plurality of outlet tube openings.

DRAWINGS

[0012] In order that the claimed subject matter may be more fully understood, reference will be made to the accompanying drawings, in which:

[0013] FIG. 1 is a perspective view of a robotic vacuum sorting system in accordance with embodiments of the present disclosure;

[0014] FIG. 2 is a front view of a portion of a robotic sorting device in accordance with embodiments of the present disclosure;

[0015] FIG. 3 is a perspective view of a pick-and-sort tool in accordance with embodiments of the present disclosure;

[0016] FIG. 4 is a side view of a pick-and-sort tool in accordance with embodiments of the present disclosure;

[0017] FIGs. 5A to 5C is a series of front views showing various relative positions of the sorting hub and picking head of a pick-and-sort tool in accordance with embodiments of the present disclosure;

[0018] FIGs. 6A and 6B is a series of front views showing first and second positions of the gate of a pick-and-sort tool in accordance with embodiments of the present disclosure;

[0019] FIGs. 7A and 7B is a series of perspective views showing first and second positions of the gate of a pick-and-sort tool in accordance with embodiments of the present disclosure;

[0020] FIG. 8 is a rear view showing a gate of a pick-and-sort tool in a second position in accordance with embodiments of the present disclosure;

[0021 ] FIG. 9 is a front view showing a sorting hub and picking head of a pick-and-sort tool in accordance with alternate embodiments of the present disclosure;

[0022] FIG. 10 is a front view showing a sorting hub and picking head of a pick-and- sort tool in accordance with other alternate embodiments of the present disclosure; [0023] FIG. 11 is a schematic diagram of a system in accordance with embodiments of the present disclosure;

[0024] FIG. 12 is a top view of a conveying area in accordance with embodiments of the present disclosure; and

[0025] FIG. 13 is a flow chart representing steps of a method in accordance with embodiments of the present disclosure.

DESCRIPTION OF VARIOUS EMBODIMENTS

[0026] It will be appreciated that, for simplicity and clarity of illustration, where considered appropriate, reference numerals may be repeated among the figures to indicate corresponding or analogous elements or steps.

[0027] Numerous specific details are set forth in order to provide a thorough understanding of the exemplary embodiments of the subject matter described herein. It will however be understood by those of ordinary skill in the art that the embodiments described herein may be practiced without these specific details. In other instances, well-known methods, procedures, and components have not been described in detail so as not to obscure the present subject matter. Furthermore, this description is not to be considered as limiting the scope of the subject matter in any way but rather as illustrating the various embodiments.

[0028] As used herein, “product” means any article or discrete portion of substance that is manufactured, refined for sale, or otherwise processed, including, but not limited to foods, pharmaceuticals, electronics, waste materials, recyclable materials, hardware components, or any other raw materials, intermediate goods or consumer goods (or components thereof). Non-limiting examples of product include, nuts, fruit, vegetables, peanuts, pills (tablets or caplets), candy, seeds, screws, bolts, nails, mixed recyclable materials, paper clips, and semi-conductor components.

[0029] As used herein, “unit of product” means a discrete article, a discrete portion of an article or a discrete portion of substance that is manufactured or refined for sale, including, but not limited to foods, pharmaceuticals, electronics, hardware components, and other relatively small consumer goods or components thereof. Non-limiting examples of product include, nuts, fruits, fruits, pills (tablets or caplets), candies, seeds, screws, bolts, ails, paper clips, and semi-conductor components, or discrete portions thereof.

[0030] As used herein, “images” and “image information” means information capable of being interpreted by a computing device to represent an artifact or series of artifacts depicting one or more physical states of a scene including, but not limited to, images, videos, image files, video files, image data, video data, data output from a laser scanner or other scanner, and raw video feed data.

[0031] FIG. 1 is a perspective view of a robotic vacuum sorting system 100 in accordance with embodiments of the present disclosure. The system 100 can be used for picking and sorting units of product from a conveying area 101 of a conveyor 102. The conveyor 102 may receive units of a product from a loading end 103 and convey the units of product towards a discharging end 104. In some embodiments, the conveying area can be the surface of a conveyor belt (as shown in FIG. 1 ). A conveyor belt can be a flat bed belt, a modular belt, a cleated belt, a curved belt, an incline/decline belt, or any other type of belt suitable for conveying units of product as described herein. As will be appreciated by the skilled reader, the conveyor belt of FIG. 1 is used for illustrative purposes only and the systems, methods and apparatus disclosed herein are not limited to being used with any such conveyor belt, nor with any mechanically, hydraulically, pneumatically or electrically driven conveyor. As used herein, the term conveyor includes any arrangement in which items are conveyed through a conveying area. For example, the conveying area 101 can be provided by a roller conveyor, a vibration conveyor, an inclined surface on which units of product are conveyed by gravity, a channel through which fluid is passed such that units of product are carried along the conveying area by the flowing fluid.

[0032] The system comprises an imaging device 105. The imaging device 105 is configured to capture images of a portion of conveying area 101 in order to determine product grading information relating to one or more physical, chemical, and/or biological characteristic of units of product traveling through the conveying area 101 , as described in more detail elsewhere herein. In some embodiments, the imaging device 105 is also configured to determine positional information relating to the location of the units of product traveling through the conveying area 101. Position information may then be used by the system to pick and sort units of product from the belt 101 , as is described in more detail elsewhere herein. In some embodiments, the position information can be acquired along substantially the entirety of the conveying area 101 (i.e., direct tracking). In other embodiments, the position information can be acquired along an initial section of the conveying area 101 and the speed of the units of product can be used to infer the position of the units of product in subsequent sections of the conveying area 101 (i.e., inference tracking).

[0033] In some embodiments, the imaging device 105 can be a machine vision camera, such as multispectral imaging camera, configured to generate image information of a two-dimensional portion of belt 101 proximate the loading end 103. A non-limiting example of a multispectral imaging camera is an FD-1665 Multispectral Camera System marketed by Ocean Insight™. In some embodiments, the imaging device 105 can be a line scanner configured to generate a line scan of the width of belt 101 proximate the loading end 103. A non-limiting example of a line scanner is a Linea SWIR line scan camera marketed by Teledyne DALSA™. As will be appreciated by the skilled reader, other imaging devices made be suitable for implemented the systems and performing the methods disclosed herein. In some embodiments, the system 100 may comprise a light 112 suitable for illuminating the portion of conveying area 101 that is imaged by the imaging device 105. In some embodiments, the light 112 can be specialized light such as, for example, a light having a spectrum selected to be detected by the imaging device 105 in order to determine product grading information relating to one or more physical, chemical and/or biological characteristic of units of product. For example, in some embodiments, imaging device 105 may comprise a hyperspectral imaging device and light 112 may comprise a radiation source configured to cooperate with the hyperspectral imaging device in order to allow the detection of defects, foreign materials, and/or any other physical, chemical and/or biological characteristics of units of product.

[0034] As will be appreciated by the skilled reader, while detection of the one or more physical, chemical, and/or biological characteristic of units of product can be carried out with a combination of an imaging device and source of light, any other suitable combination of emitter and detector may be used, including, but not limited to, electro-magnetic-based emitters and detectors (e.g., x-ray), sound-based emitters and detectors (e.g., ultrasound) and electricity-based emitters and detectors (e.g., capacitive sensing).

[0035] The system 100 comprises a robotic sorting device 106 configured to move a pick-and-sort tool 107A across a two-dimensional area of conveying area 101 (shown as the x-y plane of FIG. 1 ), as well as towards and away from conveying area 101 (shown as the z- axis in FIG. 1 ). The robotic sorting device, as well as imaging device 105, may be supported by a frame (not shown) above conveying area 101. The robotic sorting device 106 includes a main body 109 and one or more robotic arms 108, 109, 110 configured to move pick-and- sort tool 107A across the x-y plane and along the z-axis defined in FIG. 1. In the example shown in FIG. 1 , the robotic sorting device 106 comprises robotic arms 108, 109, 110 each being independently controlled by servomotors located in main body 109.

[0036] In some embodiments, the pick-and-sort tool 107A comprises a telescopically extending arm (not shown) which allows movement of the pick-and-sort tool 107A along the z-axis. In some embodiments, movement of the pick-and-sort tool 107A along the z-axis is provided by movement of robotic arms 108, 109, 110 only. In other embodiments, movement of the pick-and-sort tool 107A along the z-axis is provided by a combination of a telescopically extending arm of the pick-and-sort tool 107A and movement of robotic arms 108, 109, 110.

[0037] In some embodiments, the robotic sorting device 106 is a delta robot fitted with a pick-and-sort tool 107A. An example delta robot is one of the M-3IA series of delta robots, marketed by FANUC® America Corporation™. As will be appreciated by the skilled reader however, any other suitable robot may be used for moving the pick-and-sort tool 207 described herein along the x, y, and z axes. As will also be appreciated by the skilled reader, robotic sorting device 106 can comprise any number of robotic arms, servomotors, pneumatic or other types of actuators suitable for moving the pick-and-sort tool 107A across the x-y plane and along the z-axis defined in FIG. 1 so as to pick units of product off of a portion of conveying area 101 , and as described in greater detail elsewhere herein.

[0038] FIG. 2 is a front view of a portion of robotic sorting device 106 in accordance with embodiments of the present disclosure.107A. Pick-and-sort tool 107A comprises a sorting hub 207 and a picking head 209, 210. In the embodiment shown in FIG. 2, the picking head 209, 210 comprises movable gate 209. Sorting hub 207 comprises a plurality of outlet tubes 200, 201 , 202 each of which is associated with a respective opening 203, 204, 205. In some embodiments, the openings 203, 204, 205 form part of a sorting plate 206, which is arranged to be fixedly attached to outlet tubes 200, 201 , 202. In other embodiments, however, openings 203, 204, 205 may simply be the ends of outlet tubes 200, 201 , 202 and be physically separate. Each outlet tube 200, 201 , 202 and opening 203, 204, 205 is large enough to allow a unit of product to freely travel therethrough, and small enough to maintain suction through the outlet tubes 200, 201 , 202 in cooperation with a local or remote vacuum source, as is described in more detail elsewhere herein. Each of outlet tube 200, 201 , 202 may be associated with a grade or category of product such that pick-and-sort tool 107A is operable to convey units of product from the surface of conveying area 101 to one of outlet tubes 200, 201 , 202 in order to separate product into grades or categories.

[0039] Pick-and-sort tool 107A comprises a picking head 209, 210 comprising a suction nozzle 210. In some embodiments, the suction nozzle 210 forms part of the gate 209 and is configured to focus the suction created by the vacuum source to a point small enough to lift a unit of product out of the conveying area 101 when the suction nozzle 210 is positioned close enough to the unit of the product that is to be removed. In some embodiments, the suction nozzle 210 is surrounded by a circular flange 211 designed to help create a vacuum seal between the unit of product and the suction nozzle 210. In some embodiments, the circular flange 211 may be made of the same material as gate 209. In some embodiments, the gate 209 may be made of steel. In other embodiments, the circular flange 211 can be made of a flexible and resilient material such as, but not limited to, silicon. The circular flange 211 is configured to partially wrap around the unit of product to create a seal even when the suction nozzle 210 is not centered and/or perpendicular to the top surface of the unit of product

[0040] In some embodiments, a local vacuum source 208 can be used to generate the vacuum that produces the suction via the suction nozzle 210. The local vacuum source 208 can be located between the picking head 209, 210 and the sorting hub 207 such that the suction nozzle 210 creates suction strong enough to retain a unit of product when gate 209 is in a first position and to convey a unit of product into one of the openings 203, 204, 205 of a respective outlet tube 200, 201 , 202 when gate 209 is in a second position, as will be described in more detail elsewhere herein. In some embodiments, the local vacuum source 208 may be an inline vacuum conveyor such as, for example, a LineVac™ conveyor marketed by Exair Corporation™. As will be appreciated by the skilled reader however, any other suitable device may be used to implement local vacuum source 208.

[0041] In other embodiments, a remote vacuum source (not shown) can be used to generate the vacuum that produces the suction via the suction nozzle 210. The remote vacuum source can be located at a distal end of each of outlet tubes 200, 201 , 202 and the sorting hub 207 and picking head 209, 210 can be positioned close enough to each other such that the suction nozzle 210 creates suction strong enough to retain a unit of product when gate 209 is in a first position and to convey a unit of product into one of the openings 203, 204, 205 of a respective outlet tube 200, 201 , 202 when gate 209 is in a second position, as will be described in more detail elsewhere herein. In some embodiments, the remote vacuum source may form part of a vacuum conveyor system. In some embodiments, the vacuum conveyor system may be a compressed air vacuum conveyor system. As will be appreciated by the skilled reader, however, any other suitable device may be used to implement a remote vacuum source. In yet other embodiments, a local vacuum source 208 located between the picking head 209, 210 and the sorting hub 207 can be used together with a remote vacuum source located at a proximate end of each of outlet tubes 200, 201 , 202.

[0042] FIG. 3 is a perspective view of pick-and-sort tool 107A in accordance with embodiments of the present disclosure, and FIG. 4 is a side view of pick-and-sort tool 107A in accordance with embodiments of the present disclosure. As can be seen from FIGs. 3 and 4, picking head 209, 210 is rotatably attached to sorting hub 207 at attachment point 400. As such, picking head 209, 210 may rotate around axis A shown in FIG. 4. In the embodiments shown in FIG. 3 and FIG. 4, the local vacuum source 208 is also fixed to picking head 209, 210 . As such, local vacuum source 208 also may rotate together with picking head 209, 210 such that picking head 209, 210 is always generally aligned with suction nozzle 210. In the embodiments shown in FIG 4, suction nozzle 210 is defined by an aperture formed between a first portion 209i and a second portion 2092 of gate 209.

[0043] Picking head 209, 210 and the sorting hub 207 are movable relative to each other such that the suction nozzle 210 can be selectively aligned with any of the plurality of openings 203, 204, 205 of outlet tubes 200, 201 , 202. In the embodiments shown in FIG. 3, openings 203, 204, 205 are axially disposed around axis A at a radius that generally coincides with the distance of the center suction nozzle 210 and/or the center of local vacuum source 208 from axis A, such that, as gate 209 is rotated around axis A, suction nozzle 210 and/or the center of local vacuum source 208 can be similarly aligned with one of openings

203, 204, 205 of outlet tubes 200, 201 , 202. This alignment generally allows the suction created by local vacuum source 208 and/or the remote vacuum source to convey units of product from the suction nozzle 210 up and into outlet tubes 200, 201 , 202.

[0044] As will be appreciated by the skilled reader, other arrangements may be possible for providing alignment between the suction nozzle 210 of picking head 209, 210 and the openings 203, 204, 205 of outlet tubes 200, 201 , 202. For example, openings 203,

204, 205 of outlet tubes 200, 201 , 202 may be arranged along a single axis in the x-y plane of FIGs. 3 and 4, and the gate 209 may be movable along the axis using a linear actuator. Non-limiting examples of such actuators include servomotors and linear air cylinders.

[0045] The distal ends of outlet tubes 200, 201 , 202 can, for example, communicate with receptacles, each of which being provided to receive and cumulate units of product of various grades or categories. It will however be appreciated by the skilled reader that the distal ends of outlet tubes 200, 201 , 202 can instead be located in any suitable location without departing from the scope of the present disclosure. Moreover, as will also be appreciated by the skilled reader, other embodiments may comprise any number of openings and outlet tubes. For example, some embodiments may comprise two openings connected to two outlet tubes, whereas other embodiments may comprise 10 or more openings connected to an equal number of outlet tubes.

[0046] With reference to FIGs. 5A to 5C, an example of relative movement between the sorting hub 207 and picking head 209, 210 in accordance with an embodiment of the present disclosure will now be described. FIGs. 5A to 5C is a series of front views showing various relative positions of sorting hub 207 and picking head 209, 210 of a pick-and-sort tool 107A in accordance with embodiments of the present disclosure. FIG. 5A shows a configuration in which picking head 209, 210 has been rotated to a first position under opening 203 of outlet tube 200. In this first position, when gate 209 of picking head 209, 210 is moved from a first position to a second position (as described elsewhere herein), any unit of product being retained at gate 209 can be conveyed through opening 203 and into outlet tube 200 by way of the suction created by local vacuum source 208 and/or the remote vacuum source. Pick-and-sort tool 107A is thereby operable to selectively sort some units of product into a grade or category of product associated with outlet tube 200. FIG. 5B shows a configuration in which picking head 209, 210 has been rotated to a second position under opening 204 of outlet tube 201 . In this second position, when gate 209 of picking head 209, 210 is moved from a first position to a second position (as also described elsewhere herein), any unit of product being retained at gate 209 can be conveyed through opening 204 and into outlet tube 201 by way of the suction created by local vacuum source 208 and/or the remote vacuum source. Pick-and-sort tool 107A is thereby also operable to selectively sort some units of product into a grade or category of product associated with outlet tube 201. FIG. 5C shows a configuration in which picking head 209, 210 has been rotated to a third position under opening 205 of outlet tube 202. In this third position, when gate 209 of picking head 209, 210 is moved from a first position to a second position (as also described elsewhere herein), any unit of product being retained at gate 209 can be conveyed through opening 205 and into outlet tube 202 by way of the suction created by local vacuum source 208 and/or the remote vacuum source. Pick-and-sort tool 107A is thereby also operable to selectively sort some units of product into a grade or category of product associated with outlet tube 202. In various embodiments, movement of picking head 209, 210 with respect to the sorting hub 207 can be provided by servomotors, pneumatic actuators and/or any other suitable actuator.

[0047] With reference to FIGs. 6A, 6B, 7A, 7B, and 8, operation of the gate 209 will now further be described. FIGs. 6A and 6B is a series of front views showing first and second positions of gate 209 of pick-and-sort tool 107A in accordance with embodiments of the present disclosure. FIGs. 7A and 7B is a series of perspective views showing first and second positions of gate 209 of pick-and-sort tool 107A in accordance with embodiments of the present disclosure. FIG. 8 is a rear view showing gate 209 of pick-and-sort tool 107A in the second position in accordance with embodiments of the present disclosure.

[0048] FIGs. 6A show gate 209 in a “pick” position beneath outlet tube 200 and FIG. 7B show gate 209 in a “pick” position below outlet tube 202. In each case, first portion 209i and second portion 2092 of gate 209 are adjoining. Moreover, when in the pick position, the adjoining sides of first portion 209i and second portion 2092 of gate 209 defined a generally circular aperture. The generally circular aperture, when in the pick position, is small enough to prevent a unit of product from passing through gate 209, thereby retaining the unit of product at gate 209. When gate 209 is in the pick position, it is operable to use the circular aperture to lift units of product form the surface of conveying area 101 by bringing the circular aperture close enough to a unit of product for the unit of product to be retained at the mouth of the circular aperture of gate 209 by way of the vacuum suction created by local vacuum source 208 and/or the remote vacuum source. In other embodiments, the aperture in gate 209 can be of any other shape or size suitable for creating sufficient suction to pick a unit of product from the surface of conveying area 101 .

[0049] FIG. 6B shows gate 209 in a “sort” position beneath outlet tube 200 and FIG. 7A shows gate 209 in a “sort” position beneath outlet tube 202. FIG. 8 is a rear view of the position shown in FIG. 6B. In the sort position, first portion 209i and second portion 2092 of gate 209 are remote from each other. When in the sort position, the adjoining sides of first portion 209i and second portion 2092 of gate 209 defined an aperture large enough to allow a unit of product to pass therethrough, thereby allowing pick-and-sort tool 107A to convey the unit of product up and into outlet tubes 200, 201 , 202 by way of the vacuum suction created by local vacuum source 208 and/or the remote vacuum source. In other embodiments, the aperture can be of any other shape or size suitable for allowing a picked unit of product to be conveyed up and into outlet tubes 200, 201 , 202.

[0050] FIG. 8 shows a rear view of the position shown in FIG. 7A. As can be seen from FIG. 8, side arms 801 and 802, which support first portion 209i and second portion 2092 of gate 209, respectively, can be displaced laterally away from each other in order to move from the pick position to the sort position. In various embodiments, movement of side arms can be provided by linear servomotors, pneumatic actuators and/or any other suitable actuator.

[0051] As will be appreciated by the skilled reader, in other embodiments, expansion of the gate 209 aperture from a “pick” position to a “sort” position can be provided in any other suitable way including, but not limited to, gates having one, two, three or more movable pieces or iris diaphragms. [0052] FIG. 9 is a front view showing a sorting hub 207 and picking head 208, 210 of a pick-and-sort tool 107B in accordance with alternate embodiments of the present disclosure. In the embodiments shown in FIG. 9, the picking head 208, 210 includes a local vacuum source 208, as those described in more detail elsewhere herein, as well as a suction nozzle 210 formed by the lower portion 208i of local vacuum source 208.

[0053] In use, picking head 208, 210 can be moved to any one of a position in which suction nozzle 210 is aligned with opening 203, a position in which suction nozzle 210 is aligned with opening 204, or a position in which suction nozzle 210 is aligned with opening 205. This alignment generally allows the suction created by local vacuum source 208 and/or a remote vacuum source to convey units of product from the suction nozzle 210 up and into outlet tubes 200, 201 , 202, as described in more detail elsewhere herein. As such, pick-and- sort tool 900 is operable to selectively sort units of product into a grade or category of product associated with any one of tubes 200, 201 , 202. In various embodiments, movement of picking head 208, 210 with respect to the sorting hub 207 can be provided by servomotors, pneumatic actuators and/or any other suitable actuator.

FIG. 10 is a front view showing a sorting hub 207 and picking head 500, 210 of a pick-and- sort tool 107C in accordance with other alternate embodiments of the present disclosure. In the embodiments shown in FIG. 10, the picking head 500, 210 includes a picking tube 500, as well as a suction nozzle 210 formed by the lower portion of picking tube 500.

[0054] In use, picking head 500, 210 can be moved to any one of a position in which suction nozzle 210 is aligned with opening 203, a position in which suction nozzle 210 is aligned with opening 204, or a position in which suction nozzle 210 is aligned with opening 205. This alignment generally allows the suction created by a remote vacuum source to convey units of product from the suction nozzle 210 up and into outlet tubes 200, 201 , 202, as described in more detail elsewhere herein. As such, pick-and-sort tool 107C is operable to selectively sort units of product into a grade or category of product associated with any one of tubes 200, 201 , 202. In various embodiments, movement of picking head 500, 210 with respect to the sorting hub 207 can be provided by servomotors, pneumatic actuators and/or any other suitable actuator. [0055] As will be appreciated by the skilled reader, because pick-and-sort tools 107B and 107C do not comprise a gate 209, in both sets of embodiments, suction nozzle 210 should be sized and shaped in such a way as to be operable to remove units of product from the conveying area 101 by bringing suction nozzle 210 close enough to a unit of product. Moreover, suction nozzle 210 should also be sized and shaped in such a way as to be operable to remove units of product from the conveying area 101 without removing units of product which may be located proximate the unit of product that is to be removed in the conveying area 101 .

[0056] FIG. 11 is a schematic diagram showing a control system for controlling robotic vacuum sorting system 100 described herein, in accordance with various methods 800 also described herein. As such, the control system can be configured to control one or more robotic sorting devices 106 and one or more imaging device 105 to carry out any of the movement, operations and/or methods described herein.

[0057] The control system may include a processor 600, memory 601 including one or more data storage devices 602. Processor 600 may comprise one or more processors for performing processing operations that implement functionality of the various methods described herein with reference to FIGs. 12 and 13, for example. Processor 600 may be a general-purpose processor executing program code stored in memory 601 to which is has access. Alternatively, a processor of the processors 600 may be a specific-purpose processor comprising one or more preprogrammed hardware or firmware elements (e.g., application-specific integrated circuits (ASICs), electrically erasable programmable read-only memories (EEPROMs), etc.) or other related elements.

[0058] Memory 600 comprises one or more storage devices 602 for storing program code executed by processor 600 and data used during operation of robotic vacuum sorting system 100. Memory 600 may be a semiconductor medium (including, e.g., a solid-state memory), a magnetic storage medium, an optical storage medium, and/or any other suitable type of memory. A storage device 602 of memory 600 may be read-only memory (ROM) and/or random-access memory (RAM), for example.

[0059] In some embodiments, two or more elements of processor 600 may be implemented by devices that are physically distinct from one another and may be connected to one another via data-communication bus 603. As will be appreciated by the skilled reader, the hardware components of the control system may be implemented in any suitable way in order to implement the methods disclosed herein.

[0060] In some embodiments, the control system can include a communication module 604 configured to communicate with ancillary components, such as communication device 605 and/or conveyor 102, in order to control communication device 605 and/or conveyor 102 and/or to received/send information thereto/therefrom .

[0061] The control system may also be configured to interface and be controlled by communication device 605, which may be configured to implement a User Interface (Ul) 606 for allowing users to monitor and control the robotic vacuum sorting system 100, as well as to interact with the control system in accordance with some methods described herein. For example, in some embodiments, the communication device 605 may communicate user defined instructions to the control system. In some embodiments, the communication device 605 might be a wired control panel. In other embodiments, the communication device 605 may be a smartphone, tablet, head-mounted display, or other communication device which is carried or worn by the user/operator of robotic vacuum sorting system 100.

[0062] It should be noted that the pick-and-sort tools 107A, 107B, 107C described herein are not limited to being used with system 100. For example, pick-and-sort tools 107A, 107B, 107C could be used in a system in which no imaging information and/or no position information is collected or required in order to pick and sort units of product. For example, pick-and-sort tools 107A, 107B, 107C could be used in a system in which a pick-and-sort tool remains stationary in the x-y plane, as defined elsewhere herein. In such a system, units of product can be sequentially positioned below pick-and-sort tool 107A, 107B, 107C and the tool can be operated to pick and sort units of product without the need for the system to track the position of the units of product.

[0063] FIG. 12 is a top view of a conveyor area in accordance with embodiments of the present disclosure. Conveyor 102 is operable to receive units of a product from a loading end 103 and convey the units of product 700, 701 , 702 towards discharging end 104 along direction D, as defined in FIG. 12. Units of product 700, 701 , 702 are supported by belt, which can be a flat bed belt, a modular belt, a cleated belt, a curved belt, an incline/decline belt, or any other type of belt suitable for conveying units of product 700, 701 , 702 from loading end 103 towards discharging end 104 without obstructing units of product 700, 701 , 702 from imaging device 105. As described in more detailed elsewhere herein, the conveying area 101 may convey units of product in any other suitable way.

[0064] In order to categorize the units of product traveling through the conveying area 101 , imaging device 105 is configured to image an imaging zone 703 of belt 101. As such, imaging device is configured to identify and determine the location of each unit of product which passes through the imaging zone 703. Grading (or categorizing) of product, such as nuts, for example, requires the separation of the units of product into categories on the basis of one or more measurable physical properties. Accordingly, the speed with which the control system of FIG. 11 will be able to run conveyor 102 will depend on the size of the imaging zone 703, as well as the time required by processor 600 to measure the physical, chemical and/or biological property of each of the units of product loaded onto the conveyor 102. In the example shown in FIG. 12, some partial units 701 represent broken or otherwise damaged unis of product. Full units of product 700 represent units of product that have not been damaged. Discolored units of product 702 represent units of product that are considered suboptimal because of discoloration. Small units of product 705 represent units of product that are considered suboptimal because they are smaller than a predetermined size.

[0065] FIG. 13 is a flow chart representing steps of a method 800 in accordance with embodiments of the present disclosure. In particular, FIG. 13 is a flow chart representing steps of a method 800 for picking-and-sorting the units of product shown in FIG. 12. At step 801 , imaging device 105 generates image information of the conveying area 101. In some embodiments, the imaging device 105 is configured to generate image information of an imaging zone 703 only. In other embodiments, imaging device 105 is configured to generate image information of the entire conveying area 101. The image information may include information capable of being analyzed by processor 600 to determine measurable physical properties of each unit of product being conveyed in the conveying area 101. At step 802, the processor uses the image information to identify units of product in the conveying area 101. Such identification can be performed using any known methods, including, but not limited to, artificial intelligence, computer vision, or combinations thereof. [0066] Then, at step 803, each identified unit of product is categorized based on measurable physical, chemical and/or biological characteristics. In the example shown in FIG. 12, partial units 701 can be characterized as broken based on their shape and size, and subsequently conveyed by the robotic vacuum sorting system 100 to outlet tube 200, for example. Discolored units of product 702 can be characterized as discolored based on their color, and subsequently conveyed by the robotic vacuum sorting system 100 to outlet tube 201 , for example. Small units of product 705 can be characterized as too small based on their size, and subsequently conveyed by the robotic vacuum sorting system 100 to outlet tube 202, for example. Finally, full units of product 700 can be carried by conveyor 102 to discharging end 104 for further processing. As will be appreciated, steps 801 , 802 and 803 can be carried out continuously, as shown in FIG. 11 .

[0067] As step 804, once the processor 600 has categorized the units of product into different categories, the processor 600 can use the imaging information and the speed of the conveyor to determine the locations over time of any units of product that require sorting. At step 805, the robotic sorting device 106 is moved to a location in the x-y plane of a first unit of product that is to be picked. Then, at step 806, the robotic sorting device 106, lowers pick- and-sort tool 107A along the z axis and picks the first unit of product. As will be appreciated, the steps 804, 805 and 806 are performed while conveyor 102 is in operation. As such, processor 600 and robotic sorting device 106 are operable to track locations in real-time in order to carry out the pick-and-sort operations described herein.

[0068] At step 808, processor 600 chooses the next unit of product that is to be picked and then the robotic sorting device 106 is moved to a location in the x-y plane of a next unit of product that is to be picked at step 805. At step 807, the robotic vacuum sorting system 100 can sort the units of product as described elsewhere herein in more detail. In some embodiments, at step 807, the robotic vacuum sorting system 100 can sort the first unit of product that is to be picked before carrying out step 808 and step 805 in relation to a subsequent unit of product. In other embodiments, at step 807, the robotic vacuum sorting system 100 sorts the first unit of product that is to be picked while carrying out step 808 and step 805 in relation to a subsequent unit of product. This ability to perform overlapping picking and sorting operations provide significant advantages over prior art systems. [0069] A person of skill in the art will readily recognize that steps of various abovedescribed methods can be performed by programmed computers. Herein, some embodiments are also intended to cover program storage devices, e.g., digital data storage media, which are machine or computer readable and encode machine-executable or computer-executable programs of instructions, wherein said instructions perform some or all of the steps of said above-described methods. The program storage devices may be, e.g., digital memories, magnetic storage media such as a magnetic disks and magnetic tapes, hard drives, or optically readable digital data storage media. The embodiments are also intended to cover computers programmed to perform said steps of the above-described methods.

[0070] The description and drawings merely illustrate the principles of the invention. It will thus be appreciated that those skilled in the art will be able to devise various arrangements that, although not explicitly described or shown herein, embody the principles of the invention and are included within the scope of the appended claims. Furthermore, all examples recited herein are principally intended expressly to be only for pedagogical purposes to aid the reader in understanding the principles of the invention and the concepts contributed by the inventors to furthering the art and are to be construed as being without limitation to such specifically recited examples and conditions. For example, a person skilled in the art will readily understand that the various structural features described herein and shown in the figures are susceptible to modification without departing from the scope of the invention as defined in the claims appended hereto. Moreover, all statements herein reciting principles, aspects, and embodiments of the invention, as well as specific examples thereof, are intended to encompass equivalents thereof.

[0071 ] The functions of the various elements shown in the Figures, including functional blocks labelled as “processor”, may be provided through the use of dedicated hardware as well as hardware capable of executing software in association with appropriate software. When provided by a processor, the functions may be provided by a single dedicated processor, by a single shared processor, or by a plurality of individual processors, some of which may be shared. Moreover, explicit use of the term “processor” should not be construed to refer exclusively to hardware capable of executing software, and may implicitly include, without limitation, digital signal processor (DSP) hardware, network processor, application specific integrated circuit (ASIC), field programmable gate array (FPGA), read only memory (ROM) for storing software, random access memory (RAM), and non-volatile storage. Other hardware, conventional and/or custom, may also be included.

[0072] It should be appreciated by those skilled in the art that any block diagrams herein represent conceptual views of illustrative circuitry embodying the principles of the invention. Similarly, it will be appreciated that any flow charts, flow diagrams, state transition diagrams, pseudo code, and the like represent various processes which may be substantially represented in computer readable medium and so executed by a computer or processor, whether or not such computer or processor is explicitly shown.

Claims

CLAIMS:

1. A robotic vacuum sorting system for picking and sorting units of product being conveyed in a conveying area, the robotic vacuum sorting system comprising: an imaging device configured to generate image information relating to the units of product; a processor configured to use the image information to identify and locate the units of product in the conveying area and to assign one of a plurality of product categories to at least one of the units of product; and a robotic sorting device comprising a pick-and-sort tool and one or more robotic arms configured to move the pick-and-sort tool over the conveying area, wherein the pick-and-sort tool comprises: a sorting hub including a plurality of outlet tubes each being associated with one of the plurality of product categories and having an opening, each opening being configured to receive a unit of product therethrough; and a picking head having a suction nozzle, the suction nozzle being configured to remove a unit of product from the conveying area and allow the removed unit of product to pass through the picking head to one of the plurality of outlet tube openings, wherein the picking head and the sorting hub are movable relative to each other such that the suction nozzle can be selectively aligned with any of the plurality of outlet tube openings, and wherein the processor is further configured to control the movement and action of the robotic sorting device to remove individual units of product from the conveying area and selectively convey each removed unit into the outlet tube associated with its assigned product category.

2. The robotic vacuum sorting system of claim 1 , wherein the pick-and-sort tool comprises a local vacuum generator located between the picking head and the sorting hub and wherein the local vacuum generator is configured to generate vacuum suction suitable to remove a unit of product from the conveying area and to inject the unit of product into one of the plurality of outlet tubes.

3. The robotic vacuum sorting system of any one of claims 1 or 2, wherein the local vacuum generator is an inline vacuum generator located between the suction nozzle and the sorting hub.

4. The robotic vacuum sorting system of claim 3, wherein the suction nozzle forms part of the local vacuum generator.

5. The robotic vacuum sorting system of any one of claims 1 to 4, wherein the openings of the plurality of outlet tubes are located at proximal ends of the outlet tubes and the system further comprises one or more remote vacuum generators located at one or more distal ends of the outlet tubes, and wherein each remote vacuum generator is configured to generate vacuum suction in an outlet tube.

6. The robotic vacuum sorting system of any of claims 1 to 5, wherein the picking head comprises a gate being movable from a first position configured to allow a unit of product to be retained at the gate by vacuum suction and a second position configured to allow a unit of product to pass through the picking head.

7. The robotic vacuum sorting system of any one of claims 2 to 6, wherein the local vacuum generator forms part of the picking head and is fixed with respect to the suction nozzle.

8. The robotic vacuum sorting system of any one of claims 1 to 7, wherein the robotic arms are fixedly attached to the sorting hub and the picking head is movably attached to the sorting hub.

9. The robotic vacuum sorting system of claim 8, wherein the picking head is rotatably attached to the sorting hub.

10. The robotic vacuum sorting system of claim 9, wherein each of the plurality of outlet tubes is radially disposed around the rotational axis of the picking head.

11 . The robotic vacuum sorting system of any one of claims 1 to 10, wherein the product is one of fruit, nuts, pills, hardware components, or candy.

12. The robotic vacuum sorting system of any one of claims 1 to 11 , wherein each of the plurality of product categories is associated with a respective grade of defect in the product.

13. The robotic vacuum sorting system of any one of claims 1 to 12, wherein the imaging device is a line scanner.

14. The robotic vacuum sorting system of any one of claims 1 to 13, wherein the imaging device is a machine camera.

15. A computer-implemented method of controlling a robotic vacuum sorting system including a robotic sorting device, the robotic sorting device being operable to remove a unit of product from a conveying area and inject the unit of product into one of a plurality of outlet tubes extending from the robotic sorting device, the method comprising: generating image information of the conveying area; identifying units of product in the conveying area using the image information; categorizing at least one of one or more of the units of product in the conveying area into one of a plurality of product categories, wherein each product category is associated with one of the plurality of outlet tubes; determining the position of the categorized units of product in the conveying area using the image information; moving the robotic sorting device to a location of a categorized unit of product; removing the categorized unit of product from the conveying area using the robotic sorting device; and injecting the categorized unit of product into the outlet tube associated with the product category of the unit of product.

16. The computer-implemented method of claim 15, wherein moving the robotic sorting device to a location of a categorized unit of product, removing the categorized unit of product from the conveying area and injecting the categorized unit of product into the outlet tube are sequentially repeated for each of the categorized units of product.

17. The computer-implemented method of claim 16, wherein injecting the categorized unit of product into the outlet tube associated with the product category of the unit product can be performed for a categorized unit of product in the sequence while moving the robotic sorting device to a location of a categorized unit of product is performed for the following categorized unit of product in the sequence.

18. The computer-implemented method of any one of claims 15 to 17, wherein the product is one of fruit, nuts, pills, hardware components, or candy.

19. The computer-implemented method of any one of claims 15 to 18, wherein each the plurality of product categories is associated with a respective grade of defect in the product.

20. The computer-implemented method of any one of claims 15 to 19, wherein moving the robotic sorting device to a location of a categorized unit of product includes tracking the movement of the categorized unit of product in the conveying area.

21. The computer-implemented method of any one of claims 15 to 20, wherein injecting the categorized unit of product into the outlet tube associated with the product category of the unit of product is performed when the robotic sorting device is proximate the conveying area.

22. The computer-implemented method of any one of claims 15 to 21 , wherein removing the categorized unit of product from the conveying area using the robotic sorting device is performed by way of vacuum suction.

23. A pick-and-sort tool for a robotic vacuum sorting system arranged to pick and sort units of product being conveyed in a conveying area, the pick-and-sort tool comprising: a sorting hub including a plurality of outlet tubes each having an opening, each opening being configured to receive a unit of product therethrough; and a picking head having a suction nozzle, the suction nozzle being configured to remove a unit of product form a conveying area and allow the removed unit of product to pass through the picking head to one of the plurality of outlet tube openings, wherein the picking head and the sorting hub are movable relative to each other such that the suction nozzle can be selectively aligned with any of the plurality of outlet tube openings.

24. The pick-and-sort tool of claim 23 further comprising a local vacuum generator located between the picking head and the sorting hub and wherein the local vacuum generator is configured to generate vacuum suction suitable to remove a unit of product from the conveying area and to inject the unit of product into one of the plurality of outlet tubes.

25. The pick-and-sort tool of any one of claims 23 or 24, wherein the local vacuum generator is an inline vacuum generator located between the suction nozzle and the sorting hub.

26. The pick-and-sort tool of any one of claims 24 or 25, wherein the suction nozzle forms part of the local vacuum generator.

27. The pick-and-sort tool of any one of claims 23 to 26, wherein the picking head comprises a gate being movable from a first position configured to allow a unit of product to be retained at the gate by vacuum suction and a second position configured to allow a unit of product to pass through the picking head.

28. The pick-and-sort tool of claim 27, wherein the gate comprising a first portion and a second portion configured to be moved together to arrive at the first position and moved apart to arrive at the second position.

29. The pick-and-sort tool of any one of claims 23 to 28, wherein the sorting hub is configured to be fixedly attached to robotic control arms and the picking head is movably attached to the sorting hub.

30. The pick-and-sort tool of claim 29, wherein the picking head is rotatably attached to the sorting hub.

31. The pick-and-sort tool of claim 30, wherein each of the plurality of outlet tubes is radially disposed around the rotational axis of the picking head.

32. The pick-and-sort tool of any one of claims 23 to 31 , wherein the product is one of fruit, nuts, pills, hardware components, or candy.