Determine the thickness profile of the work product

Abstract

A processing system (10) and corresponding method for processing a work product (WP), including a food product, to locate and quantify voids, undercuts, and similar anomalies in the work product is provided. The work product is conveyed by a conveyor (12) past an X-ray scanner (14). Data from the X-ray scan is transmitted to a control system (18). While the work product is being X-ray scanned, the work product is optically scanned at the same location on the work product where the X-ray scan occurs. Data from the optical scanner is also transmitted to the control system. Such data is analyzed to develop or generate a thickness profile of the work product. Based on the difference between the X-ray scan data and the thickness profile generated by the optical scan data, the control system can determine the location of the voids, undercuts, and similar anomalies. The processing system (10) uses this information to process the work product as needed, including adjusting the location and size of voids, undercuts, and similar anomalies present in the work product.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Application No. 62 / 855,700, filed May 31, 2019, the entire contents of which are incorporated herein by reference in their entirety. Background Art

[0003] Work products including food are portioned or otherwise cut into smaller parts by the processor according to customer needs. Customers usually want to divide and / or trim the work products into uniform sizes, for example, steaks served in restaurants, frozen dinners or chicken burgers or chicken slices or bacon slabs from streaky pork. High-speed portioning machines are now used for most work products, especially portioning / trimming of food. When the food is advancing on the mobile conveyor, these machines rely on various scanning technologies to determine the size and shape of the food. The information is analyzed by means of a computer to determine how to most effectively cut the food into the best size or portion. For example, a customer may need to divide bacon into one-pound pieces, or may need two different weight sizes of chicken breast, but without fat or with a limited amount of acceptable fat. Pork belly or chicken breast is scanned when they move on the feed conveyor, and by using a computer to determine how to best portion the pork belly or chicken breast to reach the weight required by the customer, so as to use the streaky pork or chicken breast most effectively.

[0004] The cutting and / or trimming of the work product may be performed by a variety of cutting devices, including high speed liquid jet cutters, where the liquid may include, for example, water or liquid nitrogen. Alternatively, the cutting device may consist of a rotating or reciprocating blade. Once the cutting / trimming occurs, the resulting parts are removed from the cutting conveyor and placed on a take-away conveyor for further processing or possibly placed in a storage bin.

[0005] The aforementioned type of portioning machine is known in the art. Such portioning machines or parts thereof are disclosed in existing patents, such as U.S. Patents No. 4,962,568 and No. 5,868,056, which are incorporated herein by reference. Typically, the work product is first transported by a feed conveyor through a scanning station, where the work product is scanned to determine selected physical parameters, such as size and shape, including length, width and / or thickness profiles. Based on this information, the weight of the work product or parts thereof can be determined by utilizing the assumed density of the work product.

[0006] Scanning of the work product can be performed using a variety of techniques, including X-ray scanning and optical scanning. In X-ray scanning, X-rays are passed through the work product, and the level of attenuation of the work product is related to the quality of the work product. Optical scanning systems can utilize CCD cameras or video cameras to view the work product illuminated by one or more light sources. Optical cameras are able to determine the physical parameters of the overall external configuration of the work product, including its size and shape. These scanning techniques assume that the bottom of the work product lies flat on the conveyor, and the work product is transported on the conveyor during scanning and subsequent trimming or cutting. However, the bottom surface of the work product may not lie flat on the top surface of the conveyor, but there may be undercuts under the work product. In addition, there may be invisible voids inside the work product. If these conditions exist, the undercut or void will not be detected in a typical scanning system. Therefore, the work product is analyzed as if the undercut or void does not exist. In this way, erroneous information about the physical parameters of the work product is used. If the goal is to cut the work product into uniform parts by weight, the presence of undercuts or voids will cause the end to be outside the approved weight range of the part cut from the work product.

[0007] X-ray scanners can "see through" work products, including food products. However, X-ray scanners cannot detect undercuts or voids. Additionally, optical scanners are able to determine physical aspects of the exterior of a work product, but cannot determine if voids exist within the work product or if undercuts exist beneath the work product.

[0008] The present disclosure seeks to provide a method and system for locating voids, undercuts, and similar anomalies in a work product, and then analyzing the work product taking into account the voids, undercuts, or other anomalies so as to portion or otherwise process the work product after understanding the presence, location, size, and shape of any voids, undercuts, or similar anomalies in the work product. Summary of the invention

[0009] This Summary is provided to introduce selected concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

[0010] Embodiments of the present disclosure include a method for determining a thickness profile of a work product, comprising (a) scanning the work product using an X-ray scanner, (b) analyzing data from the X-ray scanner using a computer processor to generate a thickness profile of the work product, (c) scanning the work product using an optical scanner, (d) analyzing data from the optical scanner using a computer processor to generate a thickness profile of the work product based on the optical scan data, (e) comparing a thickness profile based on the X-ray scan data and a thickness profile based on the optical scan data and determining (quantifying) a difference between the thickness profile based on the X-ray scan data and the thickness profile based on the optical scan data, and (f) mapping a location on the work product at which a difference exists between the thickness profile based on the X-ray scan data and the thickness profile based on the optical scan data.

[0011] The method of any embodiment of the present disclosure, wherein differences between the thickness profile based on the X-ray scan data and the thickness profile based on the optical scan data correspond to voids, undercuts, and similar locations associated with the work product that are not occupied by the work product.

[0012] The method of any embodiment of the present disclosure, wherein the work product is a food, and the difference between the thickness profile generated based on the X-ray scanning data and the thickness profile generated based on the optical scanning data corresponds to: a gap in the work product; an undercut under the work product; or other locations where the work product is absent.

[0013] The method of any embodiment of the present disclosure, wherein the food includes meat, and the difference between the thickness profile based on the X-ray scan and the thickness profile based on the optical scan includes voids in the meat, undercuts in the lower surface of the meat, or other locations where the meat is absent.

[0014] The method of any embodiment of the present disclosure further includes transporting the work product on a conveyor past the X-ray scanner and the optical scanner.

[0015] The method of any embodiment of the present disclosure further includes positioning the X-ray scanner and the optical scanner relative to the conveyor.

[0016] The method of any embodiment of the present disclosure further includes positioning the X-ray scanner and the optical scanner to simultaneously scan the same location on the work product.

[0017] The method of any embodiment of the present disclosure also includes processing the work product using the difference determined between the thickness profile based on the X-ray scanning data and the thickness profile based on the optical scanning data and the location of the difference between the thickness profile based on the X-ray scanning data and the thickness profile based on the optical scanning data on the work product.

[0018] The method of any embodiment of the present disclosure, wherein the work product is processed by trimming, cutting, or portioning.

[0019] The method of any embodiment of the present disclosure further includes transporting the work product in a direction of travel past the X-ray scanner and the optical scanner.

[0020] The method of any embodiment of the present disclosure, wherein the X-ray scanner scans the work product along a line extending transverse to the direction of travel of the work product.

[0021] The method of any embodiment of the present disclosure, wherein the optical scanner scans the work product along a line extending transverse to the direction of travel of the work product.

[0022] The method of any embodiment of the present disclosure, wherein the optical scanner scans the work product along the same line as the X-ray scanner scans the work product.

[0023] The method of any embodiment of the present disclosure, wherein the conveying device includes a first conveyor corresponding to the X-ray scanner and a second conveyor corresponding to the optical scanner.

[0024] The method of any embodiment of the present disclosure further includes (g) wherein the data from the X-ray scan includes a first data set corresponding to a two-dimensional shape of the work product, (h) wherein the data set from the optical scan includes a second data set corresponding to the two-dimensional shape of the work product, (i) comparing the first data set and the second data set corresponding to the two-dimensional shape of the work product from the X-ray scan and the optical scan, and (j) determining whether there is sufficient change between the first data set and the second data set to require converting the first data set to the second data set.

[0025] The method of any embodiment of the present disclosure, wherein converting a first data set from an X-ray scan into a second data set from an optical scan comprises one or more of: (i) directional conversion of the work product; (ii) rotational conversion of the work product; (iii) dimensional scaling of the work product; and (iv) shear deformation of the work product.

[0026] The method of any embodiment of the present disclosure, wherein the conveying device includes a first conveyor corresponding to the positions of the X-ray scanner and the optical scanner; and also includes a second optical scanner and a second conveyor corresponding to the position of the second optical scanner.

[0027] The method of any embodiment of the present disclosure, wherein the data set from the optical scanner includes a second data set corresponding to a two-dimensional shape of the work product, wherein the data from the second optical scanner includes a third data set corresponding to the two-dimensional shape of the work product, and further includes comparing the second data set and the third data set corresponding to the two-dimensional shape of the work product from the optical scanner and from the second optical scanner, and determining that there is sufficient change between the second data set and the third data set to require conversion of the second data set to the third data set.

[0028] In the method of any embodiment of the present disclosure, converting the second data set into the third data set comprises one or more of the following: orientation conversion of the work product; rotation conversion of the work product; size scaling of the work product; shear deformation of the work product.

[0029] The method of any embodiment of the present disclosure, wherein the conveying device includes a first conveyor corresponding to the X-ray scanner and the optical scanner and a second conveyor corresponding to a processing station, at which the work product is processed using a thickness profile determined based on the X-ray scanning data and the optical scanning data.

[0030] Another embodiment of the present disclosure includes a system for determining a thickness profile of a work product, comprising: a conveyor, the conveyor being used to convey the work product; an X-ray scanner, the X-ray scanner being used to scan the work product conveyed on the conveyor and generate a first data set regarding physical properties of the work product, the first data set including the thickness profile of the work product; an optical scanner, the optical scanner being used to scan the work product conveyed on the conveyor and generate a second data set regarding physical properties of the work product, the second data set including the thickness profile of the work product; and a control system, the control system being configured to: generate a thickness profile of the work product based on the X-ray scan data and the optical scan data; quantify a difference between a thickness profile of the work product based on the X-ray scan data and a thickness profile of the work product based on the optical scan data; and map a position on the work product at which a difference exists between a thickness profile based on the X-ray scan data and a thickness profile based on the optical scan data.

[0031] The system of any embodiment of the present disclosure, wherein a difference between a thickness profile of the work product based on the X-ray scan data and a thickness profile of the work product based on the optical scan data corresponds to a void in the work product, an undercut beneath the work product, or other locations with respect to the work product where no work product is present.

[0032] The system of any embodiment of the present disclosure, wherein the work product includes a food product, and a difference between a thickness profile of the food product based on the X-ray scan data and a thickness profile of the food product based on the optical scan data corresponds to a void in the food product, an undercut beneath the food product, or a location with respect to the food product where no food product is present.

[0033] The system of any embodiment of the present disclosure, wherein the food is meat, and the difference between the thickness profile of the meat based on the X-ray scan and the thickness profile of the meat based on the optical scan is due to the presence of voids within the meat, undercuts beneath the meat, or other locations with respect to the meat where there is no meat.

[0034] The system of any embodiment of the present disclosure, wherein the X-ray scanner and the optical scanner are positioned relative to the conveyor to scan the same location on the work product simultaneously.

[0035] The system of any embodiment of the present disclosure, wherein the X-ray scanner is configured to scan the work product along a line extending transverse to a direction of travel of the work product on the conveyor.

[0036] The system of any embodiment of the present disclosure, wherein the optical scanner is configured to scan the work product along a line extending transverse to a direction of travel of the work product on the conveyor.

[0037] A system according to any embodiment of the present disclosure, wherein the optical scanner is configured to scan the work product along the same line as the X-ray scanner is configured to scan the work product.

[0038] The system of any embodiment of the present disclosure, wherein the optical scanner is configured to scan the work product along the same line as the X-ray scanner is configured to scan the work product.

[0039] The system of any embodiment of the present disclosure, wherein the conveying device includes a first conveyor corresponding to the X-ray scanner and a second conveyor corresponding to the optical scanner.

[0040] The system of any embodiment of the present disclosure, wherein the control system compares a first data set corresponding to the two-dimensional shape of the work product from the X-ray scan data with a second data set corresponding to the two-dimensional shape of the work product from the optical scan data, and compares the first data set and the second data set from the X-ray scan and the optical scan to determine whether there is sufficient change between the first data set and the second data set to require conversion of the first data set to the second data set.

[0041] The system of any embodiment of the present disclosure, wherein converting the first data set from the X-ray scan to the second data set from the optical scan includes one or more of: directional conversion of the work product; rotational conversion of the work product; dimensional scaling of the work product; and shear deformation of the work product.

[0042] The system of any embodiment of the present disclosure further includes a processing station located downstream of the optical scanner, wherein the processing station is used to process the work product using a quantified difference between a thickness profile of the work product based on the X-ray scan and a thickness profile of the work product based on the optical scan.

[0043] The system of any embodiment of the present disclosure, wherein the processing station includes a cutter for trimming, cutting and / or portioning the work product. BRIEF DESCRIPTION OF THE DRAWINGS

[0044] The foregoing aspects and many of the attendant advantages of the present invention will become more readily understood by reference to the following detailed description, which advantages may be better appreciated when taken in conjunction with the accompanying drawings, in which:

[0045] Figure 1 is a schematic representation of a system and apparatus for processing work product according to a first embodiment of the present disclosure;

[0046] Figure 2 is a schematic diagram of an X-ray scanner that may be used in the systems and methods of the present disclosure;

[0047] Figure 3 is a schematic diagram of another X-ray scanner that may be used with the systems and methods of the present disclosure;

[0048] Figures 4A-4C is a thickness profile of the work product produced by X-ray scanning and optical scanning, showing the difference between them;

[0049] Figure 5 is used Figure 1 Flowchart of the work product processing method of the system and equipment;

[0050] Figure 6 is a schematic diagram of another embodiment of a system and apparatus for processing work product according to the present disclosure;

[0051] Figures 7A-7F schematically illustrates the manner in which a work product moves or twists as it is transferred from a first conveyor belt to a second conveyor belt;

[0052] Figure 8 It is to explain the use Figure 6 A flowchart of a method of a system and apparatus;

[0053] Fig. 9 is a schematic diagram of another embodiment of a system and apparatus for processing work product according to the present disclosure; and

[0054] Fig.10 This is a schematic illustration of the use Fig. 9 Flowchart of the system and method of the apparatus. DETAILED DESCRIPTION

[0055] This explanation is set forth below in conjunction with the accompanying drawings, wherein the same numerals refer to the same elements, are intended to be a description of the various embodiments of the disclosed subject matter and are not intended to represent the only embodiments. Each embodiment described in this disclosure is provided only as an example or explanation, and should not be construed as a preferred embodiment or superior to other embodiments. The illustrative examples provided herein are not intended to be exhaustive or to limit the present disclosure to the disclosed precise form. Similarly, any step described herein can be interchanged with other steps or a combination of steps to achieve the same or substantially similar results.

[0056] In the following description, many specific details are set forth to provide a thorough understanding of the exemplary embodiments of the present disclosure. However, it will be apparent to those skilled in the art that many embodiments of the present disclosure may be practiced without some or all of the specific details. In some cases, in order to avoid unnecessarily confusing various aspects of the present disclosure, well-known processing steps are not described in detail. In addition, it should be understood that embodiments of the present disclosure may employ any combination of the features described herein.

[0057] The present application may include references to “directions” such as “forward,” “rearward,” “front,” “rear,” “front,” “back,” “upward,” “downward,” “above,” “below,” “top,” “bottom,” “right-hand,” “left-hand,” “inside,” “outside,” “extended,” “superior,” “retractable,” “proximal,” and “distal.” These references and other similar references in the present application are intended only to aid in the description and understanding of the present disclosure and are not intended to limit the present invention to these directions.

[0058] The present application may include modifiers, such as the words "generally," "approximately," "about," or "substantially." These terms are intended to be used as modifiers to indicate that the "size," "shape," "temperature," "time," "amount," "percentage," or other physical parameter in question need not be exact, but may vary, so long as the desired function can be performed. For example, in the phrase "the shape is generally circular," the shape need not be an exact circle, so long as the desired function of the structure in question can be achieved.

[0059] In the following description, various embodiments of the present disclosure are described. In the following description and the accompanying drawings, corresponding system components, devices, and units may be identified by the same part number, but with a letter suffix or a prime or double prime mark. The description of the same or similar parts / components in such system components, devices, and units will not be repeated in this application.

[0060] In this application, references to "food", "food products", "food pieces" and "food items" are used interchangeably.

[0061] System Overview

[0062] One embodiment of the processing system 10 of the present disclosure is Figure 1 1 is shown as comprising a basic form of a conveyor 12 in the form of a conveyor 28 having an endless belt 30 for carrying a work product or workpiece WP, such as a food product, such as pork belly, poultry breast, and other types of food products, through an X-ray scanner 14 to determine physical parameters of the work product. Such physical parameters may include the size and / or shape of the work product, including, for example, the length, width, aspect ratio, thickness, thickness profile, shape, outer contour, outer perimeter, outer perimeter shape, volume, and / or weight of the work product. With respect to the thickness profile of the work product, such thickness profile may be determined along the length of the work product, across the width of the work product, and across the width and length of the work product. Data from the X-ray scanner 14 is transmitted to the control system 18. Such data is coordinated with corresponding data from an encoder 20, which is associated with the conveyor 12, so as to match the X-ray scan data with a position along the conveyor corresponding to the position of the work product being scanned.

[0063] The system 10 also includes an optical scanner 22 positioned relative to the conveyor 12 to scan the work product while performing the X-ray scanning. The optical scanner also determines physical parameters of the work product, including, for example, physical parameters related to the size and / or shape of the work product as discussed above with respect to the X-ray scanner 14. Data from the optical scan is also transmitted to the control system 18 and can be used to form a thickness profile of the work product.

[0064] The thickness profile of the work product determined from the X-ray scanner is based on the mass of the work product. Therefore, if there are voids within the work product or undercuts at the bottom of the work product, this can be determined by the X-ray scanner due to the reduction in mass caused by the voids or undercuts. However, the optical scanner determines the height and shape of the top exterior of the work product and does not consider whether there are voids within the work product or undercuts below the work product. In this way, the two thickness profiles generated by the X-ray scan and the optical scan can be compared. If there are voids within the work product or undercuts below the work product, the thickness of the work product determined by the optical scan will be greater than the thickness of the work product determined by the X-ray scan. Using this information, the control system 18 can determine not only the presence of voids or undercuts, but more specifically the shape, size, and location of the voids or undercuts. The control system 18 can use this information to determine how to trim, cut, and / or separate the work product into desired final pieces, such as final pieces with a desired weight or weight range.

[0065] If the X-ray scanner and the optical scanner are configured to scan the same location of the work product simultaneously, the need to map thickness data determined from the X-ray scan with thickness data determined from the optical scan can be reduced or potentially eliminated.

[0066] Even though it is still necessary to map thickness data from the X-ray and optical scanning operations, the matching or mapping of the data may be more accurate if the scanning occurs simultaneously. In addition, the matching / mapping may be accomplished by simple time stamping without the need to use encoder "counting" or other monitoring technology to monitor the position of the work product on the conveyor.

[0067] The work product may be trimmed or cut at the cutting station 26 using one or more cutters controlled by the control system 18. Thereafter, the trimmed or cut work product may be transferred onward for other or further processing. Other types of processing in addition to or in lieu of cutting or trimming the work product may be performed using information related to the thickness profile of the work product determined using data from the x-ray scanner 14 and the optical scanner 22.

[0068] Conveyor

[0069] Next, the above aspects of the processing system 10 are described in more detail, referring to Figure 1, the conveyor 12 has the form of a belt conveyor 28 having an endless belt 30 looped around end rollers 32 and 34. An encoder 20 is associated with the end roller 34. The roller 34 is powered to drive the conveyor belt in a downstream direction as indicated by arrow 36, past the x-ray scanner 14, the optical scanner 22, and the cutting station 26. As described above, the encoder 20 monitors the position or location of the belt 30 along the length of the conveyor 28.

[0070] Belt 30 is shown as having an open form or grid structure so that the water jets at cutting station 26 can freely pass downwardly through the belt to a collection tank or other container (not shown) located below the conveyor. Various configurations of conveyor belts corresponding to belt 30 are described in U.S. Pat. No. 6,854,590, which is incorporated herein by reference.

[0071] X-ray scan

[0072] The X-ray scanner 14 is used to inspect the work product WP to determine physical parameters of the work product, including the shape and size of the work product as described above, and also including, for example, the thickness and thickness profile of the work product. The X-ray scanner can also determine whether there is unwanted material in the work product, such as bone, fat, metal, plastic, glass.

[0073] Generally, X-rays are attenuated when passing through an object in proportion to the total mass of the material through which the X-rays pass. The intensity of the X-rays received by the X-ray detector after the X-rays pass through an object such as the work product WP is inversely proportional to the total mass of the object. For example, an X-ray passing through a work product having a void or undercut will be attenuated less than an X-ray passing through a work product without an undercut or void. Therefore, the portion of the work product where the void or undercut is located will be analyzed as having a thickness less than the thickness of an adjacent portion of the work product without the undercut or void.

[0074] In addition, using a given value for the density of the work product being analyzed, whether it is beef, poultry or fish, the dimensional thickness of the work product can be calculated. This information can be determined for the entire volume of the work product. A general description of the properties and uses of X-rays in processed foods can be found in U.S. Patent No. 5,585,603, which is incorporated herein by reference.

[0075] As described above, the system 10 includes a position sensor in the form of an encoder 20 that generates a signal indicative of the position of the belt 30, thereby indicating the position of the work product WP along the length of the conveyor 28. As the work product moves along the conveyor 28, the position of the work product relative to the x-ray scanner 14 along the length and width of the conveyor belt 30 can be determined by the x-ray system. As described above, in addition to the thickness or thickness profile of the work product described above, the x-ray scanner can also provide other information about the physical parameters of the work product. Such physical parameters include, for example, the length, width, aspect ratio, profile, outer profile configuration, perimeter, outer perimeter configuration, outer perimeter size and / or shape, volume, and / or weight of the work product. With respect to the outer perimeter configuration of the work product, the x-ray scanner can be used to determine the position along the outer perimeter of the work product, including based on an XY coordinate system or other coordinate system.

[0076] The X-ray scanner 14 includes an X-ray source or generator 40 for emitting X-rays 42 downwardly toward the work product. An X-ray detector 44 is located below the upper section of the conveyor belt 30 for receiving the X-rays 42 that have passed through the work product. The X-ray detector 44 includes a linear array of detector units that extend across the bottom side of the conveyor belt 30 to generate a signal corresponding to the intensity of the X-rays impinging thereon. The signals generated by the X-ray detector 44 are transmitted to an image processor 46, which forms part of the overall control system 18. The control system processes the data signals from the X-ray detector 44 to determine physical parameters of the work product, including the thickness profile of the work product, across the width of the work product, and along the length of the work product. As described above, the physical parameters that can be determined from the X-ray scan also include the shape and size of the work product and the position of the work product on the conveyor belt 20.

[0077] Reference Figure 2 , the X-ray detector 14 is shown as including a layer or strip of scintillator material 48 located above a plurality of photodiodes 50a-50n. The X-ray source or generator 40 is located above the conveyor belt 30 at a sufficient distance so that the X-rays 42 emitted from the generator 40 completely surround the length of the X-ray detector 44 extending through the conveyor belt 30. The X-rays 42 pass through the work product WP, pass through the upper section of the conveyor belt 30, and then impinge on the layer or strip of scintillator material 48. Since the photodiodes 50a-50n respond only to visible light, the scintillator material 48 serves to convert the X-ray energy impinging thereon into a flash of visible light that is proportional to the intensity of the received X-rays. The photodiodes 50a-50n generate electrical signals having amplitudes that are proportional to the intensity of the light received from the scintillator material 48. These electrical signals are relayed to the image processor 46.

[0078] like Figure 1As shown, the photodiodes 50a-50n are arranged in a line across the width of the conveyor belt 30 for detecting X-rays that pass through a line or "slice" of the work product WP. Alternative photodiode layouts are possible, for example, the photodiodes can be positioned in several rows to form a rectangular grid to increase the scan area of ​​the X-ray detector 44 if desired.

[0079] Other embodiments of X-ray scanners may be utilized that are also capable of detecting the intensity (or attenuation) of X-rays that have passed through the work product WP to determine the thickness profile of the work product. Figure 3 , an alternative embodiment of the x-ray detector 14' includes a fluoroscope screen 54. The screen is activated to produce a flash of light proportional to the attenuation of the impinging x-rays 42. The flash is then recorded by a camera 56 or other device capable of capturing a "picture" produced by the fluoroscope screen 54. The image captured by the camera 56 is transmitted to the image processor 46 and converted into a digital value related to the intensity of the light generated by the fluoroscope screen 54.

[0080] Further alternatively, direct flat panel X-ray imaging techniques or direct radiography may be used. For example, an amorphous selenium detector array may be used as an X-ray detector to directly detect the intensity of the impinging X-rays and transmit data in this regard to the image processor 46.

[0081] Other X-ray options include using a dual energy X-ray source or a photon counting, multi-bin X-ray system.

[0082] Additionally, other types of scanners may be employed, such as infrared scanning, sonar / ultrasound scanning, CT scanning, or MRI scanning.

[0083] Optical Scanning

[0084] Reference Figure 1, an optical scanner 22 is positioned along the conveyor system 12. The optical scan may be performed using a variety of techniques, including using a scanner such as the scanner 22 to view the work product WP illuminated by one or more light sources 60. Light from the light source 60 extends across the moving conveyor belt 30 to define a distinct shadow or light bar 61, where the area in front of the transverse light beam is dark. When the conveyor belt 30 is not carrying work product, the shadow line / light bar 61 forms a straight line across the conveyor belt 30. However, when the work product WP passes by the shadow line / light bar, the upper irregular surface of the work product produces an irregular shadow line / light bar, as observed by a camera 62 directed downwardly toward the work product and the shadow line / light bar 61. The camera detects the displacement of the shadow line / light bar 61 from the position it would occupy if no work product was present on the conveyor belt 30 (i.e., in the Z-axis direction). This upward displacement of the light bar 61 represents the "thickness" of the work product along the shadow line / light bar as observed by the optical scanner.

[0085] The length of the work product is determined by the length of time that the work product creates the shadow line 61. In this regard, the encoder 20 generates pulses at fixed time intervals corresponding to the forward movement of the conveyor belt 30. During this movement of the conveyor belt, a thickness profile of the entire work product in the "X" and "Y" directions relative to the direction of the conveyor belt is generated.

[0086] like Figure 1 As shown, the light source 60 and the camera 62 are positioned relative to the x-ray scanner 14 so that the light bar 61 is coincident and aligned with the x-ray detector 44 positioned across the conveyor belt 30. In this way, the x-ray scanner and the optical scanner simultaneously scan the same lateral position (slice) across the work product. This alignment of the light bar 61 with the x-ray detector 44 can eliminate the need to convert data from the x-ray scanner 14 to data from the optical scanner 22 due to workpiece movement or displacement. However, because the viewpoints of the x-ray detector and the optical camera are slightly different, it may be necessary to map the data from the x-ray scanner to the data from the optical scanner during calibration or setup of the processing system 10.

[0087] Although a single light source 60 is shown in the figure, multiple light sources may be utilized. For example, a second light source may be positioned on a side of the X-ray generator 40 opposite to the light source 60 .

[0088] In addition, although Figure 16 shows two cameras 62 being used, but a single camera may be used. However, if a single camera is used, a "shadow" may occur. In this regard, the light bar may be temporarily blocked from view by a portion of the workpiece extending upwardly over surrounding portions of the workpiece and not visible to the single camera. This may not be a problem or source of inaccuracy. However, if the shadow causes height data to be lost, the X-ray image data will be used to fill in the lost data.

[0089] In addition, as described above, the processing system 10 is designed to determine whether there are voids in the work product WP or undercuts on the bottom side of the work product or whether the work product is lying flat on the conveyor belt 20. In this regard, as described above, the upward displacement of the light bar 61 from the optical scanner provides the thickness of the work product, spanning the width of the work product at the location of the light bar. However, the optical scan cannot determine whether there are voids, undercuts, etc. Instead, the optical scan instead provides a height profile of the upper surface of the work product WP relative to the top surface of the conveyor belt 30.

[0090] On the other hand, an X-ray scan provides the actual thickness of the work product corresponding to the location of the X-ray detector through the work product. If there is a void, undercut, or similar anomaly in the work product, the work product at that location will be determined to be thinner because the intensity of the X-rays passing there will be greater than if no void, undercut, or other anomaly exists. Therefore, if the "thickness" of the work product from the optical scan is compared to the thickness of the work product from the X-ray scan, any difference therein will indicate the presence of a void, undercut, or similar anomaly, resulting in reduced attenuation of the X-rays reaching the X-ray detector.

[0091] The above analysis Figures 4A-4C It is schematically shown in Figure 4A , contour line 70 depicts the thickness profile above a datum "D" across a "slice" of the work product generated by optical scanner 22. Contour line 72 depicts the thickness profile above a datum "D" along the same slice of the work product as determined by the x-ray scan. When the x-ray height is subtracted from the optical height, contour line 74 represents the height of the bottom surface of the work product. In most cases, contour line 74 is located at zero height above the datum because the height of the work product determined by the optical scan is the same as the height of the work product determined by the x-ray scan. However, as Figure 4C As shown, portion 76 of contour line 74 is relative to reference "D". Portion 76 of contour line 74 represents the shape, size and location of the void or undercut in the work product. Except for the location of contour 74, the resulting height is zero relative to reference "D". The above analysis enables more accurate processing of the work product, for example, trimming or cutting the work product into desired portion weights.

[0092] It will be appreciated that in certain types of food products, relatively large undercuts or voids may occur, particularly if the food product has curled or otherwise presents a configuration that causes the work product to not lie flat on the conveyor belt 30. For example, it is not uncommon for the edges of a smoked pork belly to curl or curl underneath it, causing a large portion of the bottom side of the pork belly to not lie flat on the conveyor belt upon which the pork belly is supported during cutting of the pork belly into fixed weight portions. This typically occurs along the edges of the pork belly.

[0093] Chicken breasts, especially very fresh ones, may have undercuts from the edge inward or from the front to the back. In addition, in the chicken breast, where the muscle ("tenders") are removed, a depression may appear, which is called a "tender tunnel". This can lead to inaccuracies when cutting or portioning the chicken breast.

[0094] As described above, an assumed density value for the work product is used to convert mass-related data from an x-ray scan into a height or thickness of the work product. In many cases, the density value will be assumed to apply to the entire work product, such as a chicken breast or fish fillet. In these cases, fat, which has a lower density than the meat itself, is typically located at the edges of the meat. Furthermore, the amount of fat is typically not significant, so the error introduced by applying a generalized density value is typically relatively small. Furthermore, if fat present on the surface of the food product is visible to the optical scanner, the control system 18 may apply a different density value to the fat.

[0095] There are other types of food, such as pork belly, which may contain up to 50% fat, which is distributed throughout the muscle. In this case, a generalized density value that takes into account the likely fat content of the food can be used.

[0096] Furthermore, in meat products, as shown below, the density of fat is less than the density of whole muscle. In this regard, the density of the scanned food product can be calculated by dividing the mass measured by the X-ray scan by the volume determined by the optical scan. If the calculated density is even less than the density of fat, then it is concluded that there must be a void or undercut at the location of the food product being analyzed.

[0097] Alternatively, if the food FP is known to lie flat on the conveyor 30, for example if the food has been extruded prior to scanning, the above method of calculating density by dividing the mass determined by the X-ray scan by the volume determined by the optical scan may be used to determine the fat / protein muscle ratio in the food.

[0098] For example, if the density of pork is 1.1 g / cm 3 The density of fat in pork is 0.9g / cm 3 , if the density is calculated as 1.0 using the above procedure, the fat content of the pork belly analyzed is approximately 50%.

[0099] Reference Figure 1 As described above, the x-ray scanner 14 and the optical scanner 22 are positioned relative to each other so that the same "slice" across the work product is analyzed by both the x-ray scanner and the optical scanner. Although this configuration of the portioning system 10 can simplify the analysis of the x-ray scans and the optical scans by not requiring data from the x-ray scans to be converted into data for the optical scans or vice versa, it should be understood that the x-ray scanner can be positioned at a different location along the conveyor 12 than the location of the optical scanner 22, as described below with respect to Figure 6 discussed. In that case, it would be necessary to convert the data from the X-ray scan to data from the optical scan. However, this process should be fairly simple since both the X-ray scan and the optical scan can view the work product in slice form across the width of the work product. The encoder data can be used to match the X-ray scan data with the optical scan data for the same slice location on the work product.

[0100] As described above, the X-ray detector 44 is configured as a line array detector to receive X-rays along the same slices or lines across the conveyor belt as the positions of the light strips 61 from the optical scanner 22. As described above, the X-ray detector may be configured to have a width along the length of the conveyor belt 20. In that case, the data from the X-ray detector may need to be "correlated" with the data from the optical scanner. In this case, the X-ray data may need to be converted to data from the optical scanner using existing conversion techniques.

[0101] Control System

[0102] Figure 1 The control system 18 of the operation of the control processing system 10 is schematically illustrated. The control system includes a computer 80, and the image processor 46 is operably connected to the computer 80, and the image processor 46 receives data from the X-ray detector 44 and from the optical camera 62 and processes such data for use by the computer. As described herein, the control system also includes an interface 81 for receiving signals and information from the encoder 20 and from other data sources of the system 10. A memory unit 82 is provided for storing information for use by the control system including the computer 80. A keyboard or other input device 84 is provided to enable an operator to communicate with the control system 18. In addition, a display or other output device 86 is provided to transmit information from the control system including from the computer 80 to the operator. As described below, the control system 18 controls the operation of the portioning system 10 including the conveyor 12, the X-ray scanner 14, the optical scanner 22 and the cutting station 26. The control system 18 can be connected to a network 88. In addition, instead of using a local computer 80, a network computing system can be used for this purpose.

[0103] Cutting device

[0104] Once the work product has passed through the X-ray scanner 14 and the optical scanner 22, the work product WP moves to the cutting station 26. As described above, the information from the X-ray scanner and the optical scanner can be combined so that the location of voids, undercuts and similar anomalies is known. Using this information, the control system 18 determines how to trim or cut the work product into parts with desired weights or other dimensions and parameters, for example.

[0105] Various types of cutting devices may be used at cutting station 26 to cut or trim the work product as desired. One type of cutter 90 that may be used employs a high pressure water jet as disclosed in U.S. Patent Nos. 4,875,254, 5,365,186, and 5,868,056, which are incorporated herein by reference.

[0106] like Figure 1 As shown schematically, the water jet cutter 90 includes a nozzle 92 that can be moved relative to the conveyor belt 30 in the longitudinal direction of the belt and in the transverse direction of the belt and vertically relative to the upper surface of the belt. This enables the water jet cutter 90 to cut and / or trim the work product to achieve one or more desired configurations, sizes, parts, etc.

[0107] although Figure 1 Only one water jet cutter 90 is shown, but it should be understood that at least several water jet cutters can be used in conjunction with the system 10 to achieve the desired production level. For example, four, eight, or even more water jet cutters can be used in a coordinated manner to cut and / or trim the work product at the cutting station 26.

[0108] method

[0109] Figure 5 The diagram shows the use of Figure 1 -4. The process begins at step 200, where a work product WP is loaded onto a conveyor 28 at step 202. Thereafter, the work product is scanned using an X-ray scanner 22 at step 204. Next, at step 206, data from the X-ray scan of the work product is transmitted to the image processor 46.

[0110] Thereafter, at step 208, concurrently with the x-ray scanning of the work product, the work product is also optically scanned by the scanner 22. At step 210, the data from the optical scanner is sent to the image processor 46.

[0111] Next, at step 214, the data from the X-ray scanner and the optical scanner are processed and the results of such processing are made available to the computer 80 so that thickness profiles from the X-ray scanner and the optical scanner can be generated at step 216. At step 218, the two thickness profiles are analyzed so that the locations of voids, undercuts, and similar anomalies can be mapped.

[0112] Thereafter, at step 220, the computer 80 generates a cutting path for the water jet or other type of cutter 90. Next, at step 222, the work product is cut, trimmed, or otherwise separated into portions having desired physical parameters, such as weight. Next, at step 224, the work product may be subjected to one or more further processing operations.

[0113] Another embodiment

[0114] Figure 6 Another embodiment of the present disclosure is shown, wherein Figure 1 Parts or components that operate the same as those in the Figure 1 Similar parts or components are designated by a prime symbol ('). Figure 6 In the embodiment of the present invention, the processing system 10' includes a conveying system 12', which is composed of a first conveyor 100 associated with an X-ray scanner 14 and a second conveyor 102 associated with an optical scanner 22. Although positioned separately from each other, the X-ray scanner 14 and the optical scanner 22 function in the manner described above with respect to the portioning system 10.

[0115] The first conveyor 100 is operationally and structurally compatible with the X-ray scanner 14. In this regard, the first conveyor 100 includes a flat, X-ray transparent endless belt 104 arranged on end rollers 106. The endless belt 104 can be powered in a conventional manner. An encoder 108 is associated with the end rollers 106 in a manner similar to the encoder 20 associated with the rollers 34 of the conveyor 102. The encoder 108 monitors the position or location of the belt 104 along the length of the conveyor 100 and thus monitors the work product WP.

[0116] As mentioned above, conveyor belt 104 is made of the material that can see through X-ray, for example rubber, plastics or both combinations.Due to this structure, X-ray is easy to pass through conveyor belt, and impacts on the detector 44 that is positioned at conveyor belt 104 upper sections below.

[0117] It should be understood that conveyors 12 and 12' and other conveyors described herein are not limited to belt conveyors for continuously or intermittently moving work products. For example, the conveyors described herein may be replaced by mobile platforms for conveying work products or other conveying mechanisms.

[0118] X-ray scanner 14, in addition to the above Figure 1 In addition to forming a thickness profile in the manner described, other physical parameters of the work product are also used to determine other physical parameters of the work product, including the overall shape and size of the work product, the outer perimeter configuration of the work product, and the position of the work product on the conveyor belt 104. These physical parameters are determined by the control system based on the data generated by the scanner 14.

[0119] After being scanned by the X-ray scanner 14 on the conveyor belt 10, the work product is transferred to the second downstream conveyor belt 102. The conveyor belt 102 is Figure 1 The conveyor belt 28 is constructed as shown above. Figure 6 As shown, the optical scanner 22 and cutter station 26 are located above the downstream conveyor 102. After the work product is scanned on the upstream conveyor 100, it is transferred to the downstream conveyor 102 for optical scanning and processing.

[0120] As described above, the external configuration of the work product may be discerned by the optical scanner 22, which determines parameters related to the size and / or shape of the work product, such as length, width, aspect ratio, thickness, thickness profile, shape (two-dimensional and three-dimensional), outer contour configuration, perimeter, outer perimeter configuration, outer perimeter size and / or shape, volume, and / or weight. Figure 6 The scanner 22 shown in FIG. Figure 1 The scanner 22 shown in FIG. operates in the same manner. Figure 6 The data of the scanners 14 and 22 shown in FIG. 1 are similar to those described above with respect to Figure 1 The same mode is analyzed so that the presence and position of gaps, undercuts or other anomalies of the working product can be determined. In addition, as mentioned above, under certain conditions, the data from scanners 14 and 22 can be combined to determine the degree or percentage of fat in the meat processing product.

[0121] Furthermore, as also described above, since the x-ray scanner 14 and the optical scanner 22 are located separately from each other, they no longer simultaneously scan the same slice on the work product at the same time. Instead, the x-ray scanning of the work product occurs first on the conveyor 100, and then the optical scanning of the work product occurs on the conveyor 102. As also described above, the information from the two scanners must be integrated together or otherwise converted so that the data from the x-ray scan corresponds to the same slice taken on the work product when scanned by the optical scanner 22.

[0122] For the above analysis, it is important to verify that the data from the X-ray scanning setup corresponds to the same work product as the data subsequently obtained from the optical scan. In this regard, the control system 18 can identify coordinates along the outer perimeter of the work product determined by the X-ray scanner and then by the optical scanner, and can compare the data. If these data sets match within a fixed threshold level, then the work product scanned at the optical scanner is confirmed to be the same as the work product previously scanned at the X-ray scanner.

[0123] However, for example, if a work product is removed from the conveyor 100 or conveyor 102 before the work product reaches the optical scanner 22, the next work product scanned at the optical scanner 22 will not match the scan data from the X-ray scanner 14 because the X-ray scan data will correspond to the work product that has been removed. Therefore, the control system 18 will determine that there is no match between the perimeter coordinate data sets of the work products from the X-ray scanner 14 and the optical scanner 22. As such, the optical scanner 22 will scan the next work product that passes by to determine whether such next work product matches the scan data of the work product scanned at the X-ray scanner 14 and transmitted to the control system 18. The processor will determine whether the work product scanned at the optical scanner 22 corresponds to the work product scanned at the X-ray scanner 14 immediately after the removed work product was X-ray scanned. The control system 18 matches the correct scan data from the X-ray scanner 14 with the scan data of the same work product from the optical scanner 22. Of course, this is essential so that the thickness profile information of the work product determined by the optical scanner 14 coincides with the thickness profile information of the work product scanned by the optical scanner 22.

[0124] The control system 18 will go through a finite number of "matching" processes. An example of determining the number of data sets from the X-ray scanner that must be checked can be determined as follows. Divide the distance between the scanners by the sum of the product length + product gap + dimensional safety factor. For example, if there is a distance of 9 feet between the X-ray scanner and the optical scanner, and the work product is a product that is approximately 450 mm long, then the maximum number of data sets in the queue that will be checked is calculated as: 9*12 / (17.7+2+2)=4.9, so five matching attempts are made. The data set from the optical scanner will be compared with the five data sets from the X-ray scanner stored in the memory unit 82. For longer length products, the number of data sets in the storage queue is less than the number of data sets for shorter work products. In addition, if the distance between the scanners is short enough, only one matching comparison is performed. In addition, it should be understood that differences or changes in belt speed can change the number of possible comparisons. The faster the belt speed, the larger the gap and / or the larger the safety margin may be required between products, and the time to perform the necessary calculations will be less.

[0125] If there is no match, a "No Match Found" error message is generated. The system continues processing the next work product that arrives at the optical scanner and begins searching for a new work product.

[0126] For example, if a work product is removed from conveyor 100 after an X-ray scan but before an optical scan, only two matching attempts should be required before a match occurs. However, in the event that the work product WP is so distorted during transfer from belt 104 to belt 30 that the control system 18 cannot recognize the X-ray image of the work product, then after the predetermined matching attempt, the work product will travel down belt 30 without being cut and / or trimmed / portioned. The above-described error message is generated, and the uncut work product can be identified or marked by the control system 18 and can be removed to a specific location for reprocessing or other disposal.

[0127] It should be understood that there is no attempt to continuously track the position of the work product WP from the X-ray scanner 14 to the optical scanner 22. Rather, the foregoing method is used to match a work product scanned at the X-ray scanner 14 with the same work product scanned at the optical scanner 22. Moreover, while the foregoing description does indicate that the system of the present disclosure can be used to locate a work product on the first conveyor and / or the second conveyor at one or more specific points in time, the specific position of the work product is not continuously tracked. Furthermore, in the present system 10', it is not necessary to locate the work product along the conveyor 12' at any specific time.

[0128] Scanning data from scanners 14 and 22 can be used to determine whether the work product has been accurately transferred from conveyor 104 to conveyor 30 and to determine the extent to which the work product has been physically deformed or moved during the transfer process. Such deformation or movement can include displacement of the work product from one side to the other relative to the centerline or other reference line of the conveyor. The work product can also be displaced longitudinally along the length of the conveyor relative to the position of the work product on conveyor 100.

[0129] If the displacement of the work product occurs in the X and / or Y direction, the control system 18 is used to convert or manipulate the X-ray image of the work product and the underlying data from the X-ray imaging into an optical scan image of the work product to improve the matching of the shape or contour of the work product. Fig. 7A Schematically shown in FIG. 1 , where the work product scanned at the X-ray scanner 14 is shown in dashed lines and the work product scanned at the optical scanner 22 is shown in solid lines. The control system 18 Fig. 7A The dotted image in the figure is transformed into the optical image shown by the solid line.

[0130] like Figure 7BAs shown, the transfer of the work product from the conveyor belt 104 to the conveyor belt 30 may also cause the work product to rotate, wherein the work product scanned by the X-ray scanner 14 is shown in dashed lines, and the work product scanned by the optical scanner 22 is shown in solid lines. In order for the cutter at the cutter station 26 to trim or cut the work product WP, the contour or shape data from the X-ray scanner 14 is converted into image data from the optical scanner 22.

[0131] Another type of deformation that may occur during transfer of the work product from belt 104 to belt 30 is that the work product may increase or decrease in scale (length) in the Y direction (across belt 30) and / or in the X direction (along belt 30). Figure 7C shows that the proportion of work products increases in the Y direction, while Fig.7D The work product is shown with increasing scale in the X direction. Of course, the work product may also be decreased in scale in the X direction, especially if the scale in the Y direction is increased, and vice versa, the work product may be decreased in scale in the Y direction, especially if the scale in the X direction is increased. Nevertheless, the scan data from the X-ray scanner 14 is converted in X and Y scale to the work product scanned by the optical scanner 126.

[0132] Another form of deformation that may occur during the transfer of the work product from conveyor belt 104 to conveyor belt 30 is shear deformation in the X direction, such as Fig. 7E In shear deformation, as shown in Fig. 7E As shown, the work product may gradually deform or shift in the X direction across the width of the work product. Of course, shear deformation may occur as follows Fig. 7E Mirror images of the work product are shown. Also, shear deformation is shown as occurring gradually and linearly across the work product, but shear deformation can also occur nonlinearly across the work product. As with other types of deformation, shear deformation can be due to a variety of reasons, such as differences in conveyor belt speeds or imperfect alignment of the two conveyor belts. As a result, in the direction across the conveyor belt, the work product may have been gradually displaced backward or forward relative to the direction of travel of the conveyor belt.

[0133] Fig. 7E The work product on the second conveyor belt 30 is shown displaced forwardly (in the right-hand direction) due to shear deformation. As mentioned above, shear deformation may of course occur in the opposite direction (in the left-hand direction) so that the work product extends backward relative to the nominal position of the work product across the conveyor belt.

[0134] Figure 7F It is illustrated that shear deformation may occur in the Y direction, wherein the work product is displaced laterally relative to the belt along the length of the work product. Figure 7FThe shear deformation of the work product in the Y direction (upward along the page) is shown. It should be understood that the shear deformation can be Figure 7F occurs in the opposite direction as shown.

[0135] Regardless of the direction of the shear deformation, the data from the X-ray scanner is transformed onto the work product scanned at the optical scanner. Once the required transformation has occurred to correct for the movement and / or deformation of the work product, the shape, size and contour of the work product from the optical scanner better matches the position, orientation and / or shape of the work product scanned by the optical scanner.

[0136] It should be appreciated that without the aforementioned one or more conversion steps for correcting or adjusting for deformation and / or shifting of the work product that may occur during transfer from conveyor 100 to conveyor 102, the determination of the thickness and thickness profile of the work product may be erroneous. Thus, attempts to determine the location of voids, undercuts, and other anomalies in the work product may fail.

[0137] As with the "match" analysis described above for verifying that the work product optically scanned at the optical scanner 22 is identical to the work product previously scanned at the X-ray scanner 14, the data set analyzed by the control system 18 to perform the above transformation may consist of coordinate positions along the outer perimeter of the work product. In this regard, the control system 18 may compare data including coordinate positions along the outer perimeter of the work product determined at the X-ray scanner 14 with corresponding coordinates of the same positions along the outer perimeter of the work product determined at the optical scanner 22. Such comparison of the data sets may be used to determine whether the work product has been deformed or shifted, e.g., XY translation, rotation about the Z axis, while being conveyed to the conveyor 20. A mismatch in the data sets will indicate what type of deformation has occurred and the extent of such deformation, so that an appropriate corrective transformation of the XY scan data can be applied to the work product scanned by the optical scanner 22.

[0138] Once the work product passes the optical scanner 22, it moves to the cutting station 26. As described above, the information from the X-ray scanner and the optical scanner are combined so that the location of voids, undercuts and other anomalies can be determined.

[0139] method

[0140] Figure 8 Schematically illustrated is a method of utilizing the processing system 10' of the present disclosure. The process begins at step 300, where a work product is loaded onto the flat belt conveyor 100 at step 302. Thereafter, the work product is scanned using the X-ray scanner 14 at step 304. Next, at step 306, data from the scanned work product is transmitted to the image processor 46.

[0141] Next, at step 308, the work product is transferred from the X-ray scanning conveyor 100 to the portioning conveyor 102. Thereafter, at step 310, the work product is optically scanned by the scanner 22. Thereafter, at step 312, the data generated by the optical scanner 22 is transmitted to the image processor 46, see step 312.

[0142] Next, at step 316, computer 80 compares the output from image processor 46 to determine if the optically scanned work product is the same work product previously scanned by the x-ray scanner. As described above, the data being compared may consist of coordinate positions along the outer perimeter of the work product.

[0143] Various methods and techniques can be used to compare the first data set from the X-ray scanner 14 with the second data set from the optical scanner 22 to verify that the work product scanned by the optical scanner corresponds to the same work product previously scanned by the X-ray scanner. For example, the root mean square (RMS) error between the two data sets can be calculated and the error value can be compared with the previously established maximum RMS to verify that the food scanned by the X-ray scanner is the same as the food scanned by the optical scanner. In this regard, the RMS error of each corresponding coordinate position along the outer perimeter of the work product is calculated. In essence, the position difference of each coordinate is calculated as the square root of the sum of the squares of the differences in the X and Y coordinate values. Thereafter, the square values ​​of these distances are added and the sum is divided by the number of corresponding coordinate pairs. Finally, the square root of the quotient is taken as the RMS error. The calculated RMS error is compared with the predetermined maximum RMS error allowed, and it is also concluded that the optical scanner and the X-ray scanner have scanned the same work product.

[0144] Another analysis method that can be used is by determining the difference in X and Y coordinate values ​​at each location along the work product and selecting a standard deviation that defines the acceptable variation or difference in the XY coordinate values. In this technique, a confidence level can be defined based on the standard deviation at each of the various coordinate locations along the perimeter of the work product. An acceptable confidence level or level of allowable standard deviation between XY coordinates is established in advance.

[0145] Other regression analysis techniques, such as least squares regression analysis, may also be utilized.

[0146] If it is determined that the work product from the optical scan matches the work product from the previous X-ray scan, then at step 320, the control system 18 proceeds to determine whether physical parameter data from the X-ray scan results need to be converted to data from the optical scan results due to movement or deformation of the work product when it was conveyed to the portioning conveyor 102. As described above, such deformation can include X and / or Y translation of the work product, rotation of the work product about the Z axis, scale changes of the work product in the X and / or Y directions, and shear deformation in the X and / or Y directions. If sufficient displacement or deformation has occurred in the work product WP, the processor 18 performs the necessary conversion. As a result, a close match between the configurations is achieved, including, for example, the outer perimeter and size and shape of the work product scanned by the X-ray scanner 14 and optically scanned by the optical scanner 22.

[0147] On the other hand, if it is determined that the work product WP from the optical scan does not match the work product WP from the previous X-ray scan, the processor compares the optical scan data with the next data set received from the X-ray scan to determine if the next work product on the conveyor is the same as the optically scanned work product at step 318. In this case, if a single work product is removed from the first conveyor 100 or the second conveyor 102 at a location upstream of the optical scanner 14, the next work product traveling along the conveyor will correspond to the work product that was optically scanned. However, if more than one work product WP is removed from the conveyor upstream of the optical scanner 22, the computer 80 continues to perform comparative analysis until a match occurs between the work product that has been optically scanned and the corresponding work product that has been scanned at the X-ray scanner. Once a match has been achieved in the data sets from the X-ray scan and the optical scan, the process moves to step 320 to determine if any conversion as described above needs to be performed.

[0148] Next, a thickness profile of the work product is generated based on the X-ray scan data and the optical scan data at step 322. Thereafter, at step 324, the thickness profile from the X-ray scan data and the optical scan data is analyzed to determine if undercuts, voids, and other anomalies are present in the work product, and if so, their location, size, and shape are mapped at step 324.

[0149] Thereafter, one or more cutting paths for cutter 90 are generated in step 326, keeping in mind the analysis results in the previous step 324. Next, in step 328, the work product is trimmed, cut, or otherwise portioned in the manner determined in step 326. Next, in step 330, the work product may undergo one or more further processing operations.

[0150] Further embodiments

[0151] Fig. 9 and 10 A further processing system 10" and method according to the present disclosure is illustrated. Fig. 9 The system 10" shown in Figure 1 -Components and parts that are identical to those in 4 and 6 are identified with the same reference numerals, and their description will not be repeated here. Instead, the following description will focus on Fig. 9 and 10 The system 10" and method shown are relative to Figure 1-8 Variations or differences of the system 10" and method shown. Nevertheless, it should be understood that applicable components and parts of the system 10" are indeed applicable Figure 1 The same applies to Figure 5 steps.

[0152] Reference Fig. 9 , portioning system 10" with Figure 1 The same arrangement as shown includes the X-ray scanner 14 and the optical scanner 22, except that they are located above the smooth X-ray transparent belt 100' rather than above the belt 100' as shown. Figure 1 Shown above the open braid 30. In addition, Fig. 9 The illustrated system 10" includes a second optical scanner 120 positioned above the belt 30 of the second conveyor 102". Although the optical scanner 120 is shown as having substantially the same construction as the scanner 22, other types of optical scanners may be used with the optical scanners 22" and 120. For example, these optical scanners may utilize a charge coupled device (CCD) or an infrared camera.

[0153] One difference between the system 10″ and the system 10′ is that the X-ray scanner 14 need not be used to determine the outer contour of the work product and then convert such data into data from the optical scanner 120 located above the conveyor 102′. Instead, data related to the outer contour of the work product can be obtained from the optical scanner 22 located above the first conveyor 100′, and such data related to the outer contour of the work product can be compared with corresponding data obtained from the downstream optical scanner 120. Therefore, such data generated in connection with determining the outer contour of the work product are of the same nature, thereby reducing the complexity of comparing the two data sets from the two optical scanners 22 and 120.

[0154] In addition to what has just been described, Fig. 9 The processing device 10" shown in Figure 6' is the same as the processing system 10' shown in . Moreover, because the imaging process of the two optical scanners 120 and 22 is the same, a better match may occur between the data from the two optical scanners than when using data from the x-ray scanner 14 and the optical scanner 22 to try to confirm that the work product being scanned by the optical scanner 22 is the same as the work product previously scanned by the x-ray scanner 14 and when trying to determine whether the work product has moved to a certain extent during the process of being conveyed from the upstream smooth belt conveyor to the downstream portioning conveyor, where the certain extent is the extent to which the data related to the physical parameters of the work product from the upstream scanner must be converted with respect to the data obtained from the downstream scan.

[0155] method

[0156] Fig.10 The method of utilizing the processing system 10" of the present disclosure is schematically illustrated. To a large extent, Fig.10 The method shown is similar to Figure 8 The method shown is the same, the difference is mainly due to the use of a second optical scanner 120 located above the portioning conveyor 102. "System 10". Accordingly, Fig.10 Zhongyu Figure 8 The same steps are indicated by the same part numbers and are the same as Figure 8 Similar steps are indicated by double primes (") after the step number. Thus, the following description will focus on Fig.10 The methods and Figure 8 The differences between the methods in .

[0157] about Fig.10 In the method, in step 307a, the work product is simultaneously optically scanned and X-ray scanned, and at the same location across the work product, e.g. Figure 1 Shown and in Figure 5 In step 307b, the first optical scanner data is sent to the image processor 46.

[0158] At step 314", the data from the X-ray scanner and the two optical scanners are processed by the image processor 46. Then at step 316", the optical scanner data from scanner 112 is compared to the data from scanner 14 to verify whether the work products are identical. If not, the process moves to step 318" in the same manner as described above, but in the present case using data from both optical scanners rather than data from the X-ray scanner and the optical scanner. Additionally, at step 320, a determination is made as to whether a transformation of the data from the first optical scanner 14 needs to be integrated into the data from the second optical scanner 120 due to movement or deformation of the work product as it was transferred from conveyor 100 to conveyor 102. In addition to these steps, Fig.10 The process shown in Figure 8 The process is the same as shown in .

[0159] Although illustrative embodiments have been illustrated and described, it will be appreciated that various changes may be made therein without departing from the spirit and scope of the invention. For example, the foregoing describes that an X-ray scan occurs before an optical scan or that the X-ray scan and the optical scan occur simultaneously. It will be appreciated that the present disclosure also contemplates performing an optical scan before an X-ray scan and then analyzing the data from the optical scan and the X-ray scan to determine whether voids, undercuts, and similar anomalies exist due to differences in the thickness profile of the work product determined by analyzing the data from the optical scan and the X-ray scan.

[0160] As another embodiment of the present disclosure, it is expected that in a similar Fig. 9 In some cases of the situation, the transfer of the work product from conveyor 100 to conveyor 102 can occur accurately enough that a second optical scanner such as scanner 120 is not required. In this case, small diameter end rollers located at each end of the conveyors can be used at the interface of conveyors 100 and 102. Or a transfer conveyor with small diameter end rollers can be used to bridge between conveyors 100 and 102. In this way, the processing of the work product can occur on conveyor 102 without the need for a second scanner 120. See, for example, U.S. Publication No. 2018 / 0029246, which is incorporated herein by reference. This can simplify the processing systems and methods and also enable faster production throughput of work products.

[0161] While illustrative embodiments have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.

Claims

1. A method for determining a thickness profile of a work product, comprising: a. Scan the work product using an X-ray scanner, b. analyzing data from the X-ray scanner using a computer processor to generate a thickness profile of the work product, c. scanning the work product using an optical scanner, d. analyzing data from the optical scanner using a computer processor to generate a thickness profile of the work product based on the optical scan data, e. comparing the thickness profile based on the X-ray scan data and the thickness profile based on the optical scan data, and determining the difference between the thickness profile based on the X-ray scan data and the thickness profile based on the optical scan data, and f. Mapping locations on the work product where there is a difference between the thickness profile based on the X-ray scan data and the thickness profile based on the optical scan data.

2. The method according to claim 1, wherein: Differences between the thickness profile based on the X-ray scan data and the thickness profile based on the optical scan data correspond to voids and undercuts associated with the work product that are not occupied by the work product.

3. The method according to claim 1 or 2, wherein: The work product is a food product, and a difference between a thickness profile generated based on the X-ray scan data and a thickness profile generated based on the optical scan data corresponds to: a void in the work product; an undercut beneath the work product; or other locations where the work product is absent.

4. The method according to claim 3, wherein: The food product includes meat, and the differences between the thickness profile based on the X-ray scan and the thickness profile based on the optical scan include voids in the meat, undercuts in the lower surface of the meat, or other locations where the meat is absent.

5. The method of claim 1 further comprising transporting the work product on a conveyor past the X-ray scanner and the optical scanner.

6. The method of claim 5, further comprising positioning the X-ray scanner and the optical scanner relative to the conveyor.

7. The method of claim 1 further comprising positioning the X-ray scanner and the optical scanner to simultaneously scan the same location on the work product.

8. The method of claim 2, further comprising processing the work product using a determined difference between the thickness profile based on the X-ray scan data and the thickness profile based on the optical scan data and a location on the work product where the difference between the thickness profile based on the X-ray scan data and the thickness profile based on the optical scan data exists.

9. The method according to claim 8, wherein: The work product is processed by trimming, cutting, or portioning.

10. The method of claim 1, further comprising transporting the work product in a direction of travel past the X-ray scanner and the optical scanner.

11. The method according to claim 10, wherein: The X-ray scanner scans the work product along a line extending transverse to the direction of travel of the work product.

12. The method according to claim 11, wherein: The optical scanner scans the work product along a line extending transverse to a direction of travel of the work product.

13. The method according to claim 12, wherein: The optical scanner scans the work product along the same line as the X-ray scanner scans the work product.

14. The method according to claim 5, wherein: The conveying device includes a first conveyor corresponding to the X-ray scanner and a second conveyor corresponding to the optical scanner.

15. The method according to claim 14, further comprising: g. wherein the data from the X-ray scan includes a first data set corresponding to a two-dimensional shape of the work product, h. wherein the data set from the optical scan includes a second data set corresponding to the two-dimensional shape of the work product, i. comparing the first and second data sets corresponding to the two-dimensional shape of the work product from the X-ray scan and the optical scan, and j. Determining whether there is sufficient change between the first data set and the second data set to require converting the first data set to the second data set.

16. The method according to claim 15, wherein: The conversion of the first data set from the X-ray scan to the second data set from the optical scan comprises one or more of: (i) the change of direction of the work product; (ii) rotational transformation of said work product; (iii) scaling of the work product; (iv) shear deformation of the work product.

17. The method according to claim 5: in, The conveying device includes a first conveyor corresponding to the positions of the X-ray scanner and the optical scanner; and Also included is a second optical scanner and a second conveyor corresponding to the position of the second optical scanner.

18. The method according to claim 17, wherein: the data set from the optical scanner includes a second data set corresponding to a two-dimensional shape of the work product; wherein the data from the second optical scanner includes a third data set corresponding to a two-dimensional shape of the work product; Also comprising comparing the second data set and the third data set corresponding to the two-dimensional shape of the work product from the optical scanner and from the second optical scanner; and A determination is made that sufficient change exists between the second data set and the third data set to require conversion of the second data set to the third data set.

19. The method according to claim 18, wherein: The conversion of the second data set into the third data set comprises one or more of the following: a change in direction of said work product; rotational transformation of said work product; Scaling of the work product; Shear deformation of the work product.

20. The method according to claim 5, wherein: The conveying device includes a first conveyor corresponding to the X-ray scanner and the optical scanner and a second conveyor corresponding to a processing station where the work product is processed using a thickness profile determined based on the X-ray scanning data and the optical scanning data.

21. A system for determining a thickness profile of a work product, the system comprising: a conveying device, the conveying device being used to convey the work product; an X-ray scanner configured to scan the work product conveyed on the conveyor and generate a first data set regarding physical characteristics of the work product, the first data set including a thickness profile of the work product; an optical scanner for scanning the work product conveyed on the conveyor and generating a second data set regarding physical characteristics of the work product, the second data set including a thickness profile of the work product; and A control system, the control system being configured to: generating a thickness profile of the work product based on the X-ray scan data and the optical scan data; quantifying a difference between a thickness profile of a work product based on the X-ray scan data and a thickness profile of a work product based on the optical scan data; and Mapping locations on the work product where there is a difference between a thickness profile based on the X-ray scan data and a thickness profile based on the optical scan data.

22. The system of claim 21, wherein: Differences between the thickness profile of the work product based on the X-ray scan data and the thickness profile of the work product based on the optical scan data correspond to voids in the work product, undercuts beneath the work product, or other locations with respect to the work product where there is no work product.

23. The system of claim 22, wherein: The work product includes a food product, and a difference between a thickness profile of the food product based on the X-ray scan data and a thickness profile of the food product based on the optical scan data corresponds to a void in the food product, an undercut beneath the food product, or a location with respect to the food product where no food is present.

24. The system of claim 23, wherein: The food is meat, and the difference between the thickness profile of the meat based on the X-ray scan and the thickness profile of the meat based on the optical scan is due to the presence of voids within the meat, undercuts beneath the meat, or other locations with no meat on the meat.

25. The system of claim 21, wherein: The X-ray scanner and the optical scanner are positioned relative to the conveyor to simultaneously scan the same location on the work product.

26. The system of claim 25, wherein: The X-ray scanner is configured to scan the work product along a line extending transverse to a direction of travel of the work product on the conveyor.

27. The system of claim 26, wherein: The optical scanner is configured to scan the work product along a line extending transverse to a direction of travel of the work product on the conveyor.

28. The system of claim 27, wherein: The optical scanner is configured to scan the work product along the same line that the X-ray scanner is configured to scan the work product.

29. The system of claim 28, wherein: The optical scanner is configured to scan the work product along the same line and at the same time as the X-ray scanner is configured to scan the work product.

30. The system of claim 21, wherein: The conveying device includes a first conveyor corresponding to the X-ray scanner and a second conveyor corresponding to the optical scanner.

31. The system of claim 30, wherein: The control system compares a first data set corresponding to the two-dimensional shape of the work product from the X-ray scan data with a second data set corresponding to the two-dimensional shape of the work product from the optical scan data, and compares the first and second data sets from the X-ray scan and the optical scan to determine whether there is sufficient change between the first and second data sets to require conversion of the first data set to the second data set.

32. The system of claim 31, wherein: Converting the first data set from the X-ray scan to the second data set from the optical scan comprises one or more of: a change in direction of said work product; rotational transformation of said work product; Scaling of the work product; and Shear deformation of the work product.

33. The system of claim 21 further comprising a processing station downstream of the optical scanner for processing the work product using a quantified difference between a thickness profile of the work product based on the x-ray scan and a thickness profile of the work product based on the optical scan.

34. The system of claim 33, wherein: The processing station includes a cutter for trimming, cutting and / or portioning the work product.

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