Systems and methods for profile nozzle inspection

Abstract

A system for cleaning a nozzle of a dispenser includes a dispenser having a nozzle, a camera positioned along a side of the nozzle, and a controller configured to generate one or more signals to actuate the camera to capture an image of the side of the nozzle, process the image to generate a value, and utilize the value to determine if an anomaly associated with the nozzle is present. A method of cleaning a nozzle includes actuating a camera positioned along a side of the nozzle to capture an image of the side of the nozzle, processing the image to generate a value, and utilizing the value to determine if an anomaly associated with the nozzle is present.

Description

SYSTEMS AND METHODS FOR PROFILE NOZZLE INSPECTIONCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims priority to, and the benefit of the filing date of, U.S. provisional patent application no. 63 / 513,372, filed July 13, 2023, the contents of which are incorporated by reference herein in their entirety.TECHNICAL FIELD

[0002] The present disclosure relates to systems and methods for monitoring a nozzle of a dispenser, in particular, to imaging a side of the nozzle and determining the presence of an anomaly associated with the nozzle (e.g., an accumulation of material on an exterior surface of the nozzle, a leak associated with the nozzle, damage to the nozzle, an incorrect nozzle size for a chosen dispensing operation).BACKGROUND

[0003] Inspection of jetting nozzles for process monitoring and / or cleanliness is typically performed using a lookup camera positioned directly below the nozzle. Determining the status or cleanliness of the nozzle can be difficult using such a lookup camera, and otherwise minor differences between images may be inadequate to determine the presence of certain anomalies associated with the nozzle. Existing techniques have also been used to capture a high speed image of fluid being jetted from a nozzle, but such techniques may be inadequate to identify certain anomalies associated with the nozzle, such as excessive fluid accumulation (e.g., indicative of a leak or damage to the nozzle).

[0004] Therefore, there is a need for systems and methods for monitoring a nozzle of a dispenser and determining the presence of an anomaly associated with the nozzle by performing nozzle inspection in a profile view, such as by imaging a side of the nozzle.SUMMARY

[0005] In an example, a system for monitoring a nozzle of a dispenser is provided. The system includes a dispenser. The dispenser has a nozzle. The system further includes a camera. The camera is positioned along a side of the nozzle. The system further includes a controller. The controller is configured to generate one or more signals. The controller is configured to generate one or more signals to actuate the camera to capture an image of the side of the nozzle. The controller is further configured to generate one or more signals to process the image to generate a value. The controller is further configured to generate one or more signals to utilize the value to determine if an anomaly associated with the nozzle is present.

[0006] In certain examples, the anomaly may be an accumulation of material on an exterior surface of the nozzle. In such examples, the controller may be configured to utilize the value to determine if the nozzle should be cleaned and initiate a cleaning operation to remove at least a portion of the accumulation of material from the nozzle if it is determined that the nozzle should be cleaned. In examples, the controller may further be configured to generate the value based on a comparison of the image of the nozzle to an image of a clean nozzle. In examples, after initiating the cleaning operation, the controller may further be configured to actuate the camera to capture a second image of the side of the nozzle, process the second image to generate a second value, utilize the second value to determine if the cleaning operation was successful, and send an alert indicating an error condition or cease dispensing of a material from the nozzle if it is determined that the cleaning operation was not successful.

[0007] In some examples, the anomaly may be a leak associated with the nozzle. In such examples, the controller may be configured to utilize the value to determine if the nozzle is leaking send an alert indicating an error condition or cease dispensing of a material from the nozzle if it is determined that the nozzle is leaking. In examples, the controller may further be configured to generate the value based on a comparison of the image of the nozzle to an image of a non-leaking nozzle.

[0008] In some examples, the anomaly may be damage to the nozzle. In such examples, the controller may be configured to utilize the value to determine if the nozzle is damaged send an alert indicating an error condition or cease dispensing of a material from the nozzle if it is determined that the nozzle is damaged. In examples, the controller may further be configured to generate the value based on a comparison of the image of the nozzle to an image of a non-damaged nozzle.

[0009] In some examples, the anomaly may be a size of the nozzle. In such examples, the controller may be configured to utilize the value to determine if the nozzle is of a correct size for a chosen dispensing operation and send an alert indicating an error condition or cease dispensing of a material from the nozzle if it is determined that the nozzle is not of a correct size for the chosen dispensing operation. In examples, the controller may further be configured to generate the value based on a comparison of the image of the nozzle to an image of a nozzle of the correct size for the chosen dispensing operation.

[0010] In certain examples, the controller may be configured to actuate the camera to capture the image as a material is dispensed from the nozzle. In the same or other examples, the camera may be mounted to the dispenser. In the same or other examples, the camera may be configured to rotate about the nozzle. In the same or other examples, the nozzle may be positioned so as to dispense a material along a dispensing axis, and the camera may be positioned at an angle oblique to the dispensing axis.

[0011] In some examples, the camera may be a first camera, and the system may further comprise a second camera. In such examples, the value may be a first value and the controller may further be configured to actuate the second camera to capture a second image and process the second image to generate a second value. In examples, determining if the anomaly- associated with the nozzle is present may include utilizing the first value in combination with the second value. In examples, the second camera may be positioned below the nozzle, and the second image may be of an opening in the nozzle. In examples, the second camera may be positioned along a second side of the nozzle angularly offset from the first camera.

[0012] In another example, a method of monitoring a nozzle is provided. The method includes actuating a camera. The camera is positioned along a side of the nozzle. The camera is actuated to capture an image of the side of the nozzle. The method further includes processing the image to generate a value. The method further includes utilizing the value to determine if an anomaly associated with the nozzle is present.

[0013] In a further example, a system for monitoring a nozzle of a dispenser is provided. The system includes a dispenser. The dispenser has a nozzle. The system further includes a camera. The camera is positioned along a side of the nozzle. The system further includes a controller. The controller is configured to generate one or more signals. The controller is configured to generate one or more signals to dispense a material from the nozzle. The controller is further configured to generate one or more signals to actuate the camera to capture an image of the side of the nozzle. The controller is further configured to generate one or more signals to process the image to generate a value. The controller is further configured to generate one or more signals to utilize the value to determine if an anomaly associated with the nozzle is present. The controller is further configured to initiate a corrective operation to correct or eliminate the anomaly if it is determined that the anomaly is present. The controller is further configured to actuate the camera to capture a second image of the side of the nozzle. Thecontroller is further configured to process the second image to generate a second value. The controller is further configured to utilize the second value to determine if the corrective operation was successful. The controller is further configured to send an alert indicating an error condition or cease dispensing of the material from the nozzle if it is determined that the corrective operation was not successful.BRIEF DESCRIPTION OF THE DRAWINGS

[0014] The following description of the illustrative examples may be better understood when read in conjunction with the appended drawings. It is understood that potential examples of the disclosed systems and methods are not limited to those depicted.

[0015] FIG. 1 illustrates a system for monitoring a nozzle of a dispenser according to one example;

[0016] FIG. 2A illustrates a first portion of a method for monitoring a nozzle of a dispenser according to one example;

[0017] FIG. 2B illustrates a second portion of the method of FIG. 2A according to a first example;

[0018] FIG. 2C illustrates another second portion of the method of FIG. 2A according to a second example;

[0019] FIG. 2D illustrates another second portion of the method of FIG. 2A according to a third example;

[0020] FIG. 2E illustrates another second portion of the method of FIG. 2A according to a fourth example;

[0021] FIG. 2F illustrates another second portion of the method of FIG. 2A according to a fifth example;

[0022] FIG. 3A illustrates a captured image of a clean nozzle as taken by a lookup camera positioned directly below the nozzle;

[0023] FIG. 3B illustrates a captured image of a clean nozzle as taken by a profile camera positioned along a side of the nozzle;

[0024] FIG. 4A illustrates a captured image of a nozzle having an acceptable level of residue or fluid accumulation as taken by a lookup camera positioned directly below the nozzle;

[0025] FIG. 4B illustrates a captured image of a nozzle having an acceptable level of residue or fluid accumulation as taken by a profile camera positioned along a side of the nozzle;

[0026] FIG. 5A illustrates a captured image of a nozzle having an excessive level of residue or fluid accumulation as taken by a lookup camera positioned directly below the nozzle;

[0027] FIG. 5B illustrates a captured image of a nozzle having an excessive level of residue or fluid accumulation as taken by a profile camera positioned along a side of the nozzle;

[0028] FIG. 6A illustrates a captured image of a damaged nozzle as taken by a profile camera positioned along a side of the nozzle;

[0029] FIG. 6B illustrates a captured image of a nozzle having fibrous residue or fluid accumulation as taken by a profile camera positioned along a side of the nozzle;

[0030] FIG. 6C illustrates a captured image of a nozzle having an excessive level of residue or fluid accumulation as taken by a profile camera positioned along a side of the nozzle;

[0031] FIG. 6D illustrates a captured image of a nozzle of an incorrect size for a chosen dispensing operation as taken by a profile camera positioned along a side of the nozzle;

[0032] FIG. 6E illustrates a captured image of a leaking nozzle as taken by a profile camera positioned along a side of the nozzle; and

[0033] FIG. 6F illustrates a captured image of a missing nozzle as taken by a profile camera positioned along a side of the nozzle.DETAILED DESCRIPTION

[0034] In the following detailed description, reference is made to the accompanying drawings, which form a part hereof. In the drawings, similar symbols identify similar components, unless context dictates otherwise. The illustrative examples described in the detailed description and drawings are not meant to be limiting and are for explanatory7purposes. Other examples may be utilized, and other changes may be made, without departing from the spirit or scope of the subject matter presented herein. It will be readily understood that the aspects of the present disclosure, as generally described herein and illustrated in the drawings, may be arranged, substituted, combined, and designed in a wide variety of different configurations, each of which are explicitly contemplated and form a part of this disclosure.

[0035] The term “substantially’’ is intended to mean considerable in extent or largely but not necessarily wholly that which is specified. The term “substantially parallel” should be construed in its lay sense of two directions or surfaces that maintain a generally constant distance between them, and, in particular, should not be construed in the strict mathematical sense that such directions or surfaces will never intersect when extended to infinity. The terminology includes the above-listed words, derivatives thereof, and words of similar import.

[0036] While conventional lookup cameras for monitoring and / or inspecting jetting nozzles have been adequate for their intended purpose, there is a need for systems and methods for monitoring and / or inspecting jetting nozzles using one or more profile cameras to capture an image of a side of the nozzle for more accurately and comprehensively determining the presence of an anomaly associated with the nozzle (e.g., an accumulation of material on an exterior surface of the nozzle, a leak associated with the nozzle, damage to the nozzle, an incorrect nozzle size for a chosen dispensing operation).

[0037] Referring first to FIG. 1, an example system 10 is shown. As depicted, the system 10 may include a dispenser 100. The dispenser 100 generally includes a nozzle 102. Thenozzle 102 is generally configured and positioned to dispense (e.g., viajetting) a material along a dispensing axis 104. The dispenser 100 may further include various other components typically included in jetting dispensing systems, such as material supply devices, pumps, etc. The system 10 may include a controller 130 configured to carry out the operations described herein (e.g., actuating the camera(s), processing the captured images, and determining the presence of a nozzle anomaly).

[0038] The system 10 further includes one or more cameras. In the example illustrated in FIG. 1, the system 10 includes a first camera 110 and a second camera 120, although other examples are not so limited and may include one, two, three, four, five, or more cameras. Each camera is generally configured to capture an image of the nozzle 102. For example, the first camera 110 may generally be configured to capture one or more first images, and the second camera 120 may generally be configured to capture one or more second images.

[0039] In the example illustrated in FIG. 1, the first camera 110 is positioned at an angle 0 substantially perpendicular to the dispensing axis 104. In contrast, the second camera 120 is positioned at an angle a oblique to the dispensing axis 104. The camera(s) may generally be positioned at any angle relative to the dispensing axis 104 as desired to suit a particular application. By way of non-limiting example, one of more cameras may be positioned at an angle relative to the dispensing axis 104 of from about 15° to 175°. One or more of the cameras may be positioned below the nozzle 102 and configured to capture an image of an opening in the nozzle 102. When more than one camera is employed, the cameras may generally be positioned along different (e.g., opposite) sides of the nozzle 102 from one another and / or angularly offset from one another. By way of first non-limiting example, the system 10 may include two cameras angularly offset from one another by about 180° about the nozzle 102. By way of further nonlimiting example, the system 10 may include four cameras angularly offset from one another by about 90° about the nozzle 102.

[0040] The camera(s) may, in certain examples, be mounted to the dispenser 100, which may include mounting components, mounting structures, mounting fasteners, and / or the like. In some examples, the camera(s) may be configured to rotate about the nozzle 102, such as for capturing images of the nozzle 102 from multiple sides of the nozzle 102. In this regard, the system 10 may include components, controllers, motors, and / or the like to implement rotation the camera(s) relative to the nozzle and / or components, controllers, motors, and / or the like to implement rotation of the nozzle 102 relative to the camera(s). In examples, the camera(s) may be configured to capture images of the nozzle 102 automatically at predetermined intervals in response to commands from the controller 130, in response to user input, and / or continuously. In aspects, the user input may be provided to a human machine interface (HMI), such as one or more buttons, touchscreens, and / or the like. Further, the user input may be provided to the controller 130. As will be appreciated by those skilled in the art, in addition and / or alternatively to capturing one or more images of the nozzle, the camera(s) may be configured to capture one or more videos of the nozzle or other data associated with the nozzle.

[0041] In examples, the image(s) captured by the camera(s) may be backlit, such as by employing a light source (not shown). In examples, the camera(s) may be configured to capture images of the nozzle during a cleaning operation (i.e., while the nozzle is being cleaned), during a dispensing operation (i.e., as material is dispensed from the nozzle), or at any other timed as desired to suit a particular application.

[0042] Turning now to FIG. 2A, a first portion of a method for monitoring a nozzle of a dispenser is illustrated according to one example. Specifically, the method 200 may involve generating and / or transmitting one or more signals to execute the method on a system. The system may be. for example, the system 10 of FIG. 1. The method 200 may, for example, be executed within the system 10 of FIG. 1 using the controller 130. The forthcoming description of method 200 will be described with reference to system 10 and the components thereof, thoughit will be appreciated that such method 200 and the techniques thereof are equally applicable to other related systems and components.

[0043] At step 202, a first image of a side of a nozzle is captured. As described herein, the first image may be captured by the first camera 110, which may be actuated by the controller 130.

[0044] At step 204, the captured first image of the nozzle is processed to generate a first value. As described herein, the captured first image may be processed by the controller 130. The value is generally based on an aspect or parameter associated with the nozzle 102. By way of non-limiting example, the value may be based on the presence and / or amount of material accumulation on an exterior surface of the nozzle 102, an operational status of the nozzle 102, a size of the nozzle 102, a unique identifier for and / or feature of the nozzle 102, or combinations thereof. As described herein, in certain examples, the value may indicate a pixel intensity of the captured first image.

[0045] As depicted in FIGS. 6A-6F, a predetermined subset of images depicting the nozzle 102 may be captured, and the subset may be processed to generate the first value. As described herein, the value may, in some examples, be based on a pixel intensity of the first image. In such examples, the first image may be processed (e.g., by the controller 130) by comparing one or more pixels of the captured first image to one or more corresponding pixels of a reference image (e.g., of a new or clean nozzle), such as to identify any variations in pixel intensity. Any variations in pixel intensity may, in examples, be indicative of an anomaly associated with the nozzle 102, such as a level of fluid accumulation on the exterior surface of the nozzle 102. For example, certain portions of the imaged nozzle may be darker than other portions of the nozzle 102. and a comparison of the captured first image to an image of a new or clean nozzle may provide an array of pixel intensity variations or other related data, thereby identifying the possibility or presence of an anomaly associated with the nozzle 102.

[0046] By way of non-limiting example, FIG. 3B depicts a captured image of a new, clean nozzle from a side of the nozzle 102, lacking any discernable anomaly as indicated by the existence of the nozzle 102 in the captured image and the amount of light pixels. The image of FIG. 3B may be processed by the controller 130 to generate, for example, a high value (e.g., 80- 90 on a scale of 0 to 100) to indicate that the nozzle 102 is comparable to an image of a new, clean nozzle. When employing the method 200 of FIG. 2A, the controller 130 may therefore determine, at step 206, that no anomaly is present and may send one or more signals to the system 10 to begin or continue dispensing via the nozzle 102. For comparison, FIG. 4B depicts a captured image of a nozzle from a side of the nozzle 102 after a few dispensing cycles. As seen, there is minimal accumulation of material on the exterior surface the nozzle 102. Depending upon the threshold value or range described herein, such accumulation may generally be low enough to avoid reducing dispensing efficiency or accuracy. The image of FIG. 4B may be processed by the controller 130 to generate, for example, a value (e.g., 60-70 on a scale of 0 to 100) that is relatively high, but lower than the value associated with the new, clean nozzle. On the other hand, FIG. 5B depicts a captured image of a nozzle from a side of the nozzle 102 having substantial material accumulation on the exterior surface, as indicated by the number of dark pixels. As will be appreciated, the accumulation of material may block an opening of the nozzle 102, thereby reducing the quality of dispensing to an unacceptable level. Based on the processing of FIG. 5B, the controller 130 may determine the presence of an anomaly (i.e., unacceptable level of material accumulation on the exterior surface of the nozzle) when processing the image of FIG. 5B and generate, for example, a relatively low value (e.g., 9-18 on a scale of 0 to 100). As may be appreciated, the ability and / or effectiveness of the controller 130 at processing the captured image(s) may be increased by employing a profile camera that captures an image of a side of the nozzle 102 (e.g., as depicted in the captured images of FIGS.3B. 4B. and 5B) as contrasted with the use of a lookup camera that captures an image of fromdirectly below the nozzle 102 (e.g., as depicted in the captured images of FIGS. 3A, 4A, and5 A). For example, relatively “small'’ but nevertheless potentially consequential differences (e.g., pixel intensity' variations) may be more difficult to identify when using a lookup camera (e.g., compare FIG. 4 A and FIG. 4B) than when using a profile camera as described herein (e.g., compare FIG. 5A and FIG. 5B).

[0047] At step 206, the generated first value is utilized to determine the presence of a possible nozzle anomaly (e.g., an accumulation of material on an exterior surface of the nozzle 102, a leak associated yvith the nozzle 102, damage to the nozzle 102, an incorrect nozzle size for a chosen dispensing operation). In certain examples, the generated value may be compared to a threshold value or range (e.g., a predetermined threshold value or range) to determine if the value is above or below the value or within or outside of the range, thereby indicating the presence of an anomaly associated with the nozzle. Such comparison may, in examples, be relative to (e.g., greater than or equal to) a predetermined value for a new or clean nozzle. If the value is less than the threshold or within the acceptable range, the controller 130 may thereby determine that the nozzle 102 imaged is clean or otherwise adequate for a chosen dispensing operation, and the controller 130 may send one or more signals to begin or continue dispensing via the nozzle until it is desirable to once again determine the presence of a possible anomaly associated with the nozzle 102. Conversely, if the value is greater than the threshold or outside the acceptable range, the controller 130 may send an alert indicating an error condition and / or cease dispensing via the nozzle 102, as described herein.

[0048] The controller 130 may generally be capable of determining the presence of an anomaly associated with the nozzle 102. which may, for example, take any of the non-limiting forms illustrated in FIG. 2B-2F and described herein.

[0049] With reference to FIG. 2B, the controller 130 may be capable of determining the presence of an anomaly in the form of an accumulation of material on an exterior surface of thenozzle 102 (e.g., an excessive level of fibrous residue or fluid accumulation as depicted in the captured images of FIG. 6B and FIG. 6C). At step 208a, the controller 130 may utilize the generated first value to determine if the nozzle 102 should be cleaned. The controller 130 may, for example, perform any of the functions described herein, such as comparing the captured first image of the nozzle 102 to an image of a clean nozzle (e.g., by comparing pixel intensity ) or by capturing multiple time-offset images of the nozzle to determine whether the generated value is changing over time (e.g., by identifying that the pixel intensity' is increasing over time, which may be indicative of increasing material accumulation over time). If the controller 130 determines, for example, that the level of material accumulation on the exterior surface of the nozzle does not exceed a threshold value or is within an acceptable range, the controller 130 may determine that no such anomaly is present and may send one or more signals to the system 10 to begin or continue dispensing. Conversely, if the controller 130 determines that the level of material accumulation on the exterior surface of the nozzle 102 exceeds a threshold value or is outside an acceptable range, the controller 130 may determine that an anomaly is present in the form of an accumulation of material on an exterior surface of the nozzle 102. In response to such a determination, the controller 130 may, at step 210a, initiate a nozzle cleaning operation intended to remove at least a portion of the accumulation of material from the nozzle 102. The nozzle cleaning operation may generally include any nozzle cleaning operation known in the art, such as the nozzle cleaning techniques described in U.S. Patent No. 10,906,058 and U.S. Patent Publication No. 2023 / 0060352, the entire disclosures of which are appended hereto and fully incorporated herein by reference in their entirety and which are owned by the assignee of the present disclosure. After initiating the nozzle cleaning operation in step 210a, it may generally be desirable to determine whether the nozzle cleaning operation was successful (i.e., whether the nozzle cleaning operation removed enough of the material accumulation to result in the level of material accumulation being below the threshold value or within the acceptable range). As such.at step 212a, a second image of the nozzle 102 may be captured. As described herein, the second image may be captured using the first camera 110 or the second camera 120. It may be desirable for purposes of more accurate comparison to capture the second image using the same camera and / or from the same angle relative to the nozzle. At step 214a, the captured second image is then processed to generate a second value. The second image may generally be processed and the second value may generally be generated using any of the techniques described herein with respect to processing the first image and generating the first value. At step 216a, the generated second value may then be utilized to determine whether the nozzle cleaning operation initiated in step 210a was successful (i.e., whether the nozzle cleaning operation removed enough of the material accumulation to result in the level of material accumulation being below the threshold value or within the acceptable range). If the controller 130 determines, in step 216a, that the nozzle cleaning operation was successful, the controller 130 may generally send one or more signals to the system 10 to begin, resume, or continue dispensing via the nozzle 102.Conversely, if the controller 130 determines, in step 216a, that the nozzle cleaning operation was not successful, the controller 130 may generally send an alert to the system 10 indicating an error condition (e g., a visible or audible alarm) and / or send one or more signals to the system 10 to cease dispensing via the nozzle 102.

[0050] Referring now to FIG. 2C, the controller 130 may be capable of determining the presence of an anomaly in the form of a leak associated with the nozzle 102 (e.g., as depicted in the captured image of FIG. 6E). At step 208b, the controller 130 may utilize the generated first value to determine if the nozzle 102 is leaking. The controller 130 may, for example, perform any of the functions described herein, such as comparing the captured first image of the nozzle 102 to an image of anon-leaking nozzle (e.g.. by comparing pixel intensity) or by capturing multiple time-offset images of the nozzle 102 to determine whether the generated value is changing over time (e.g.. by identifying that the pixel intensity is increasing over time, whichmay be indicative of a leak over time). If the controller 130 determines, for example, that the level of fluid on the exterior surface of the nozzle 102 or proximate the nozzle 102 but not along the dispensing axis does not exceed a threshold value or is within an acceptable range, the controller 130 may determine that no such anomaly is present and may send one or more signals to the system 10 to begin or continue dispensing. Conversely, if the controller 130 determines that the level of fluid on the exterior surface of the nozzle 102 or proximate the nozzle 102 but not along the dispensing axis exceeds a threshold value or is outside an acceptable range, the controller 130 may determine that an anomaly is present in the form of a leak associated with the nozzle 102. In response to such a determination, the controller 130 may generally, at step 210b, send an alert to the system 10 indicating an error condition (e.g., a visible or audible alarm) and / or send one or more signals to the system 10 to cease dispensing via the nozzle 102.

[0051] Referring now to FIG. 2D, the controller 130 may be capable of determining the presence of an anomaly in the form of damage to the nozzle 102 (e.g., as depicted in the captured image of FIG. 6 A). At step 208c, the controller 130 may utilize the generated first value to determine if the nozzle 102 is damaged. The controller 130 may, for example, perform any of the functions described herein, such as comparing the captured first image of the nozzle 102 to an image of a non-damaged nozzle (e.g., by comparing pixel intensity) or by capturing multiple time-offset images of the nozzle 102 to determine whether the generated value is changing over time (e.g., by identifying a change in pixel intensity in a portion of the captured image, which may be indicative of, for example, that the nozzle 102 has been chipped). If the controller 130 determines, for example, that a portion of the captured image has a pixel intensity value that matches an expected value or is within an acceptable range, the controller 130 may determine that no such anomaly is present and may send one or more signals to the system 10 to begin or continue dispensing. Conversely, if the controller 130 determines that a portion of the captured image has a pixel intensity value that matches an expected value or is within anacceptable range does not match a threshold value or is outside an acceptable range, the controller 130 may determine that an anomaly is present in the form of damage to the nozzle 102. In response to such a determination, the controller 130 may generally, at step 210c, send an alert to the system 10 indicating an error condition (e.g., a visible or audible alarm) and / or send one or more signals to the system 10 to cease dispensing via the nozzle 102.

[0052] Referring now to FIG. 2E, the controller 130 may be capable of determining the presence of an anomaly in the form of an incorrect nozzle size for a chosen dispensing operation or a missing nozzle (e.g., as depicted in the captured images of FIG. 6D and FIG. 6F). At step 208d, the controller 130 may utilize the generated first value to determine if the nozzle 102 is missing or of an incorrect nozzle size for a chosen dispensing operation. The controller 130 may, for example, perform any of the functions described herein, such as comparing the captured first image of the nozzle 102 to an image of a correct size for the chosen dispensing operation (e.g., by comparing pixel intensity). If the controller 130 determines, for example, that a portion of the captured image has a pixel intensity value that matches an expected value or is within an acceptable range, the controller may determine that no such anomaly is present and may send one or more signals to the system 10 to begin or continue dispensing. Conversely, if the controller 130 determines that a portion of the captured image has a pixel intensity value that matches an expected value or is within an acceptable range does not match a threshold value or is outside an acceptable range, the controller 130 may determine that an anomaly is present in the form of an incorrect nozzle size for a chosen dispensing operation or a missing nozzle. In response to such a determination, the controller 130 may generally, at step 21 Od, send an alert to the system 10 indicating an error condition (e.g., a visible or audible alarm) and / or send one or more signals to the system 10 to cease dispensing via the nozzle 102.

[0053] As described herein, in certain examples, if the controller 130 determines that an anomaly is present, the controller 130 may initiate a corrective operation intended to correct oreliminate the anomaly. After determining the presence of an anomaly associated with the nozzle102 (and any desired measures intended to correct or eliminate the anomaly ), it may generally be further desirable thereafter to determine whether the anomaly is still present or has ceased or been corrected. As such, with reference to FIG. 2F, at step 212f, a second image of the nozzle 102 may be captured. As described herein, the second image may be captured using the first camera 110 or the second camera 120. It may be desirable for purposes of more accurate comparison to capture the second image using the same camera and / or from the same angle relative to the nozzle 102. At step 214f, the captured second image is then processed to generate a second value. The second image may generally be processed and the second value may generally be generated using any of the techniques described herein with respect to processing the first image and generating the first value. At step 216f, the generated second value may then be utilized to determine the presence of an anomaly (including any originally-identified anomaly or another anomaly) associated with the nozzle 102. By way of non-limiting example, the second image may be captured at a time after the first image is captured, and the generated second value may be compared to the first generated value to determine whether the value (e.g., pixel intensity) is varying over time, which may be indicative of an anomaly as described herein. If the controller 130 determines, in step 216f, that no anomaly is present, the controller 130 may generally send one or more signals to the system 10 to begin, resume, or continue dispensing via the nozzle 102. Conversely, if the controller 130 determines, in step 216f, that an anomaly is present, the controller 130 may generally send an alert to the system 10 indicating an error condition (e.g.. a visible or audible alarm) and / or send one or more signals to the system 10 to cease dispensing via the nozzle 102.

[0054] As will be appreciated, various techniques may be employed for processing captured data associated with the nozzle 102, generating one or more values based upon such captured data, and / or utilizing such generated one or more values to determine the presence of ananomaly associated with the nozzle 102. For example, the techniques described herein may utilize or incorporate machine learning and / or artificial intelligence. Machine learning could include the use of any of various machine learning tools that employ machine learning algorithms, including neural networks such as Deep Neural Networks (DNN). Other examples of machine learning tools include, but are not limited to: XGBoost, Convolutional Machine Learning Tool (CNN), Support Vector Machine (SVM), Multiple Linear Regression, Random Forest, AdaBoost, Artificial Machine Learning Tool (ANN): “Conventional” Machine Learning Tool, Decision Tree (DT), Naive Bayes, K Nearest Neighbor (KNN), Hidden Markov Model (HMM), cybernetics and brain simulation, symbolic, cognitive simulation, logic-based, antilogic, knowledge-based, sub-symbolic, embodied intelligence, computational intelligence and soft computing, and / or the like. The machine learning may utilize feature vector processes, classification processes, grouping processes, classification processes, regression processes, analysis processes, matching processes, training processes, diagnostic processes, and / or the like. In one example, one or more side profile images of the nozzle may be input into a machine learning tool for closed loop control, such as for determining a classification of the one or more images, and a value may be generated based on such classification. Tn another example, one or more side profile images of the nozzle may be assigned a quality class to train a machine learning tool for closed loop control, such as by assigning each of the one or more images a quality class, in accordance with a quality classification system, to train the machine learning tool to associate quality classes with images. Depending on the quality class assigned to an image, the trained machine learning tool may control the system 10, such as to begin, continue, or cease dispensing via the nozzle depending upon a determination as to the presence of an anomaly as described herein.

[0055] Aspects of the system 10 may include various drivers, control modules, and / or the like for controlling operation of the nozzle 102, the controller 130, the first camera 110, thesecond camera 120, and / or any other components of the system 10. Aspects of the system 10 may include communication channels for communication of control signal, data, images, and / or the like between the nozzle 102, the controller 130, the first camera 110, the second camera 120, and / or any other components of the system 10. The communication channels may be any type of wired or wireless electronic communications network, such as, e.g., a wired / wireless local area network (LAN), a wired / wireless personal area network (PAN), a wired / wireless home area network (HAN), a wired / wireless wide area network (WAN), a campus network, a metropolitan network, an enterprise private network, a virtual private network (VPN), an internetwork, a backbone network (BBN), a global area network (GAN), the Internet, an intranet, an extranet, an overlay network, and / or the like.

[0056] The system 10 and / or the controller 130 may be implemented in any type of computing devices, such as, e.g., a desktop computer, personal computer, a laptop / mobile computer, a personal data assistant (PDA), a mobile phone, a tablet computer, cloud computing device, and the like, with wired / wireless communications capabilities via the communication channels. In aspects, the controller 130 may be implemented as an inspection controller, a cleaning controller, a camera operation controller, a dispensing system controller, and / or the like.

[0057] Further in accordance with various aspects of the disclosure, the method 200 may be intended for operation with dedicated hardware implementations including, but not limited to, PCs, PDAs, semiconductors, application specific integrated circuits (ASIC), programmable logic arrays, cloud computing devices, and other hardware devices constructed to implement the methods described herein.

[0058] It should also be noted that the controller 130 and / or the method 200 may utilize software implementations that may be optionally stored on a tangible storage medium, such as: a magnetic medium such as a disk or tape; a magneto-optical or optical medium such as a disk; or a solid state medium such as a memory card or other package that houses one or more read-only(non-volatile) memories, random access memories, or other re-writable (volatile) memories. A digital file attachment to email or other self-contained information archive or set of archives is considered a distribution medium equivalent to a tangible storage medium. Accordingly, the disclosure is considered to include a tangible storage medium or distribution medium, as listed herein and including art-recognized equivalents and successor media, in which the software implementations herein are stored.

[0059] Additionally, the various aspects of the system 10 and / or the controller 130 may be implemented in a non-generic computer implementation. Moreover, the various aspects of the disclosure set forth herein improve the functioning of the system 10 as is apparent from the disclosure hereof. Furthermore, the various aspects of the disclosure involve computer hardware that it specifically programmed to solve the complex problem addressed by the disclosure. Accordingly, the various aspects of the disclosure improve the functioning of the system overall in its specific implementation to perform the process set forth by the disclosure and as defined by the claims.

[0060] The camera may include a charge coupled device (CCD), CMOS image sensors. Back Side Illuminated CMOS, or the like. Images captured by the camera may be converted and stored in various formats including a JPEG file format, RAW feature format such as the Android (operating system) 5.0 Lollipop, and the like.

[0061] It should be noted that the illustrations and descriptions of the examples shown in the figures are for exemplary purposes only, and should not be construed limiting the disclosure. One skilled in the art will appreciate that the present disclosure contemplates various examples. Additionally, it should be understood that the concepts described above with the above-described examples may be employed alone or in combination with any of the other examples described above. It should further be appreciated that the various alternative examplesdescribed above with respect to one illustrated example can apply to all examples as described herein, unless otherwise indicated.

[0062] Unless explicitly stated otherwise, each numerical value and range should be interpreted as being approximate as if the word “about,’' “approximately,'’ or “substantially” preceded the value or range. The terms “about” and “approximately” can be understood as describing a range that is within 15 percent of a specified value unless otherwise stated.

[0063] Conditional language used herein, such as, among others, “can,” “could,” “might,” “may,” “e.g.,” and the like, unless specifically stated otherwise, or otherwise understood within the context as used, is generally intended to convey that certain examples include, while other examples do not include, certain features, elements, and / or steps. Thus, such conditional language is not generally intended to imply that features, elements, and / or steps are in any way required for one or more examples or that one or more examples necessarily include these features, elements and / or steps. The terms “comprising,” “including,” “having,” and the like are synonymous and are used inclusively, in an open-ended fashion, and do not exclude additional elements, features, acts, operations, and so forth.

[0064] While certain examples have been described, these examples have been presented by way of example only and are not intended to limit the scope of the inventions disclosed herein. Thus, nothing in the foregoing description is intended to imply that any particular feature, characteristic, step, module, or block is necessary or indispensable. Indeed, the novel methods and articles described herein may be embodied in a variety of other forms; furthermore, various omissions, substitutions, and changes in the form of the methods and articles described herein may be made without departing from the spirit of the inventions disclosed herein. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of certain of the inventions disclosed herein.

[0065] It should be understood that the steps of the exemplary methods set forth herein are not necessarily required to be performed in the order described, and the order of the steps of such methods should be understood to be merely exemplary. Likewise, additional steps may be included in such methods, and certain steps may be omitted or combined, in methods consistent with various examples of the present invention.

[0066] Although the elements in the following method claims are recited in a particular sequence with corresponding labeling, unless the claim recitations otherwise imply a particular sequence for implementing some or all of those elements, those elements are not necessarily intended to be limited to being implemented in that particular sequence.

[0067] It will be understood that reference herein to “a” or “one” to describe a feature such as a component or step does not foreclose additional features or multiples of the feature. For instance, reference to a device having or defining “one” of a feature does not preclude the device from having or defining more than one of the feature, as long as the device has or defines at least one of the feature. Similarly, reference herein to “one of’ a plurality of features does not foreclose the invention from including two or more, up to all, of the features. For instance, reference to a device having or defining “one of a X and Y” does not foreclose the device from having both the X and Y.

Claims

What is Claimed:

1. A system for cleaning a nozzle of a dispenser, the system comprising: a dispenser having a nozzle; a camera positioned along a side of the nozzle; and a controller configured to generate one or more signals to: actuate the camera to capture an image of the side of the nozzle; process the image to generate a value; and utilize the value to determine if an anomaly associated with the nozzle is present.

2. The system of claim 1, wherein the anomaly is an accumulation of material on an exterior surface of the nozzle and the controller is configured to: utilize the value to determine if the nozzle should be cleaned; and if determined that the nozzle should be cleaned, initiate a cleaning operation to remove at least a portion of the accumulation of material from the nozzle.

3. The system of claim 2, wherein the controller is configured to generate the value based on a comparison of the image of the nozzle to an image of a clean nozzle.

4. The system of claim 2, wherein, after initiating the cleaning operation, the controller is configured to: actuate the camera to capture a second image of the side of the nozzle; process the second image to generate a second value; utilize the second value to determine if the cleaning operation was successful: andif determined that the cleaning operation was not successful, send an alert indicating an error condition or cease dispensing of a material from the nozzle.

5. The system of claim 1, wherein the anomaly is a leak associated with the nozzle and the controller is configured to: utilize the value to determine if the nozzle is leaking; and if determined that the nozzle is leaking, send an alert indicating an error condition or cease dispensing of a material from the nozzle.

6. The system of claim 5, wherein the controller is configured to generate the value based on a comparison of the image of the nozzle to an image of a non-leaking nozzle.

7. The system of claim 1, wherein the anomaly is damage to the nozzle and the controller is configured to: utilize the value to determine if the nozzle is damaged; and if determined that the nozzle is damaged, send an alert indicating an error condition or cease dispensing of a material from the nozzle.

8. The system of claim 7, wherein the controller is configured to generate the value based on a comparison of the image of the nozzle to an image of a non-damaged nozzle.

9. The system of claim 1, wherein the anomaly is a size of the nozzle and the controller is configured to: utilize the value to determine if the nozzle is of a correct size for a chosen dispensing operation; andif determined that the nozzle is not of a correct size for the chosen dispensing operation, send an alert indicating an error condition or cease dispensing of a material from the nozzle.

10. The system of claim 9, wherein the controller is configured to generate the value based on a comparison of the image of the nozzle to an image of a nozzle of the correct size for the chosen dispensing operation.

11. The system of claim 1, wherein the controller is configured to actuate the camera to capture the image as a material is dispensed from the nozzle.

12. The system of claim 1, wherein the camera is mounted to the dispenser.

13. The system of claim 1, wherein the camera is configured to rotate about the nozzle.

14. The system of claim 1 , wherein the nozzle is positioned so as to dispense a material along a dispensing axis and the camera is positioned at an angle oblique to the dispensing axis.

15. The system of claim 1, wherein the camera is a first camera, the system further comprising a second camera.

16. The system of claim 15, wherein the value is a first value and the controller is further configured to: actuate the second camera to capture a second image; andprocess the second image to generate a second value, wherein determining if the anomaly associated with the nozzle is present includes utilizing the first value in combination with the second value.

17. The system of claim 16, wherein the second camera is positioned below the nozzle and the second image is of an opening in the nozzle.

18. The system of claim 16, wherein the second camera is positioned along a second side of the nozzle angularly offset from the first camera.

19. A method of cleaning a nozzle, the method comprising: actuating a camera positioned along a side of the nozzle to capture an image of the side of the nozzle; processing the image to generate a value; and utilizing the value to determine if an anomaly associated with the nozzle is present.

20. A system for cleaning a nozzle of a dispenser, the system comprising: a dispenser having a nozzle; a camera positioned along a side of the nozzle; and a controller configured to generate one or more signals to: dispense a material from the nozzle; actuate the camera to capture an image of the side of the nozzle; process the image to generate a value; utilize the value to determine if an anomaly associated with the nozzle is present;if determined that the anomaly is present, initiate a corrective operation to correct or eliminate the anomaly; actuate the camera to capture a second image of the side of the nozzle; process the second image to generate a second value; utilize the second value to determine if the corrective operation was successful; and if determined that the corrective operation was not successful, send an alert indicating an error condition or cease dispensing of the material from the nozzle.

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