Cased article inspection system and method therefor - Patents.com

Abstract

An inspection apparatus for inspection of cased articles includes at least one conveyor, at least one camera for acquiring case image data for each of the cased articles advanced on the at least one conveyor and passing through the inspection apparatus, and a processor configured to receive the case image data from the at least one camera, the processor configured to characterize an exterior case protrusion of the cased article as an open case flap from the case image data, the processor configured to interpret the case image data and determine that the exterior case protrusion is a coherent plane, and the processor is programmed with a parameter array of physical characteristic parameters describing coherence attributes of the case flap that determine the coherent plane that defines the open case flap state.

Description

[Technical Field]

[0001] [CROSS-REFERENCE TO RELATED APPLICATIONS] This application is a nonprovisional application of and claims the benefit of U.S. Provisional Patent Application No. 63 / 287,631, filed December 9, 2021, and U.S. Provisional Patent Application No. 63 / 138,946, filed January 19, 2021, the entire disclosures of which are incorporated herein by reference.

[0002] [Technical field] Aspects of the disclosed embodiments relate to product inspection, and more particularly to a cased item inspection system and method therefore. [Background technology]

[0003] There is a need for improved cased item inspection systems and methods.

[0004] Typically, cased item inspection systems include LED (light-emitting diode) array (curtain) illumination. The LEDs in these arrays have significant spacing (greater than 5 mm) between them, so they only produce "sample" images instead of fully imaging the cased item. Other approaches use laser triangulation, which is fast, accurate, and robust, but is susceptible to reflective surfaces like shrink wrap. Some cased item inspection systems utilize image comparison to detect features of cased items (such as open flaps), where multiple images of cased items with known / predetermined configurations are used to detect the features. Other cased item inspection systems utilize laser scanners to detect features of cased items (such as open flaps). Summary of the Invention

[0005] The foregoing aspects and other features of the disclosed embodiments are explained in the following description taken in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0006] [Figure 1] 1 is a schematic illustration of a case inspection system in accordance with aspects of the disclosed embodiment; [Figure 1A] 1 is a schematic illustration of a case inspection system in accordance with aspects of the disclosed embodiment; [Figure 1B] 1 is a schematic illustration of a case inspection system in accordance with aspects of the disclosed embodiment; [Figure 1C] 1 is a schematic illustration of a case inspection system in accordance with aspects of the disclosed embodiment; [Figure 2A] 1 is a schematic illustration of a perspective view of an example inspected product case in accordance with aspects of the disclosed embodiment; [Figure 2B] 1 is a schematic illustration of a perspective view of an example inspected product case in accordance with aspects of the disclosed embodiment; [Figure 3] FIG. 10 is a schematic diagram illustrating a flow diagram of a product detection process in accordance with aspects of the disclosed embodiment; [Figure 4] FIG. 10 illustrates a typical captured image without a product as seen by a camera vision system in accordance with aspects of the disclosed embodiment; [Figure 5] 5 illustrates an example region of interest analyzed from the generic image illustrated in FIG. 4 in accordance with aspects of the disclosed embodiment. [Figure 6] FIG. 6 illustrates an expanded example of one analysis region from FIG. 5 in accordance with aspects of the disclosed embodiment. [Figure 7] FIG. 10 is a schematic diagram illustrating a flow diagram of a product measurement process in accordance with aspects of the disclosed embodiment; [Figure 8] 8A-8C are schematic diagrams illustrating side and top views of product measurements obtained by the process of FIGS. 3 and 7 in accordance with aspects of the disclosed embodiment; [Figure 9] 8A-8C are schematic diagrams illustrating side and top views of actual box product measurements obtained by the process of FIGS. 3 and 7 in accordance with aspects of the disclosed embodiment; [Figure 9A] 8A-8C are schematic diagrams illustrating side and top views of actual box product measurements obtained by the process of FIGS. 3 and 7 in accordance with aspects of the disclosed embodiment; [Figure 9B] 8A-8C are schematic diagrams illustrating side and top views of actual box product measurements obtained by the process of FIGS. 3 and 7 in accordance with aspects of the disclosed embodiment; [Figure 9C] 8A-8C are schematic diagrams illustrating side and top views of actual box product measurements obtained by the process of FIGS. 3 and 7 in accordance with aspects of the disclosed embodiment; [Figure 10] 8A-8C are schematic diagrams illustrating outer box product measurements in side and top views obtained by the process of FIGS. 3 and 7 in accordance with aspects of the disclosed embodiment; [Figure 11] 8A-8C are schematic diagrams illustrating, in side and top views, maximum bulge measurements obtained by the process of FIGS. 3 and 7 in accordance with aspects of the disclosed embodiment; [Figure 11A] 10 is another schematic, illustrative example of a bulge on one or more sides of a product in accordance with aspects of the disclosed embodiment; [Figure 11B] 10 is another schematic, illustrative example of a bulge on one or more sides of a product in accordance with aspects of the disclosed embodiment; [Figure 11C] 10 is another schematic, illustrative example of a bulge on one or more sides of a product in accordance with aspects of the disclosed embodiment; [Figure 12] 10A-10C illustrate the detection of the presence of debris on a camera system window in accordance with aspects of the disclosed embodiment; [Figure 13A] 1 is an exemplary diagram illustrating a cased article having an open flap according to aspects of the disclosed embodiment; [Figure 13B] 1 is an exemplary diagram illustrating a cased article having an open flap according to aspects of the disclosed embodiment; [Figure 13C] 1 is an exemplary diagram illustrating a cased article having an open flap according to aspects of the disclosed embodiment; [Figure 13D] 1 is an exemplary diagram illustrating a cased article having an open flap according to aspects of the disclosed embodiment; [Figure 13E]1 is an exemplary diagram illustrating a cased article having an open flap according to aspects of the disclosed embodiment; [Figure 13F] 1 is an exemplary diagram illustrating a cased article having an open flap according to aspects of the disclosed embodiment; [Figure 14A] 1 and 1A-1C according to aspects of the disclosed embodiment. [Figure 14B] 1 and 1A-1C according to aspects of the disclosed embodiment. [Figure 14C] 1 and 1A-1C according to aspects of the disclosed embodiment. [Figure 14D] 1 and 1A-1C according to aspects of the disclosed embodiment. [Figure 15] 1 and 1A-1C for open flap determination according to aspects of the disclosed embodiment; [Figure 16] 1 and 1A-1C for open flap determination according to aspects of the disclosed embodiment; [Figure 17] 1 and 1A-1C for open flap determination according to aspects of the disclosed embodiment; [Figure 18] 1 and 1A-1C for open flap determination according to aspects of the disclosed embodiment; [Figure 19] 1 and 1A-1C for open flap determination according to aspects of the disclosed embodiment; [Figure 20] 1 and 1A-1C for open flap determination according to aspects of the disclosed embodiment; [Figure 21] FIG. 2 is a schematic illustration of the operation of the case inspection system of FIGS. 1 and 1A-1C in accordance with aspects of the disclosed embodiment. [Figure 22] 1 is an exemplary flow diagram of method(s) according to aspects of the disclosed embodiment; [Figure 23A] FIG. 2 is a schematic perspective view of image data obtained with the case inspection system of FIGS. 1 and 1A-1C showing a cased article having a concave surface in accordance with aspects of the disclosed embodiment. [Figure 23B] 23A-23C are exemplary schematic diagrams illustrating case image data (corresponding to the concave surface of FIG. 23A) obtained with the case inspection system of FIGS. 1 and 1A-1C in accordance with aspects of the disclosed embodiment. [Figure 23C] 1 is a schematic perspective view of a cased article having a combination of cased article properties (which may affect the handling, storage, and transportation of the cased article) in accordance with aspects of the disclosed embodiment; [Figure 24A] FIG. 1B is a perspective view of cased item image data obtained with the case inspection system of FIGS. 1 and 1A-1C illustrating a bulge in the top surface of the cased item in accordance with aspects of the disclosed embodiment. [Figure 24B] 10 is an exemplary schematic side view of cased item image data having a bulge on the bottom surface of the cased item in accordance with aspects of the disclosed embodiment; [Figure 25] FIG. 1B is a schematic diagram of cased article data obtained with the case inspection system of FIGS. 1 and 1A-1C showing a side view of a cased article having one or more tapers or narrowings on one or more sides of the cased article in accordance with aspects of the disclosed embodiment. [Figure 25A]FIG. 1B is a schematic diagram of cased article data obtained with the case inspection system of FIGS. 1 and 1A-1C showing a side view of a cased article having one or more tapers or narrowings on one or more sides of the cased article, in accordance with aspects of the disclosed embodiment. [Figure 26] FIG. 10 is a schematic illustration of cased item data obtained with the case inspection system of FIGS. 1 and 1A-1C showing a side view of a cased item having multiple products therein, in accordance with aspects of the disclosed embodiment; [Figure 27] FIG. 1B is a schematic diagram of cased article data obtained with the case inspection system of FIGS. 1 and 1A-1C showing a side view of a cased article having one or more tapers on one or more sides of the cased article in accordance with aspects of the disclosed embodiment. [Figure 28A] FIG. 10 is a schematic top view of anticipated cased item dimensions in accordance with aspects of the disclosed embodiment; [Figure 28B] FIG. 10 is a schematic side view of anticipated cased item dimensions in accordance with aspects of the disclosed embodiment; [Figure 29] 1 is a schematic top view of a plurality of cased articles moving substantially side-by-side along a conveyor in accordance with aspects of the disclosed embodiment; [Figure 30] 1 is an exemplary flow diagram of method(s) according to aspects of the disclosed embodiment; DETAILED DESCRIPTION OF THE INVENTION

[0007] It is noted that like features have like labels throughout the drawings. It is also noted that references to the modifiers "top" and "bottom" (and other spatial modifiers) made herein are made with reference only to the orientation of the drawings as presented in this application and do not imply absolute spatial orientation.

[0008] 1 illustrates an exemplary cased item inspection system 100 in accordance with aspects of the disclosed embodiment. While aspects of the disclosed embodiment will be described with reference to the drawings, it should be understood that aspects of the disclosed embodiment can be embodied in many forms. Furthermore, any suitable size, shape, or type of elements or materials may be used.

[0009] One example of a cased item(s) handled by cased item inspection system 100 is a shrink-wrapped product container or shrink-wrapped product 200 containing one or more product containers or an array of product(s) as illustrated in FIG. 2A. Another example of a cased item(s) is a boxed product 210 (such as a cardboard box or other suitable shipping container) as illustrated in FIG. 2B, enclosing a product container or one or more product containers or an array of unpacked product(s) therein. The term "product" as used herein should be construed to include, without limitation, any type of consumer item(s) in any packaging, such as a sealed carton, tote bag, open-top carton, tray, bag, pouch, or the like, with or without shrink-wrap film (i.e., the terms "product" and cased item include shrink-wrapped product 200 and boxed product 210). The dimensions of the product(s) / case(s) 102 (generally referred to herein as products or cased articles) (e.g., input products) received by the cased item inspection system 100 can vary greatly among various types of products. For illustrative purposes only, typical dimensions (width (W) x length (L) x height (H)) can be between approximately 4 inches x 4 inches x 2 inches (approximately 10 cm x 10 cm x 5 cm) and approximately 25 inches x 30 inches x 30 inches (approximately 63 cm x 76 cm x 76 cm). While the example in FIGS. 2A and 2B is illustrated as having a generally hexahedral shape, the product(s) and / or product case may have any desired three-dimensional shape, such as cylindrical, curved, pyramidal, oval, etc., and one or more surfaces on any side may be curved or angled relative to another side or another surface on the same side. As described in more detail below, one or more of the products 102 include flaps that can be folded to close the opening of the product container. Aspects of the disclosed embodiment provide for at least detection of these flaps in an open or partially open configuration.

[0010] The cased item inspection system or apparatus 100 includes at least one input conveyor 110, at least one output conveyor 120, a vision system 150, a controller 199, and a user interface 198 (see FIGS. 8-12 for exemplary user interface 198 outputs). The cased item inspection system 100 forms, at least in part, or is otherwise included in an inbound conveyor system 195 for introduction of cased items 102 into a logistics facility 190, with at least one of the conveyors 110, 120 configured to advance the cased items 102 into the logistics facility 190. By way of example only, the cased item inspection system 100 is in communication with the at least one conveyor 110, 120 to receive cased items 102 arriving at the input conveyor 110 individually in any orientation and position, and the cased items 102 are transferred from the input conveyor 110 to the output conveyor 120 as described herein. The output of the cased item inspection system 100 includes various (quantitative) measurements that characterize each cased item, e.g., the case of the item. Examples of quantitative measurements include "full box," "maximum box," "maximum bulge," "orientation angle," "distance from one side of the conveyor," open flaps, indentations (e.g., inward bulge), etc.

[0011] The at least one input conveyor 110 is configured to advance the cased articles 102 through the cased article inspection system 100 (also referred to herein as the "cased article inspection device 100"). For example, the at least one input conveyor 110 is one or more of a conveyor belt (e.g., a mat top high-grip conveyor), a roller conveyor, or any other suitable product conveying device configured to transport the incoming cased articles 102 from any suitable equipment (e.g., automated or otherwise) or warehouse personnel (e.g., human). The at least one input conveyor 110 is configured to move the cased articles 102 to and through the vision system 150 with minimal vibration and slippage (e.g., below any suitable predetermined threshold for vibration and slippage, which may depend on the resolution of the components of the vision system 150). At least one output conveyor 120 is generally similar to at least one input conveyor 110 and transports the cased articles 102 away from the vision systems 150, 170 to any suitable destination, including suitable product processing equipment located downstream of or processually behind the cased article inspection system 100.

[0012] 1 and 1A-1C, a vision system 150 is positioned (e.g., mounted) at least in part around and about the conveyors 110 and / or 120 to view and measure characteristics of the cased articles 102 (described above) advanced on the conveyor(s) 110, 120 and passing through the cased item inspection system 100. As described herein, the vision system 150 includes at least one camera (e.g., at least one sensor / imager 171-173, etc.) positioned to capture case image data for each of the cased articles 102 advanced on the at least one input conveyor 110 and passing through the cased item inspection system 100.

[0013] In accordance with aspects of the disclosed embodiment, the vision system 150 includes a flap detection system 170 (also referred to herein as an “imaging system” or “detection system”) that includes at least one sensor / imager 171-173 (referred to herein as sensors 171-173) for detecting (or otherwise providing detection of) an open flap, bulge, and / or depression on the cased articles 102. The sensor may be any suitable sensor configured to detect / sense at least a flap, bulge, and / or depression on the cased articles 102, including, but not limited to, a camera (three are illustrated for illustrative purposes only, and it should be understood that there may be more or less than three), a laser detection system, or any other suitable optical or acoustic detection system for detecting a flap on the cased articles 102. The sensors 171-173 may be any suitable camera, such as, for example, a three-dimensional camera, including, but not limited to, a time-of-flight camera or any other suitable three-dimensional imaging camera. In one or more aspects of the disclosed embodiment, sensors 171-173 are positioned adjacent to one or more of conveyors 110, 120 to detect open flaps, bulges, and / or depressions in cased articles 102, as described in more detail below. As can be seen in FIGS. 1A-1C , in one or more aspects of the disclosed embodiment, flap detection system 170 includes lasers, and each sensor 171-172 (for illustrative purposes, only two cameras are illustrated in FIGS. 1A-1C , but it should be understood that more or fewer than two cameras may be provided) is paired with a laser 172L, 173L (note that sensor 171 may also be paired with laser 171L, which is not illustrated in FIGS. 1A-1C for clarity). Lasers 171L, 172L, 173L are configured to emit illumination sheets that provide respective scan lines on cased articles 102, which illuminate a profile of cased articles 102.Illumination of the profile by the scan line, in one or more embodiments, facilitates detection of open flaps, bulges, and / or depressions in the cased articles 102 (e.g., via image recognition of case image data from sensors 172, 173). In still other embodiments, one or more of sensors 171-173 are paired with a respective laser, while other sensors 171-173 do not have an associated laser. In one or more embodiments, lasers 171L, 172L, 173L are generally similar to light sources 182, 183 described herein.

[0014] The vision system 150 may further include another imaging system (e.g., a profile detection system 180, also referred to as a case inspection system or station) that is separate and distinct from the at least one sensor 171-173 of the flap detection system 170. The profile detection system 180 images the cased articles 102 separately and differently from the imaging of the cased articles 102 by the at least one sensor 171-173, for inspection of the cased articles other than detecting a dent condition. The profile detection system 180 may be generally similar to that described in U.S. patent application Ser. No. 15 / 416,922, filed Jan. 26, 2017 (and entitled "Cased Goods Inspection System and Method," now bearing U.S. Patent No. 6,114,159), the entire disclosure of which is incorporated herein by reference.

[0015] Profile detection system 180 includes at least one sensor / imager 181, 184 positioned adjacent one or more of conveyors 110, 120 and configured to detect / sense the top and side profiles of products 102. The at least one sensor / imager 181, 184 of profile detection system 180 is configured to capture an image of the shadow of each cased article 102 advanced through case inspection station 100, as described herein. The at least one sensor 181, 184 of profile detection system 180 is separate and distinct from flap detection system 170, which images cased articles 102 separate and distinct from at least one sensor 171-173 of flap detection system 170 for inspection of cased articles 102 other than detection of open case flaps. Here, the profile detection system 180 images the cased articles 102 for verification by the controller 199 / processor 199P of the identity of each of the cased articles 102 (e.g., having a predetermined or expected identity for each of the cased articles), and for verification by the controller 199 / processor 199P of the compatibility of each of the cased articles 102 with (e.g., predetermined or expected) case size parameters for the verified cased articles 102.

[0016] According to aspects of the disclosed embodiment, profile detection system 180 includes a first light source 182 that emits a first light sheet, e.g., a continuous surface of substantially parallel / collimated light, within the small gap GP between conveyors 110 and 120. For example, first light source 182 can be positioned above conveyors 110, 120 as otherwise shown in FIG. 1 or below conveyors 110, 120. In one or more aspects, first light source 182 can be common to (i.e., shared between) both profile detection system 180 and flap detection system 170 (e.g., first light source can function as one of lasers 172L, 173L described above, or vice versa).

[0017] The profile detection system 180 further includes a first camera system 184 disposed, for example, on the opposite side of the first light source 182 with respect to the conveyors 110, 120. The first camera system 184 is positioned to receive parallel / collimated light emitted by the first light source 182, for example, through the gap GP. For example, if the first light source 182 is disposed above the conveyors 110, 120, the first camera system 184 is disposed below the conveyors 110 and 120. In other embodiments, the orientation of the first light source 182 and the first camera system 184 can be rotated as desired about an axis defined by the direction of movement of the conveyors 110, 120 while maintaining the relationship between the light source 182 (e.g., light emitter) and the camera system 184 (e.g., light receiver).

[0018] The second light source 183 emits a second light sheet, i.e., a continuous surface of substantially parallel / collimated light, across the small gap between the conveyors 110, 120. For example, the second light source 183 can be positioned on one side of the conveyors 110, 120 (with the transmission of the second sheet's parallel / collimated light beam substantially perpendicular to the continuous surface of parallel / collimated light of the first light sheet). In one or more embodiments, the second light source 183 can be common to (i.e., shared between) both the profile detection system 180 and the flap detection system 170 (e.g., the second light source can function as one of the lasers 172L, 173L described above, or vice versa).

[0019] The second camera system 181 is positioned correspondingly (e.g., opposite the second light source 183) with respect to the conveyors 110, 120 to receive illumination from the second light source 183. The second camera system 181 is positioned to receive parallel / collimated light emitted by the second light source 183. For example, if the second light source 183 is positioned on one side of the conveyors 110, 120, the second camera system 181 is positioned on the other opposite side of the conveyors 110, 120.

[0020] In accordance with one or more aspects of the disclosed embodiment, at least one light source 182 or 183 may include a light shaper LS made of lenses or mirrors that provides a collimated output beam. The light source may be any suitable light source, including but not limited to, one or more of a laser, a light emitting diode (LED), a gas lamp, and any other device of electromagnetic radiation suitable for electromagnetic illumination of a target object, the reflection or transmission of which may be captured by a suitable imaging system to generate an image or simulated image of the illuminated target object.

[0021] The collimated output light beam(s) of the light source(s) 182, 183, when obstructed by the cased article 102, provide a parallel propagating light sheet(s) that projects an orthogonal projection onto the input window of the corresponding camera system 184, 181 opposite the corresponding light source 182, 183. In this regard, the camera system 184, 181 receives the incident collimated input beam(s) output by the corresponding light source.

[0022] In the illustrated example, both camera systems 184, 181 include at least one camera 181C, 184C. Camera systems 184, 181 may also include mirrors 181M, 184M and diffusing screens 181D, 184D (referred to as diffusers in the drawings). Mirrors 181M, 184M are utilized, for example, in reducing the overall footprint of the cased item inspection system by redirecting the light sheet parallel to the conveyors 110, 120. The diffusion screens 181D, 184D, which may be any suitable type of illumination diffuser, are examples of input beam shapers that broaden the input beam by diffusing the collimated light incident thereon from the corresponding light sources 182, 183, thereby enabling the corresponding cameras 184, 181 (e.g., camera imaging arrays having a desired predetermined width, defined structurally, such as an array, or by any suitable controller, such as controller 199) to capture and digitize the diffused light from the full width of the corresponding light sheet emitted by the light sources 182, 183. As can be appreciated, the camera(s) 184, 181 can image the case(s) and / or product(s) within the full width of the light sheet (which, as can further be appreciated, may span the lateral boundaries of the conveyors 110, 120 and the height H of the inspection system opening 101).

[0023] To reduce the light footprint or to allow the use of less powerful laser-class light sources for flap detection system 170 and profile detection system 180, smaller sheets of collimated light can be used with overlap to maintain continuity and cover a larger surface. Any suitable calibration procedure can be used to realign these separate sheets as a single sheet, for example by software in controller 199.

[0024] As described herein, at least one sensor / imager 171-173 of flap detection system 170, separate and distinct from at least one camera 181, 184, is connected to case inspection station 100. At least one sensor / imager 171-173 is positioned to capture other case image data 1400 of each cased article 102 advanced through case inspection station 100, in addition to the case image data captured by at least one camera 181, 184. In the example illustrated in FIGS. 1 and 1A-1C, flap detection system 170 utilizes case image data or any other suitable data from profile detection system 180, as described in more detail herein. Here, flap detection system 170 is positioned downstream from profile detection system 180 relative to the direction of product movement along conveyor(s) 110, 120 (e.g., product 120 passes profile detection system 180 before passing flap detection system 170), although in other embodiments, flap detection system 170 may be positioned upstream of profile detection system 180. The relative positioning of flap detection system 170 and profile detection system 180 is such that flap detection system 170 images one or more outer sides of cased article 102 (e.g., in one or more embodiments, all visible outer sides that are not seated, e.g., relative to conveyor(s) 110, 120) at approximately the same time that profile detection system 180 images cased article 102 as described herein.

[0025] 1, flap detection system 170 includes one or more platforms, posts, or other suitable supports positioned adjacent conveyor(s) 110, 120, upon which sensors / imagers 171-173 (and in one or more embodiments, lasers 171L-173L) are positioned. It is again noted that while three sensors 171-173 are illustrated in FIG. 1, in other embodiments, more or fewer sensors (e.g., such as the two sensors illustrated in FIGS. 1A-1C) may be positioned to image all five visible outer sides of cased article 102 that is not seated relative to conveyor(s) 110, 120. The sensors / imagers 171-173 are positioned relative to the conveyors 110, 120 to image any suitable number of surfaces of each cased item 102 as the products pass through the flap detection system 170, although in other embodiments a single sensor / imager equipped with a suitable prism or mirror may provide images of any suitable number of surfaces of each cased item 102.

[0026] 1, sensors 171-173 are positioned such that each sensor 171-173 images at least one or more respective exterior sides of cased articles 102. For example, sensor 171 images the side (and longitudinal and top profiles) of cased articles 102, sensor 173 images the top (and side and longitudinal profiles) of cased articles 102, and sensor 172 is angled to image the side, top, and longitudinal sides of cased articles 102. In FIGS. 1A-1C, sensors 172, 173 are angled relative to each other and positioned on opposite sides of conveyor(s) 110, 120 to image both side, both longitudinal, and top sides of cased articles 102 (e.g., two sensors image five visible sides of cased articles 102). In some aspects of the disclosed embodiments, the flap detection system is provided with any suitable lighting (e.g., laser / collimated light source as described above, etc.) that facilitates imaging of the cased articles 102 moving along the conveyors 110, 120. In one aspect, the exposure (e.g., ISO and / or shutter speed) of the sensors / imagers 171-173 is such that the cased articles 102 moving along the conveyors 110, 120 appear stationary and the resulting images of the cased articles 102 moving along the conveyors are not blurred, although in other aspects a "stop motion effect" of the cased articles 102 moving along the conveyors 110, 120 may be created by any suitable strobe lighting.

[0027] As described above, sensors / imagers 171-173 may be any suitable sensor / imager, such as, for example, a time-of-flight camera or any other suitable imager capable of generating a three-dimensional depth map or point cloud of each cased article 102 moving along conveyors 110, 120. In FIG. 1 , sensor / imager 172 is positioned adjacent conveyors 110, 120 to image at least the leading edge 102F of cased articles 102 (e.g., the front or longitudinal face of each cased article 102 relative to the direction of movement along conveyors 110, 120; note that the term “front” is used herein for illustrative purposes only, and any spatial terminology may be used). For example, sensor / imager 172 may be mounted to post 170M in any suitable manner to face in a direction substantially opposite the direction of movement along conveyors 110, 120 to image cased articles 102 moving toward sensor / imager 172. Sensor / imager 173 is also mounted to support post 170M and positioned above conveyors 110, 120 to image a plan view of at least the top surfaces 102T (e.g., the "top" surface is opposite the side of the cased articles 102 seated on the conveyors 110, 120; note that the term "top" is used herein for illustrative purposes only and any spatial terminology may be used) of the cased articles 102 moving along the conveyors 110, 120. Sensor / imager 171 is mounted to any suitable surface adjacent to the conveyors 110, 120 to image the side surfaces 102L of the cased articles 102 moving along the conveyors 110, 120. 1A-1C, the sensor 172 is mounted (in a manner similar to that of FIG. 1) so as to be positioned relative to the conveyors 110, 120 to capture a perspective view of the cased article 102, including one side surface 102L1, the top surface 102T, and the rear or "back" longitudinal surface 102R of the cased article 102.Sensor 173 is mounted (in a manner similar to FIG. 1) to be positioned relative to conveyors 110, 120 to capture a perspective view of cased article 102, including one opposing side surface 102L2, top surface 102T, and leading or front longitudinal surface 102RF of cased article 102. Each of sensors / imagers 171-173 is positioned to generate an image of at least a respective side of cased article 102, and as can be appreciated, the number of cameras can depend on the particular cased article being inspected.

[0028] As described herein, at least one camera (e.g., sensor / imaging device 171-173) is positioned to image each exposed case side 102T, 102F, 102R, 102L1, 102L2 of each cased article 102 advanced on at least one conveyor 110, 120 and passing through the inspection device 100, thereby imaging at least one of the concave condition (or inward variance) of the case side and the outward protrusion of the case that are evident in each imaged case side 102T, 102F, 102R, 102L1, 102L2 from the common image of each imaged case side 102T, 102F, 102R, 102L1, 102L2. At least one sensor / imaging device 171-173 is positioned to capture case image data 1400 of each cased article 102 advanced on at least one conveyor 110, 120 and passing through the inspection apparatus 100, whereby the case image data embodies at least one of the case side indentations 2300 (also referred to herein as inner variations (see, for example, FIG. 23A)) and case outer protrusions 220, with at least one exposed case side 102F, 102R, 102T, 102L1, 102L2 being oriented in the orientation of each exposed case side of the cased article 102.

[0029] In other embodiments, at least one sensor / imaging device 171-173 is positioned to capture case image data 1400 for each cased article 102 advanced on at least one conveyor 110, 120 and passing through the inspection apparatus 100, whereby the case image data 1400 embodies a concave condition (or interior alteration condition) with the concave condition manifested on at least one exposed case side 102T, 102L, 102F, 102R (and in some embodiments, the bottom side 102B, as described herein) and with the at least one exposed case side positioned in the orientation of each exposed case side of the cased article 102. In addition to or instead of determining the case outward protrusion, the at least one exposed case side 102T, 102L, 102F, 102R imaged by the at least one sensor / imager 171-173 is positioned such that the concave condition revealed from the concave condition manifested on the imaged at least one exposed case side 102T, 102L, 102R, 102F extends from the at least one exposed case side 102T, 102L, 102R, 102F adjacent to the conveyor seating surface 110S, 120S on which the cased item 102 is seated.

[0030] The cased item inspection system 100 includes any suitable controller 199 (including any suitable processor 199P, such that references to a controller 199 performing or configured to perform the tasks / functions described herein imply the operation of the processor 199P), or any other device or system (local or remote) including a computer-readable medium having stored thereon non-transitory computer program code that configures the controller 199 to register and analyze case image data from the vision system 150 and calculate desired measurements (as described herein) or other suitable characteristics of the cased items 102. The controller 199 is operably coupled to at least one conveyor 110, 120 in any suitable manner, such as via any suitable wired or wireless connection, to receive case image data from at least one sensor 171-173 (see Figures 14A-14H for exemplary case image data 1400 from sensors 171-173), 181, 184 (see Figures 5, 6, and 8-11 for exemplary case image data from sensors 181, 184), and is communicatively coupled to at least one sensor 171-173, 181, 184 of the vision system 150.

[0031] It is noted that the controller 199 (e.g., via the processor 199P) is configured such that the inspection of the cased items based on the case item image from the profile detection system 180 is resolved separately and differently from the resolution of at least one of the case side dents (also referred to as the case side dent state) and the open case flap from the case image data 1400 (see Figures 14A-14D) from at least one sensor 171-173 of the flap detection system 170. The controller 199 is also configured to determine the presence of any case side indentations 2300 and any case outer protrusions 220 of the cased items 102 from the image data of the profile detection system 180, which is separate and distinct from the case image data 1400 captured by at least one sensor 171-173 of the case detection system 170 (see Figures 9-11 in addition to Figures 2A and 2B), and to resolve at least one of the case side indentations and case outer protrusions 220 as a respective case side indentation and open case flap from the case image data 1400 of at least one sensor 171-173 of the flap detection system 170, which is separate and distinct from the image of the profile detection system 180. In one or more embodiments, the controller 199 is configured to determine the presence of at least one of a case side recess and a case outer protrusion 220 from the case image data 1400 captured by at least one sensor 171-173 of the flap detection system 170, independently from the image of the cased item 102 captured by the profile detection system 180.

[0032] In one or more embodiments, the controller 199 is configured to characterize at least one of the case side recesses 2300 (as described herein, see FIG. 23A ) and the case outer protrusions 220 of the cased items 102 as case flaps in an open state from case image data 1400 generated from a common image of the cased items 102 captured by at least one sensor 171-173 (see FIGS. 23B and 23C - e.g., an image from one of the at least one sensors 171-173 or a combined image from multiple sensors of the at least one sensor 171-173). Here, at least one exposed case side 102F, 102R, 102T, 102L1, 102L2 imaged by at least one sensor 171-173 is positioned so that at least one of the case side recess 2300 and the case outer protrusion 220 apparent in the imaged at least one exposed case side 102F, 102R, 102T, 102L1, 102L2 extends from at least one exposed case side 102F, 102R, 102T, 102L1, 102L2 adjacent to the conveyor seating surface 110S, 120S (FIG. 1) on which the cased item 102 is seated.

[0033] When the processor is configured to characterize at least one case top surface 102T or at least one case side surface 102L, 102R, 102F in a concave state from case image data 1400 of cased items captured by at least one sensor 171-173, the processor 199P is programmed to ascertain from the image data 1400 interior variations (or concavities) of at least one case top surface 102T or at least one case side surface 102L, 102R, 102F from predetermined planar coherence characteristics of the case top surface 102T or case side surface 102L, 102R, 102F (e.g., from expected case dimensions and case item type, such as a stockkeeping unit (SKU) as described herein). The processor 199P is configured to determine from the image data 1400, for the presence of each resolved internal change, physical characteristics describing the recessed state of at least one case top surface 102T or at least one case side surface 102L, 102R, 102F.

[0034] Referring to Figure 3, the operation of the cased item inspection system 100 is described. The cased items 102 arrive at the conveyor 110 at any orientation and position. In one or more embodiments, the position of the cased items 102 on the conveyor 110 includes a distance or gap from one side of the conveyor 110. Figure 3 illustrates the product measurement process. The profile detection system 180 is triggered, for example, by an input conveyor encoder, or alternatively, by a stepper motor drive circuit that advances at least one of the conveyors 110 and 120, to perform repeated image acquisitions to image cache storage (e.g., in the processor 199P of the controller 199) (Figure 3, block 310).

[0035] FIG. 4 illustrates a representative example of what may be referred to as a raw acquired image (using the camera imagers of camera systems 181, 184) at a given encoder index value, such as might be generated for four light sources (e.g., as might be used in any of light sources 182, 183) and one camera system (e.g., camera system(s) 181, 184). The image includes subregions of illuminated and unilluminated (unexposed) pixels 4GI, 4GV. The image analysis computer program algorithm does not consider the complete acquisition region of the camera image sensor, where no pixels are exposed. Instead, it considers a specific subregion 4GI, e.g., having a height 4H of three pixels and a full light sheet width 4W. FIG. 5 illustrates a considered region 5GI (such as one that may correspond to such a light source), identified by a dotted rectangle representing the registered image subregion 5L processed by the image analyzer. FIG. 6 shows details of one specific region 6GI enlarged to better illustrate the region being considered by the image analysis algorithm.

[0036] For each acquired image (FIG. 4), the image analysis algorithm compares the pixel light intensity of pixels within the particular region 5h being analyzed (FIG. 5) to normalized intensity values ​​obtained from comparable subregion samples, e.g., 10 raw baseline sample images (FIG. 3, block 320). Referring to FIG. 3, the normalized baseline may be a rolling baseline; at each image acquisition step 320 (without the possibility of detection, as described below), the oldest image in the sample is deleted or erased from the registry and replaced with a newly acquired rendered image (FIG. 3, block 322). The number of images used in the baseline sample can vary. The normalized intensity values ​​may represent ambient illumination levels, for example, to account for varying lighting conditions in the environment surrounding the cased item inspection system and the presence of dust, liquid residue, or small debris on the photoreceptor.

[0037] For illustrative purposes, using an image acquired from camera system 184 located below conveyors 110 and 120, controller 199 verifies whether the number of pixels in a considered portion of the acquired image (the acquired image registered by at least one of cameras 184, 181, or both cameras 184, 181, if desired) has a drop in intensity, e.g., greater than about 40%, compared to the normalized intensity value, and whether it represents a width of about 30 mm (about 1.2 inches) or more from the full width of the illumination sheet captured by the acquired image ( FIG. 3 , block 330). As can be appreciated, the width referred to herein as the threshold width of the reduced intensity portion of the acquired image can be set as desired based on environmental conditions. The reduced intensity width of the image portion corresponds to and is the result of a drop in spatial intensity caused by a sustained, disruption and / or obstruction or blockage of at least a portion of the input beam(s) forming the illumination sheet, over the duration of the acquired image(s), such as due to an object passing through the beam(s), which may be partially opaque or translucent. In other words, as the product, case, and / or packaging passes through the sheet, what is sometimes referred to as a gray-level image is generated for at least a portion of the width of the acquired image. In this case, the controller considers the likelihood of detecting the product or cased item ( FIG. 3 , block 332). The intensity drop threshold (both the threshold width and the threshold intensity variance) can be varied as desired (e.g., the intensity drop threshold can be reduced by approximately 10% from normalization). As can be appreciated, both threshold settings determine the portion of opaque or translucent material within the illuminated sheet, the breakdown of which results in a gray image in which such material is detectable and measurable, as further explained (and the threshold width can be approximately 5 mm or approximately 0.2 inches). By comparison, entirely opaque material will reflect and consequently obstruct illumination almost completely, thereby obstructing the relevant portion of the graphic projection image or the graphic projection image itself.

[0038] The steps of the above process, e.g., blocks 310-332 of FIG. 3, are repeated ( FIG. 3 , block 334) for as long as the number of pixels in a given acquired image have an intensity drop (also expressed as an absolute intensity value threshold) greater than a predetermined threshold intensity drop, e.g., greater than about 40%, and represent a width greater than a predetermined threshold width, e.g., greater than about 30 mm (about 1.2 inches), and the process is stopped when this condition is no longer true. While this first condition is true (established by exceeding both thresholds), if the number of images satisfying this condition represents a potential product length of approximately 60 mm (approximately 2.4 inches) or longer (which may be determined by an appropriate encoder synchronized acquisition rate that specifies the conveyor displacement and speed (e.g., conveyor advance speed) to be correlated or proportional to the acquired images and / or image frames), the controller considers a cased item 102 to have been detected, or in other words, confirms the detection as true (Figure 3, block 336) (the potential cased item length for cased item confirmation may be set to be greater or less than a displacement, such as approximately 10 mm (approximately 0.4 inches)). In this case, the controller 199 (using combiner 199PC (FIG. 1) of processor 199P) combines previously acquired upstream images from both camera systems 181 and 184, e.g., representing approximately 60 mm (approximately 2.4 inches) of conveyor displacement before the image establishing the detection of the detected cased article 102 (a typical length can be, for example, longer or shorter than approximately 10 mm or approximately 0.4 inches), the number of images in which the cased article 120 was detected, and subsequently acquired downstream images, e.g., representing 60 mm (approximately 2.4 inches) of conveyor displacement after the detection assertion of the cased article 102, to construct a combined, continuous, complete composite image of the cased article 102 from the series of images acquired during the aforementioned durations before and after the detection of the cased article 102 (the duration(s) before and / or after detection can be varied and need not be symmetrical) (FIG. 3, block 340).If the number of images that meet the first and second conditions (i.e., threshold and duration 330, 336) represent potential products having a width / length of, for example, less than about 60 mm (about 2.4 inches), the controller asserts that the detection was a false positive (FIG. 3, block 337) or asserts that the detected cased article 102 is below the minimum allowable length / width that would normally continue the image acquisition process. The system is robust to noise and parasitic signals such as falling debris.

[0039] As noted above, while both conditions are asserted, the continuous construction of a combined image (or pseudo-image) of the scanned cased article 102 continues until the maximum allowable product dimension is reached, e.g., beyond about 60 mm (about 2.4 inches). In other words, when the controller 199 determines (such as from the acquired images when both cameras 184, 181 are present) that, for example, the acquired image(s) of camera system 184 (corresponding to the desired conveyor movement, e.g., about 60 mm or 2.4 inches) no longer meets the above-mentioned threshold (e.g., the considered portion of the acquired image has neither a width nor an intensity drop greater than the set threshold (e.g., about 30 mm (1.2 inches), about a 40% drop)), the controller 199 registers acceptable dimensions of the cased article (e.g., from registered conveyor displacements from the encoders occurring simultaneously with the image acquisition exceeding the threshold). Thus, for combining the scanned cased articles into a good combined image, the controller 199 (through appropriate programming) that causes the acquisition of raw images may continue for another, e.g., about 60 mm (about 2.4 inches) after exceeding the maximum allowable product dimension. It is understood that "combined image" (or pseudo image) and "combined product image" correspond to the relative positions and orientations of the illumination sources and include images of substantially orthogonal sides of the cased article, such as a side-view image (e.g., a side view) (e.g., of one or more side surfaces 102L) and a top-view image (e.g., of the top surface 102T).

[0040] Once the controller 199 has substantially conformed with the processor 199P's construction of the composite image(s) of the complete imaged cased item as described above, and if so desired, the controller 199 calculates various quantitative measurements by the process steps illustrated in Figure 7. Referring to Figure 8, examples of quantitative measurements include "actual box," "max box," "max bulge," "orientation angle," and "distance from one side of the conveyor."

[0041] The "real box" measurements (FIG. 7, block 710) include dimensions of the best-fit shape that can be determined based on or derived from the combined cased item images. For example, the shape utilized for the fit is a box having a length, width, and height. Alternatively, the shape utilized can be a sphere having a center and a radius. Various other shapes can be utilized for the fit, such as, but not limited to, a cylinder, an oval, a cone, etc. FIGS. 9, 9A, 9B, and 9C illustrate example "real box" measurements (shown by the dotted lines in FIG. 9 on processed images 900A, 900B, representing the combined elevation and plan views, respectively) obtained from composite images acquired / combined / constructed during inspection of the cased items 102, 200, 210 shown in FIGS. 1, 2A, and 2B. As can be seen in this example, any protrusions (such as protrusion 220 in FIGS. 2A and 2B or protrusions not yet identified as case flaps, as shown in FIG. 9C ) and / or bulges 2400 seen by vision system 150 are not considered as such when determining the dimensions of the “real box.” Here, real box dimensions include real box length RBL, real box width RBW, and real box height RBH. In this example, label LAB on cased item 200 illustrated in FIG. 2A , which represents cased item 102, can be partially separated, detected in the combined image, and resolved as part of the best-fit shape determination so as to be ignored in the footprint assessment. Nevertheless, material wraps embodied in composite materials, e.g., opaque or translucent, are included in the real box measurements to the extent that they are conformal to the best-fit shape.

[0042] The "outer box" measurements (FIG. 7, block 712) include the dimensions of the smallest shape that encompasses the entire product, which can be determined based on or derived from the combined product image (which may include protrusions 220 seen by the vision system, including distressed product portions, labels, and packaging). For example, the shape utilized for fitting is a box having a length, width, and height that represents the largest rectangular footprint of the cased articles 102 on the conveyors 110, 120. Alternatively, the shape utilized can be a sphere having a center and a radius. Various other shapes can be utilized for fitting, such as, but not limited to, a cylinder, an oval, a cone, etc. 9A, 9B, 9C, and 10 illustrate example “outer box” measurements obtained from images (1000A, 1000B, representing combined elevation / side and plan / top images, respectively) acquired / combined / constructed during inspection of cased item 102 (see also, e.g., cased items 200, 210) shown in FIGS. 1, 2A, and 2B (shown by dotted lines on the processed images). As can be seen in this example, any protrusions 220 and / or bulges 2400 imaged by vision system 150, including those gray image projections indicative of translucent or opaque packaging, are considered and included when determining the “outer box” dimensions. Here, the outer box dimensions include outer box length OBL, outer box width OBW, and outer box height OBH. In this example, a partially detached label LAB (FIG. 2A) on the cased article 102 (see, for example, cased article 200 in FIG. 2A) is advantageous in determining the footprint of the cased article 102.

[0043] The “max bulge” measurement ( FIG. 7 , block 714) is the longest dimension obtained from the cased item 102 being inspected. FIG. 11 illustrates “max bulge” measurements obtained from images 1100A, 1100B (using similar conventions to FIGS. 9 and 10 ) acquired / combined / constructed during inspection of the cased item 102 shown in FIGS. 1 , 2A, and 2B (see also, e.g., cased items 200 and 210). Once the product orientation is determined, the “max bulge” is the largest caliper measurement of width, length, and height. As described herein, a bulging cased item 102 can affect the handling, storage, and palletizing characteristics of the cased item 102 within the logistics facility 190. For example, bulges on one or more sides of the cased item 102 can cause the cased item 102 to stack unstably, such as when palletized. Bulges on one or more sides of the case items 102 may also cause improper reorientation of the case items 102, such as with respect to a case turner of a storage and retrieval system, where the case turner is configured to pivot or rotate the case items 102 to reorient the case items 102. Bulges on one or more sides of the case items 102 may cause the case items 102 to be mismeasured by the autonomous guided vehicles 190 ATVs of the logistics facility 190, which may further cause picking errors, improper transfer of the case items 102 to the autonomous guided vehicles 190 ATVs, and case item placement errors. As described further below, the maximum bulge may also be measured separately from the maximum caliper measurements of width, length, and height to determine the bulge dimensions relative to adjacent edges of the case items 102 (see FIGS. 11A-11C) to determine whether improper handling, storage, and palletizing characteristics exist for any given case item 102. In one or more embodiments, with respect to the maximum bulge in the width axis and the maximum bulge in the length axis (see FIG. 11B), only the maximum bulge in the length axis (e.g., on one lateral surface 102L1, 102L2 of the case article) may be tracked, and only the maximum bulge in the width direction (e.g., on one longitudinal surface 102F, 102R of the case article 102) may be tracked.Here, the maximum lengthwise expansion is assumed for both side surfaces, and the maximum widthwise expansion is assumed for both longitudinal surfaces 102F, 102R.

[0044] The product "orientation angle" is the angle of the product's major axis relative to the direction of travel TD of the cased articles 102 on the conveyors 110, 120. Figure 8 best illustrates the non-zero product "orientation angle" determined when a box is utilized for the best fit (see also Figure 24, which illustrates a zero product orientation angle for cased articles 102A and a non-zero product orientation angle for cased articles 102B). For illustrative purposes, when an oval shape is utilized for the fit, the measurement of the "orientation angle" can be the major axis.

[0045] Referring to Figure 8, "distance from one side of the conveyor" is determined as the minimum distance obtainable between the cased article 102 and either side of a given conveyor (expressed based on the width of the light sheet (see Figure 6)).

[0046] It should be understood that aspects of the disclosed embodiments are not limited to performing the steps illustrated in Figures 3 and 7 in the illustrated order. In one or more aspects, in addition to determining measurements, status checks are performed in parallel, for example, as the conveyors 110, 120 advance. The sequence of steps illustrated in Figures 3 and 7 can represent a hierarchy of coded logic decision networks.

[0047] Once a sufficient number of the above-mentioned measurements have been determined, the image analysis computer program of the controller 199 compares the measurements to the nominal values ​​and tolerance tolerances provided to the cased item inspection system 100 in FIG. 7, block 716 (FIG. 7, block 718). For example, a programmable logic controller (PLC) (not shown) can provide at least a portion of the nominal values ​​and tolerance tolerances for a given case inspected by the inspection system. Depending on the user / operator's preference, the "real box," "outer box," or "maximum bulge" can be considered to accept or reject the cased item 102.

[0048] According to one or more aspects of the disclosed embodiments, as can be seen from the example raw images illustrated in FIG. 4 , the recorded light intensity varies within the acquired image. As a comparison standard or reference, the intensity values ​​of non-black pixels in a selectable number of sample images, e.g., approximately 10, are considered to establish a normalized baseline value for intensity. In one aspect, the intensity value of approximately 33% of the median image from the selected number of sample images is considered to establish a normalized value for pixel intensity. This eliminates signal noise, optical interference, and the like to reduce false positives or false negatives of cased items. The sample images providing the reference for determining the normalized baseline value for intensity may be updated or refreshed on a rolling basis, which, as previously described, accounts for ambient changes due to environmental changes, detritus on the described EM source and / or vision system components, and the like.

[0049] By using the above-described process, the vision system 150 can automatically compensate for debris, etc., present on the window panel of the camera systems 181, 184. When this situation occurs, the raw constructed / combined image will exhibit a thin line 1200D of constant pixel intensity, as shown within stitch line 1200A in FIG. 12 . When the thin line of pixels is detected, a warning can be sent to an operator / user of the cased item inspection system 100, such as via the user interface 198, alerting them that the window needs to be cleaned. Here, due to the normalization of light intensity process described above, such debris can be gradually relocated or removed by the processor 199P of the controller 199 from the combined composite image of the cased item 102 constructed by the image processing algorithm within a few iterations (encoder steps, stepper motor steps, seconds, etc.), thus minimizing the impact on the operation of the cased item inspection system 100.

[0050] In one embodiment, the profile detection system 180 transmits the various measurements obtained, in addition to its decision (accept or reject) ( FIG. 7 , blocks 720A and 720B), to the user interface 198, for example, for subsequent use by a user / operator of the cased item inspection system 100 ( FIG. 7 , block 722). For example, at least the conveyors 110, 120 may be operated in any suitable manner to back up or dump rejected cased items, and / or paddles may be actuated to deflect rejected cased items to any suitable “rejected product” conveyor. In other embodiments, the large “orientation angle” may be reduced by actuating any suitable component of the cased item inspection system 100, such as a guide rail or other mechanism for reorienting the product. In yet other embodiments, the conveyors 110, 120 may be reversed so that the rejected cased items 102 can be rescanned. In other aspects, profile detection system 180, in addition to its decision (accept or reject), transmits one or more of the various obtained product measurements (e.g., product dimensions, orientation, etc.) to flap detection system 170 to facilitate flap detection, as described herein. In one or more aspects, user interface 198 receives one or more of the above-mentioned information from profile detection system 180 and receives information (as described herein) from flap detection system 170.

[0051] 1 and 1A-1C and 13A-13F, flap detection system 170 and profile detection system 180 are configured to operate substantially simultaneously in parallel with one another, and both are integrated into cased item inspection system 100. Flap detection system 170 is configured to detect one or more of open flaps, bulges, and depressions that may not otherwise be detected by profile detection system 180 as bumps or case exterior protrusions 220. Flap detection system 170 detects flaps by approximating the flaps to a substantially coherent plane 1410 (see FIGS. 14A-14D), where the flaps have a length / size that is coherent with (e.g., corresponds to) the length / size of the corresponding product / case 102, for example, as determined by profile detection system 180. A partial or small flap, even if it is only a portion of the length of the flap or side of the cased article to which it is attached, may not be identified as an open flap and may be detected by profile detection system 180 under the above-described "RealBox-OutsideBox" criteria. As described herein, flap detection system 170 is configured to detect flaps, bulges, and / or depressions on any outside side (e.g., top, bottom, front (e.g., leading longitudinal face), back (e.g., trailing longitudinal face), and side faces) of any given product / case 102, including flaps attached to the underside of the product / case (e.g., the bottom of a product seated on conveyors 110, 120).

[0052] As noted above, imaging of the (above-described) exterior sides of cased articles 102 by flap detection system 170 occurs substantially simultaneously with imaging of the exterior sides of cased articles 102 by profile detection system 180. For example, imaging of the exterior sides by flap detection system 170 occurs substantially simultaneously with registration (by processor 199P) of the dimensions of the cased articles from the case image data obtained by profile detection system 180 (see FIGS. 5-6 ), where processor 199P resolves the imaged cased articles into their respective stockkeeping units or SKUs (e.g., case identification information with known dimensions in or stored in memory accessible by processor 199P) and identifies any case exterior protrusions 220 as open flaps. Here, both the flap detection system 170 and the profile detection system 180 image the cased item 102 passing through the cased item inspection system 100 at approximately the same time, where the time it takes for the cased item to pass through the cased item inspection system 100 is approximately 0.1 seconds to approximately 0.01 seconds. For example, in one or more embodiments in which the flap detection system 170 does not have laser illumination, the illumination of the cased item by the profile detection system 180 may be coordinated with the imaging by the flap detection system 170 so as to avoid an illumination interface when the cased item 102 is imaged by the flap detection system 170, with a slight offset between the illumination of the cased item 102 by the profile detection system 180 and the imaging of the cased item 102 by the flap detection system 170, although it is noted that during the time frame (e.g., on the order of about 0.1 seconds to about 0.01 seconds) of the cased item 102 passing through the cased item inspection system 100, the imaging of the cased item 102 by both the flap detection system 170 and the profile detection system 180 occurs approximately simultaneously.In one or more embodiments in which the flap detection system 170 includes illumination from lasers 171L-173L, etc., the illumination of the flap detection system 170 may be continuously pulsed (or may be periodically, e.g., turned on and off at predetermined intervals) substantially simultaneously with the illumination of the cased items 102 by the profile detection system 180, such that imaging of the cased items 102 by both the flap detection system 170 and the profile detection system 180 occurs substantially simultaneously. It is noted that in one or more embodiments, one or more of the lasers 171L-173L have a fixed or predetermined orientation such that scanning / imaging of the cased articles 102 by the flap detection system 170 is effected by movement of the cased articles 102 along the conveyor(s) 110, 120, while in other embodiments, one or more of the lasers 171L-173L are movable relative to the conveyor(s) 110, 120 such that scanning / imaging of the cased articles 102 by the flap detection system 170 is effected by movement of the one or more lasers 171L-173L and is independent (or decoupled) from the movement of the cased articles along the conveyor(s) 110, 120.

[0053] As described herein, profile inspection system 180 resolves the case inspection characteristics of cased items 102 described above, where open flap detection, dent detection, and at least a portion of the bulge detection are performed by flap detection system 170. Similarly, flap detection system 170 resolves open flap detection, dent detection, and at least a portion of the bulge detection, where the case inspection characteristics are resolved by profile inspection system 180. As described below, upon controller 199 / processor 199P confirming that each case item 102 has an expected case shape, i.e., from image data obtained from profile inspection system 180, controller 199 / processor 199P is configured to determine, from other image data, i.e., from flap detection system 170, conformance of each case item 102 with predetermined case form conformance characteristics for handling, storing, and palletizing of cased items 102 within logistics facility 190. As described in more detail herein, the predetermined case form fit characteristic informs the fit allowance of each cased item 102 within a predetermined fitting space or location of the logistics facility 190 (e.g., a storage space or other holding location of the storage array 190SA, a cargo hold of the autonomous guided vehicle 190ATV, a location of a pallet load build in a pallet build formed within the logistics facility 190, etc.). As described herein, in one or more embodiments, the predetermined case form fit characteristic is an inward bulge or depression of at least one side 102T, 102L, 102F, 102R of the case shape of each cased item relative to the planar case side.

[0054] In one or more embodiments, profile inspection and open flap detection (including dent and bulge detection) of cased articles may occur substantially simultaneously, independent of one another. For example, profile inspection system 180 is not hindered by the open flap state, dent, and / or bulge of cased article 102, and resolves case inspection characteristics (for cased articles that meet the inspection criteria of profile inspection system 180) to sensors 171-173 of flap detection system 170 independently of obstruction / blocking of open flaps, dents, and / or bulges on the exterior sides of the case.

[0055] While flap detection system 170 may be initiated from profile inspection system 180, which characterizes outward case protrusions 220 (FIGS. 2A and 2B) for cased articles 102 that are acceptable / pass profile inspection criteria (i.e., cases that do not meet the profile inspection criteria for cased articles are rejected in any appropriate manner, such as by transfer to a reject conveyor or removal by trained personnel, as described herein), the determination of open flaps, bulges, and depressions is performed by flap detection system 170. While bulges on the sides of cased articles 102 may be determined by both flap detection system 170 and profile detection system 180, flap detection system 170 may provide more detailed information about the bulges relative to case handling (e.g., by automated guided vehicles 190ATV, palletizers 190P, etc.) and case placement (e.g., on pallets, in storage arrays 190SA, etc.) within logistics facility 190 (FIG. 1) of which cased item inspection system 100 is a part.Suitable examples of storage and retrieval systems in which aspects of the disclosed embodiments may be deployed include, but are not limited to, U.S. Patent No. 10,800,606 issued on October 13, 2020 (entitled "Material-Handling System Using Autonomous Transfer and Transport Vehicles"), U.S. Patent No. 10,556,743 issued on February 11, 2020 (entitled "Storage and Retrieval System"), U.S. Patent No. 10,633,184 issued on April 28, 2020 (entitled "Replenishment and Order Fulfillment System"), U.S. Patent No. 9,475,649 issued on October 25, 2016 (entitled "Pickface Builder for Storage and Retrieval Systems"), U.S. Patent No. 10,106,322 issued on October 23, 2018 (entitled "Bot Payload Alignment and Sensing"), U.S. Patent No. 10,106,322 issued on October 23, 2018 (entitled "Pallet Building Systems"), and U.S. Patent No. 10,106,322 issued on October 23, 2018 (entitled "Pallet Building Systems"). No. 10,703,585, issued July 7, 2020 (entitled "Storage and Retrieval System"), and U.S. Pat. No. 10,781,060, issued September 22, 2020 (entitled "Storage and Retrieval System Transport Vehicle"), the entire disclosures of which are incorporated herein by reference.

[0056] By way of example, with respect to detecting an open flap state for a cased item 102 that is acceptable to profile inspection system 180 and for which an external case protrusion 220 is determined (i.e., determined from profile inspection system 180), controller 199 initiates imaging of cased item 102 using sensors 171-173 of flap detection system 170. If flap detection system 170 determines that external case protrusion 220 is an open flap, controller 199 registers the open flap state with the identification information of cased item 102 (e.g., a cased item identification number as illustrated in Tables 1 and 2 described herein) in any suitable memory / database for handling of cased item 102 by any suitable cased item processing equipment (e.g., palletizer 190P, robotic arm, autonomous guided vehicle 190ATV, etc.) (note that cased item 102 remains accepted by profile inspection system 180). If flap detection system 170 determines that case exterior protrusion 220 is not an open flap, controller 199 may not process case image data 1400 (see FIGS. 14A-14H for exemplary image data) from sensors 171-173 of flap detection system 170. In one or more embodiments, if profile inspection system 180 does not detect case exterior protrusion 220, controller 199 can initialize flap detection system 170 for imaging of cased article 102 by sensors 171-173 substantially simultaneously with inspection of cased article 102 by profile inspection system 180, where flap detection system 170 images the sides of cased article 102 to detect exterior protrusions manifest on each (or one or more) visible side of the cased article, verifying the profile inspection system's finding of the presence or absence of case exterior protrusion 220 (note that the cased article remains accepted by profile inspection system 180).

[0057] As described herein, the flap detection system 170 is configured to image all (five) visible / unseated sides of the cased articles 102 (i.e., the five sides not seated on the conveyors 110, 120 and visible to the sensors 171-173) using at least one sensor 171-173. The at least one sensor 171-173 is positioned to image each exposed case side 102T, 102L, 102R, 102F of the cased articles 102 advanced on the at least one conveyor 110, 120 and passing through the cased article inspection system 100, thereby imaging the external case protrusions 220 revealed on each imaged exposed case side 102T, 102L, 102F, 102R. In one or more embodiments, case image data 1400 (see FIGS. 14A-14H for exemplary image data) captured by sensors 171-173 of each of cased articles 102 embodies each exposed case side 102T, 102L, 102R, 102F of a respective case exterior 102E ( FIG. 1 ). In one or more embodiments, case image data 1400 embodies case exterior protrusion 220 with case exterior protrusion 220 manifested in at least one exposed case side 102T, 102L, 102R, 102F, and at least one exposed case side 102T, 102L, 102R, 102F positioned in an orientation of each exposed case side of each cased article 102 (e.g., case image data 1400 identifies the side on which an open flap is detected and / or the orientation of the open flap). In one or more embodiments, the imaged exposed case sides 102T, 102L, 102R, 102F are positioned such that the open case flaps 1300 (see Figures 13A-13F), as revealed from the case outer protrusions 220 apparent on the imaged exposed case sides 102T, 102L, 102R, 102F, extend from the exposed case sides 102T, 102L, 102R, 102F adjacent to the conveyor seating surface CSS on which the cased items 102 are seated (see Figure 13E).

[0058] 13A-13F illustrate exemplary open flap configurations that flap detection system 170 is configured to detect. FIG. 13A illustrates a side view of cased article 102 in which leading edge flap 1300TA attached (e.g., hinged) to the edge of top surface 102T is partially open at angle α. Here, angle α is illustrated as an acute angle, but may be any angle ranging from about 1° to about 270°. FIG. 13B is a side view of cased article 102 in which flap 1300TA on or hinged to the leading edge of top surface 102T is open at angle α, while flap 1300TV on or hinged to the trailing edge of top surface 102T is open at approximately 90° relative to top surface 102T. Figure 13C is a side view of the cased article 102, in which the flap 1300TA at or hinged to the leading edge of the top surface 102T is angled at an angle β, while the flap 1300RH at or hinged to the trailing edge of the top surface 102T is angled at an angle θ, or an angle of approximately 180°. Here, angle β is illustrated as a reflex angle and angle θ is illustrated as being approximately 180°, but in other embodiments, angles β and θ may each range from approximately 1° to approximately 270°. Figure 13D is a side view of the cased article 102, in which the leading edge flap 1300TA1 and the trailing edge flap 1300TA2 are both angled relative to the top surface by respective angles α1 and α2, which may range from 1° to approximately 270°. 13E is a side view of cased article 102, in which flap 1300BA hinged to the leading edge of bottom surface 102B of cased article 102 opens at angle β2 relative to the bottom surface 102B, while flap 1300BR hinged to the trailing edge of bottom surface 102B of cased article 102 opens at angle θ2 of approximately 180° relative to the bottom surface. Here, angle β2 is illustrated as a reflex angle and angle θ2 is illustrated as being approximately 180°, although in other embodiments, angles β and θ may each range from approximately 1° to approximately 270°.FIG. 13F is a plan view of the top surface 102T of the cased article 102, showing that a flap 1300VR on a side edge of the rear or trailing end surface 102R of the cased article 102 opens at an angle α3 relative to the rear 102R. Here, angle α3 is illustrated as an acute angle, but may be any angle ranging from about 1° to about 270°. As noted above, FIGS. 130A-130F are non-limiting illustrative examples of flap orientations that the flap detection system 170 is configured to detect. As can be appreciated, the product 102 illustrated in FIGS. 13A-13D can have any orientation on the conveyors 120, 110 such that the hinge side of the flap extends generally transverse to the conveyors 120, 110, or generally longitudinally (i.e., along the direction of conveyor movement) relative to the orientation of the conveyors 120, 110, or any orientation therebetween.

[0059] 1 and 13A-13F and 14A-14H, as described above, flap detection system 170 includes at least one sensor / imager 171-173 positioned to capture product / case image data 1400 (see FIGS. 14A-14H for exemplary image data) of each of the cased articles or products 102 advanced by conveyors 110, 120 by at least one sensor / imager 171-173. At least one sensor / imager 171-173 captures image data 1400 at any suitable resolution to provide an open flap determination, as described herein. By way of example only, the image resolution provided by the at least one sensor / imager is about 3 mm (about 0.1 inch) in the X direction (e.g., a direction generally parallel to the product flow along the conveyors 110, 120), about 1.5 mm (about 0.05 inch) in the Y direction (e.g., a direction generally perpendicular to the product flow along the conveyors 110, 120 in a plane defined by the product support surfaces of the conveyors 110, 120), and about 1.5 mm (about 0.05 inch) in the Z direction (e.g., a direction generally perpendicular to the product support surface CSS of the conveyors 110, 120). In other embodiments, the resolution in one or more of the X, Y, and Z directions may be higher or lower than the resolutions listed above.

[0060] As described above, the controller 199 (including its processor 199P) is coupled to the conveyors 110, 120 and communicatively coupled to at least one sensor / imager 171-173 to receive case image data 1400 from the at least one sensor / imager 171-173, where triggering of the at least one sensor / imager 171-173 is effected by, such as, the profile detection system 180 in a manner described above or in a manner generally similar to that described above for the profile detection system 180. In one or more embodiments, the flap detection system 170 performs one or more image acquisitions to an image cache storage (such as the processor 199P of the controller 199), where the image acquisition is triggered by a conveyor encoder or, alternatively, by a stepper motor drive circuit that advances at least one of the conveyors 110, 120. In other embodiments, the image acquisition may be effected in any suitable manner, such as using a motion sensor.

[0061] As described herein, the controller 199 is configured (e.g., via any suitable non-transitory computer program code) to characterize the case exterior projections 220 (see FIGS. 2A and 2B) of the cased articles 102 (e.g., open case flaps) as flaps 1300TA, 1300TA1, 1300TA2, 1300TV, 1300FA, 1300RH, 1300BA, 1300BR, 1300VR (generally referred to as flaps or case flaps 1300) in an open state (e.g., see FIGS. 13A-13F) from the case image data 1400. The controller 199 (via the processor 199P) is configured to interpret the case image data 1400 and determine that the case exterior projections 220 are coherent planes 1410. Processor 199P is programmed with a parameter array 199A ( FIG. 1 , also referred to herein as parameter array 199A) of physical property parameters describing coherence attributes of case flaps that determine a coherent plane 1410 that defines an open case flap state. Processor 199P is configured to generate a physical property array 199C from case image data 1400 (e.g., using any suitable computer program code that results in the generation thereof) for each determined coherent plane 1410, and apply parameter array 199A to physical property array 199C, thereby resolving coherent plane 1410 as an open case flap, as illustrated in FIGS. 13A-13F and 14A-14H. Here, physical property array 199C describes the coherent plane as a case flap, and determine that the case flap is in an open flap state based on parameter array 199A of physical property parameters.

[0062] Processor 199P is configured to interpret case image data 1400 (in addition to or instead of resolving an open case flap state) and determine whether at least one case top surface 102T or at least one case side surface 102L, 102R, 102F has an interior variation (i.e., a dent). Processor 199P is programmed with a parameter array 199A of physical property parameters that describe interior variation attributes that determine the interior variation that defines a dent state. For each determined interior variation, processor 199P is configured to generate a physical property array 199C from case image data 1400 and apply parameter array 199A to physical property array 199C, thereby resolving the interior variation as a dent state. Although parameter array 199A and physical property array 199C are described as including both open flap characteristics and dent characteristics, in other embodiments, there may be separate parameters and physical property arrays for each of the open flap characteristics and dent characteristics.

[0063] A parameter array 199A of physical property parameters (also referred to herein as parameter array 199A (see FIG. 1 )) is programmed into controller 199 and accessible by processor 199P. Parameter array 199A of physical property parameters describes coherence attributes or characteristics of one or more case flaps of a coherent plane that, for example, determines and describes the coherence of a plane (e.g., coherent plane 1410) relative to cased item dimensions (e.g., length, width, and height of each cased item received by controller 199 from profile detection system 180). Coherent plane 1410 defines the state of open case flaps and includes any suitable physical characteristics of a given cased item / product configuration and / or flap configuration. The coherent surface or coherent plane 1410 depends on physical properties and is resolved through any suitable image processing by the controller 199, which determines whether a case exterior protrusion 220 ( FIGS. 2A and 2B ) is present (e.g., from one or more of the profile detection system 180 and the flap detection system 170) and then determines whether the case exterior protrusion is a coherent surface based on the physical properties of the coherent surface. For example, processing of image data from the flap detection system 170 determines whether the coherent surfaces converge to define an edge on at least one of the case sides (e.g., the top, side, and longitudinal sides). If it is determined that an edge is present on at least one of the case sides and the physical properties or parameters of the physical property array 199C are satisfied, the controller 199 determines that an open flap is present and registers the open flap with the identification of each cased item 102 for further processing of the respective cased item 102.

[0064] In the example provided herein, the physical properties or parameters of physical property array 199C include five parameters (as described below), although it should be understood that in other embodiments, more or fewer than five parameters may be utilized for determining the state of the open flap. These parameters are applied to each of the visible sides of cased article 102 (e.g., top surface 102T, longitudinal surfaces 102, 102R, and side surface 102L) to determine the state of the open flap on each of the sides, and registration of the state of the open flap may be for not only the identity of each cased article, but also for the side of each cased article on which an open flap is present. Knowing which side an open flap is present on facilitates the automated equipment's decision to further process each cased article or reject the cased article.

[0065] It is noted that the physical properties of physical property array 199C and parameter array 199A are properties of cased articles 102 that are different from those properties (as described above) of cased articles 102 imaged by profile detection system 180. For example, and referring also to Figures 15-20, parameter array 199A and physical property array 199C each include, but are not limited to, the following five threshold parameters (more or fewer threshold parameters may be utilized):

[0066] The minimum opening angle for the flap (e.g., the minimum angle α from the horizontal edge of the cased item 102) MH and the minimum angle α from the longitudinal edge of the cased article 102 MV(see FIGS. 15 and 16 )), minimum flap depth MFD relative to the base of the flap (e.g., the distance from the hinge side HS or base of the flap to the opposing free side FS of the flap (see FIG. 18 )), which in some embodiments may be expressed as a ratio; minimum flap depth MFD; ratio of minimum flap length MFL to product box length PBL (e.g., MFL / PBL) (see FIG. 17 ); increase in minimum product box length (or width) L due to the flap (e.g., L is the total length of the product with open flaps 1300 MPBLF minus the product box length PBL (see FIG. 19 )), where the minimum product box length (or width) is less than or equal to the minimum angle α from the horizontal edge of the cased articles 102. MH and / or the minimum angle α from the longitudinal edge of the cased item 102 MV and the increase in minimum product box length (or width) due to the flaps, L, which is a function of the minimum product box height due to the flaps, BH (e.g., BH is the total product height MPBLH with the flaps 1300 open minus the product box height PBH (see FIG. 20)), where the minimum product box height is the minimum angle α from the horizontal edge of the cased articles 102. MH and / or the minimum angle α from the longitudinal edge of the cased item 102 MV The increase in minimum product box height due to the flap is a function of BH.

[0067] The detection system 170 is configured to reject the cased item 102 when one or more of these parameters / thresholds are exceeded. In one or more embodiments, the flap detection system 170 determines a minimum opening angle α for the flap. MH , α MV, the minimum flap depth MFD, the ratio of the minimum flap length MFL to the product box length PBL, and the minimum product box length (or width) increase due to flaps MPBLF (or the minimum product box height increase due to flaps MPBHF - depending on whether the flaps are positioned on a vertical or horizontal surface of the product) are exceeded. In yet another embodiment, the flap detection system 170 is configured to reject the cased article 102 when each or all of the following are exceeded: a minimum opening angle α for the flaps MH , α MV , minimum flap depth MFD, ratio of minimum flap length MFL to product box length PBL, increase in minimum product box length (or width) due to flap MPBLF (MPBLF is the minimum opening angle α MH , α MV (depending on the minimum product box height increase MPBHF due to the flap) (MPBHF is the minimum opening angle α MH , α MV The system is configured to reject the cased article 102 when any or all of the following conditions are exceeded: (depending on the number of cases) Rejected cased article 102 may be de-routed from the conveyor and / or the operator may be notified of the rejection via the user interface 198 in a manner generally similar to that described above for the profile detection system 180.

[0068] For illustrative purposes only, the minimum opening angle α for the flap MH , α MV is about 15°, the minimum flap depth MFD is about 20 mm (about 0.7 inches), the ratio of the minimum flap length MFL to the product box length PBL is about 50%, the minimum product box length (or width) increase due to the flaps MPBLF is about 20 mm (about 0.7 inches), and the minimum product box height increase due to the flaps MPBHF is about 20 mm (about 0.7 inches). In other embodiments, the minimum opening angle α for the flaps MH , α MV, the minimum flap depth MFD, the ratio of minimum flap length MFL to product box length PBL, the increase in minimum product box length (or width) due to flaps MPBLF, and the increase in minimum product box height due to flaps MPBHF may be greater or less than those listed above.

[0069] As described herein, flap detection system 170 and profile detection system 180 operate in parallel, with at least some information (case image data) being shared between the systems. For example, to determine whether at least some of the above-mentioned parameters have been exceeded, profile detection system 180 transmits physical characteristics of any given case (e.g., length, width, height, orientation on conveyors 110, 120, and, in some embodiments, the presence or absence of case exterior protrusions 220) to flap detection system 170, which then determines whether the parameters / thresholds have been exceeded. For example, with reference to Figures 1 and 21, during operation, a flow of products 102P1, 102P2, 102P3 moves along conveyors 110, 120 through profile detection system 180 and flap detection system 170. As each cased article 102P1, 102P2, 102P3 passes by profile detection system 180, profile detection system 180 detects product characteristics (e.g., length, width, height, ridge, orientation on a conveyor as described herein, etc.) for each of these cased articles 102P1, 102P2, 102P3 and transmits at least a portion of the detected information to flap detection system 170. For example, flap detection system 170 may utilize one or more of the length, width, height, and orientation of each respective cased article 102P1, 102P2, 102P3 in combination with image data 1400 captured by flap detection system 170 to determine the presence of an open flap. Flap detection system 170 may also utilize detection of ridges by profile detection system 180 to identify areas of interest for each cased article 102P1, 102P2, 102P3 where an open flap may be present.

[0070] 14A-14H, the physical characteristics obtained by flap detection system 170 from profile detection system 180 are, in one or more embodiments, compared to image data captured by flap detection system 170 to, for example, confirm or verify the location of each product in the product flow (e.g., products pass through flap detection system 170 in the same order as they pass through profile detection system 180) and determine whether the products that passed through profile detection system 180 are suitable for storage, handling, and palletization within logistics facility 190 (FIG. 1). The physical characteristics obtained by profile detection system 180 may also be utilized by flap detection system 170 to verify at least some of the physical characteristics of products 102P1, 102P2, 102P3 determined by flap detection system 170 from image data 1400.

[0071] 14A, an example of image data 1400 captured by flap detection system 170 is illustrated. For illustrative purposes, image data 1400 illustrated in FIG. 14A is a plan view or top view of cased product 102P1. Here, the image data is point cloud data, but may be any suitable image data that enables image analysis to detect features of cased articles / products. In this example, flap detection system 170 (via any suitable image processing algorithm / program) determines that ridges or case exterior protrusions 1450, 1451, which may have been identified by profile detection system 180 as case exterior protrusions but not as open flaps, are coherent planes 1410 and identifies these case exterior protrusions 1450, 1451 as open flaps 1300A, 1300B. The flap detection system 170 constructs a physical property array 199C (see FIG. 1, Tables 1 and 2 below) for the cased item 102P1 based on the image data 1400, where the physical property array 199C includes, for example, a flap angle α (from the vertical plane of the product) VD and flap length (from the vertical plane) L DThe controller 199 compares the data in the physical characteristic array 199C with the corresponding data in the parameter array 199A to determine whether any of the thresholds / parameters in the parameter array 199A are exceeded. For example, in FIG. 14A, the flap angle α VD is the minimum angle α MV The length L of the flaps 1300A, 1300B may be larger than D is less than the length L. Here, the minimum opening angle α for the flap is α , where α is the minimum opening angle α for the flap when compared to the corresponding values ​​in parameter array 199A. MH , α MV Based on the concept that a cased article is rejected if it exceeds two or more of the minimum flap depth MFD, the ratio of the minimum flap length MFL to the product box length PBL, the increase in minimum product box length (or width) L due to the flaps, and the increase in minimum product box height BH due to the flaps), cased article 102P1 is acceptable and not rejected (e.g., depending on whether it exceeds other parameters and / or whether and which number of parameters are considered in determining the rejection).

[0072] FIG. 14B is another exemplary diagram of image data 1400 captured by flap detection system 170. For illustrative purposes, image data 1400 illustrated in FIG. 14B is a side view of cased product 102P2. Here, the image data is point cloud data, but may be any suitable image data that results in image analysis to detect product features. In this example, flap detection system 170 (via any suitable image processing algorithm / program) determines that a ridge or case exterior protrusion 1452, which may have been identified by profile detection system 180 as case exterior protrusion 220 but not as an open flap, is a coherent plane 1410 and identifies case exterior protrusion 1452 as an open flap 1300 (e.g., an open flap hinged to bottom surface 102B of cased item 102P2). The flap detection system 170 constructs a physical property array 199C (FIG. 1) for the cased item 102P2 based on the image data 1400, and the physical property array 199C includes at least the flap length L D and flap angle α VD For example, in FIG. 14B, the flap angle α VD is the minimum angle α MV The length L of the flap 1300 may be larger than D is longer than the length L. Here, the minimum opening angle α for the flap is α , which is the minimum opening angle α for the flap when compared to the corresponding values ​​in the parameter array 199A. MH , α MV Based on the concept that a cased item is rejected if it exceeds two or more of the minimum flap depth MFD, the ratio of the minimum flap length MFL to the product box length PBL, the increase in minimum product box length (or width) L due to the flaps, and the increase in minimum product box height BH due to the flaps), the cased item 102P2 may be rejected (e.g., depending on whether other parameters are exceeded and / or whether and which number of parameters are considered in determining the rejection).

[0073] FIG. 14C is another exemplary diagram of image data 1400 captured by flap detection system 170. For illustrative purposes, image data 1400 illustrated in FIG. 14B is a front (or rear / back) side view of cased product 102P3. Here, the image data is point cloud data, but may be any suitable image data that provides image analysis to detect features of the cased article / product. In this example, flap detection system 170 (via any suitable image processing algorithm / program) determines that ridges or case exterior protrusions 1453, 1454, which may have been identified by profile detection system 180 as case exterior protrusions but not as open flaps, are coherent planes 1410 and identifies the case exterior protrusions 1453, 1454 as open flaps 1300A, 1300B (e.g., open flaps hinged to top surface 102T of cased article 102P3). The flap detection system 170 constructs a physical property array 199C (FIG. 1) for the cased item 102P3 based on the image data 1400, and the physical property array 199C includes at least the flap height BH D and flap angle α HD For example, in FIG. 14C, the flap angle α of the flap 1300A is HD is the minimum angle α MH and the flap angle α of the flap 1300B can be smaller. HD is the minimum angle α MH The height of the flap 1300A may be less than the height BH, and the height of the flap 1300B may be less than the height BH. D is higher than the height BH. Here, the parameters of at least the flap 1300B (and the minimum opening angle α for the flap) when compared to the corresponding values ​​in the parameter array 199A are MH , α MVBased on the concept that a cased item is rejected if it exceeds two or more of the minimum flap depth MFD, the ratio of the minimum flap length MFL to the product box length PBL, the increase in minimum product box length (or width) L due to the flaps, and the increase in minimum product box height BH due to the flaps), the cased item 102P2 may be rejected (e.g., depending on whether other parameters are exceeded and / or whether and which number of parameters are considered in determining the rejection).

[0074] 23A-23C are other exemplary views of image data 1400 captured by flap detection system 170. For illustrative purposes, image data 1400 illustrated in FIG. 23A is a front (or rear / back) perspective view of cased article 102, e.g., having case side indentation 2300 present on the top of cased article 102 (note that the case side indentation may be present on any visible side of cased article 102 for detection by flap detection system 170). Here, image data 1400 is photographic image data of cased article 102, but may be any other suitable image data that provides image analysis to detect features of the cased article / product. FIG. 23B illustrates image data 1400 of cased article 102 of FIG. 23A as point cloud data.

[0075] In this example, flap detection system 170 (via any suitable image processing algorithm) determines the presence of case side dent 2300 by analyzing one or more sides of cased article 102, and if case side dent 2300 is present, flap detection system 170 determines the depth of dent 2300. By way of example, flap detection system 170 determines the presence of case side dent 2300 (e.g., from a three-dimensional analysis of cased article 102) by determining a failure to describe a coherent plane (i.e., a lack of a coherent plane on one or more sides) of one or more case sides within a predetermined plane threshold criterion (e.g., in a manner substantially opposite to that described above with respect to case exterior protrusion 220). For example, a lack of a coherent plane (or the presence of a non-coherent plane) on a side of cased article 102 may be determined by detecting one or more openings 2310, which may be formed, for example, by case flaps 1300. If case side indentation 2300 is present in the side of cased article 102 without a flap (or with a flap present but not separated to form an opening 2310 therebetween), the lack of a coherent plane can be determined by flap detection system 170 (e.g., from a three-dimensional analysis of cased article 102) by determining the presence of one or more of recesses 2340, wrinkles 2320, and openings (holes) 2330 on the side of cased article 102. Case side indentation 2300 can be formed in any suitable area of ​​the side of cased article 102. For example, the indentations in the case side may be substantially in the center of the side (see, e.g., recess 2340, opening 2330, and case side indentation 2300), at the edge of the side (see, e.g., crease 2320 and case side indentation 2300), and / or may extend across the side transitioning from the edge to (or beyond) the center of the side (see, e.g., crease 2320 and case side indentation 2300).

[0076] By way of example only, a case side indentation is determined if the length dimension (e.g., relative to the length, width, and / or height of the cased items), width dimension (e.g., relative to the length, width, and / or height of the cased items), or diameter of opening 2310 (e.g., formed by flap 1300) is greater than about 2 inches (in other embodiments, the criteria for determining case side indentation may be greater than about 2 inches or less than about 2 inches). Similar appropriate criteria apply to determining case side indentation 2300 based on recesses 2340, creases 2320, and openings (holes) 2330.

[0077] If a case side depression 2300 is present, flap detection system 170 determines a depth 2399 of the incoherent surface (e.g., depression, indentation, wrinkle, etc.), where depth 2399 is measured, for example, from an edge 2323 of the cased article formed by the side of the cased article on which the incoherent surface exists and an adjacent side of the cased article (here, depth 2399 is measured from the edge formed by the top surface 102T and one or more of the vertical surfaces (e.g., lateral surface 102L and / or longitudinal surfaces 102F, 102R) of the cased article (see also FIG. 11A )). In other embodiments, depth 2399 may be measured from any other suitable reference point on the cased article, such as the bottom or the side opposite the side on which the incoherent surface exists.

[0078] Here, if the depth 2399 of the incoherent surface exceeds a predetermined threshold (e.g., about 1 inch (about 25 mm)), the cased item 102 is classified as unsuitable for case handling, storage, and palletizing within logistics facility 190 (i.e., rejected for not meeting the respective predetermined case form-fit characteristics) and removed from automated handling within logistics facility 190 in the manner described above. In addition to or instead of the depth criterion, the unsuitability of the cased item for case handling, storage, and palletizing within logistics facility 190 may be determined by the side on which the incoherent surface is present and / or the location of the incoherent surface on the side of the cased item (e.g., side area) (and / or other suitable criteria affecting the stability of the case during stacking or automated transport / handling of the cased items). As an example, the vertical surfaces of the cased articles 102 may have stricter unsuitability criteria (e.g., reduced allowance / tolerance for dents) than the horizontal surfaces of the cased articles 102 because they function as higher load-bearing members than the horizontal surfaces when the cased articles are stacked for palletization. With respect to the location (e.g., side area) of incoherent surfaces (e.g., dents, depressions, wrinkles, openings, etc.) on the sides of the cased articles, incoherent surfaces located at the edges of the cased articles 102 may be held to stricter unsuitability criteria (e.g., reduced allowance / tolerance for dents) than incoherent surfaces in the middle / center of the sides. For example, incoherent surfaces located at the edges of the cased articles 102 may create "catching" or "jamming"-inducing features on the cased articles 102 that may reduce stability when stacking the cased articles for palletization or may interfere with handling of the case.

[0079] 24A is another exemplary illustration of image data 1400 captured by flap detection system 170. For illustrative purposes, image data 1400 illustrated in FIG. 24 is a front (or rear / back) perspective view of cased article 102, e.g., having case bulge 2400 present on the top of cased article 102 (note that bulge 2400 may be present on any visible side of cased article 102 for detection by flap detection system 170). Here, the image data is photographic image data of cased article 102, but may be any other suitable image data that results in image analysis to detect features of the cased article / product. In a manner similar to that described above, three-dimensional analysis of the cased articles 102 by the flap detection system 170 may determine, for example, that the top surface 102T of the cased articles 102 is an incoherent surface; while the top surface 102T is used as an example, an incoherent surface may be present and determined to be present on any one or more of the top, side, and longitudinal surfaces 102T, 102L, 102R, 102F of the cased articles 102. In one or more embodiments, a bulge may be detected on the bottom surface 102B of the cased articles 102, such as from a determination (e.g., by the flap detection system 170 and / or the profile detection system 180) of a space 2450, the space 2450 being formed by the bulge between the bottom surface 102B of the cased articles 102 and the conveyors 110, 120 (see FIG. 24B ).

[0080] Based on a three-dimensional analysis of the cased article 102, the flap detection system 170 determines a height 2499 of the bulge 2400 formed by the incoherent surface. The height 2499 is measured, for example, from an edge 2424 of the cased article formed by the side of the cased article on which the incoherent surface resides and the adjacent side of the cased article (here, the height 2499 is measured from the edge formed by the top surface 102T and one or more of the vertical surfaces (e.g., the side surfaces 102L and / or the longitudinal surfaces 102F, 102R) of the cased article) (see also FIGS. 11A-11C). In other embodiments, the height 2499 may be measured from any other suitable reference point or datum of the cased article, such as the bottom or the side opposite the side on which the incoherent surface resides. In other embodiments, instead of or in addition to determining the bulge 2400 by the flap detection system 170, the bulge 2400 may be determined by the profile detection system 180, and image data from the profile detection system 180 may be used by the flap detection system 170, in a manner similar to that described above, to determine the bulge dimensions (e.g., the three-dimensional profile of the bulge) and the conformance of each cased item 102 to predetermined form-fit characteristics to substantially ensure proper handling, storage, and palletization of each cased item 102 within the logistics facility 190.

[0081] Here, if the height 2499 of the incoherent surface exceeds a predetermined threshold (e.g., a bulge of approximately 1 inch (approximately 25 mm); or in other embodiments, a bulge longer or shorter than approximately 1 inch (approximately 25 mm), the cased items 102 are classified as unsuitable for case handling, storage, and palletization within logistics facility 190 (i.e., rejected for not meeting the respective predetermined case form-fit characteristics) and removed from automated handling within logistics facility 190 in the manner described herein. In addition to or instead of height criteria, the unsuitability of the cased items for case handling, storage, and palletization within logistics facility 190 may be determined by the side on which the incoherent surface resides and / or the location of the incoherent surface on the side of the cased item (e.g., side area) (and / or other suitable criteria affecting the stability of the case during stacked or automated transport / handling of the cased items). As an example, the vertical surfaces of the cased articles 102 may have different, more stringent standards than the horizontal surfaces of the cased articles 102 because they function as higher load-bearing members than the horizontal surfaces when the cased articles are stacked for palletization. With respect to the location of the bulge(s), a non-coherent (bulged) surface at one corner, diagonal, or middle / center of a side of the cased articles 102 may create a "catching" or "snagging" inducing feature on the cased articles that may reduce stability when stacking the cased articles for palletization or may interfere with case handling, and may be held to a more stringent non-conformance standard than a bulged surface along substantially the entire edge.

[0082] In addition to or instead of determining one or more of the characteristics of the cased articles described above (e.g., depression, open flap, solid box, maximum box, maximum bulge (determined by one or more of case inspection system 180 and flap detection system 170), outer box, length of raised / open flap, orientation angle, distance from one side of the conveyor, etc.), case inspection system 180 and / or flap detection system 170 (using information from case inspection system 180) are configured to determine one or more of: detection of multiple cases (Figure 29), verification of articles in the vertical direction within the cased articles (Figure 26), maximum narrowness of the top and / or bottom surfaces of the cased articles (Figures 11C, 25, and 27), and support surfaces of tapered case articles (Figures 25 and 26) to provide a determination of the conformance of each cased article to predetermined case form fit characteristics.

[0083] 29, an exemplary plan / top view image is provided of multiple cased articles 102A, 102B moving along conveyors 110, 120. The image shown in FIG. 29 may be provided by one or more of case inspection system 180 and flap detection system 170. Controller 199 is configured to use image data obtained from case inspection system 180 and / or flap detection system 170 to distinguish between each of the multiple cased articles 102A, 102B and determine (in a manner described herein) case article characteristics described herein for each of cased articles 102A, 102B.

[0084] 25, an exemplary image, such as that acquired by flap detection system 170 and / or case inspection system 180, is provided illustrating the top taper TP3 of cased articles 102. It is noted that the exemplary image shown in FIG. 25 is a side view (length axis) of cased articles 102 having an orientation angle of substantially zero. In other embodiments where the orientation angle is substantially 90 degrees, a similar side view (width axis) image is acquired. When the orientation angle of cased articles 102 on conveyors 110, 120 does not provide an elevational (e.g., substantially straight side) view, but rather provides an isometric view of cased articles 120, three-dimensional image data from flap detection system 170 (used in some embodiments in combination with data from case inspection system 180) can be utilized by controller 199 to determine the top taper TP3 of the cased articles along one or more of the length and width axes. The upper taper TP3 is measured, for example, from a plane defined by the bottom surface 102B (i.e., the seating surface) of the cased article 102, which rests on the surface of the conveyors 110, 120 (or which may otherwise rest on the support surface of the storage / holding position of another cased article in the stack of cased articles). If the upper taper TP3 exceeds a predetermined threshold (e.g., a threshold of about 1 inch (about 25 mm), based on the stability of other cased articles stacked above the cased article 102, for example; in other embodiments, the predetermined threshold may be greater than or less than about 1 inch (about 25 mm)), the cased article is rejected in the manner described herein.

[0085] The controller 199 is configured to present the top taper TP3 information to the user / operator in any suitable manner, such as via the user interface 198. For example, the controller indicates the amount of taper (along one or more of the length and width axes), the axis (e.g., lengthwise or widthwise) along which the taper is determined, and the orientation angle of the cased items. If a top taper TP3 determination is not available, the controller 199 provides an indication to the user (e.g., via the user interface 198) that the top taper is not available. The top taper may be utilized when determining a pallet build plan using at least the controller 199.

[0086] 25, an exemplary image (obtained from one or more of the case inspection system 180 and flap detection system 170) illustrates the top narrowing of a cased article 102 in the form of a tray 2520 containing round bottles. The exemplary image is a substantially two-dimensional image of the cased article 102, although in other embodiments, a three-dimensional image may be provided. Here, the top narrowing illustrates a reduction in value (i.e., surface area) of the top surface 102T relative to the bottom surface 102B of the cased article 102. Here, the leading longitudinal surface 102F of the cased article 102 includes a taper having, for example, an angle TP1 measured from a plane defined by the untapered portion of the longitudinal surface 102F. The trailing longitudinal surface 102R of the cased article 102 includes a taper having, for example, an angle TP2 measured from a plane defined by the untapered portion of the longitudinal surface 102R. These tapers TP1, TP2 translate into narrow values ​​DPI, DP2 that communicate the reduction in surface area of ​​the top surface 102T relative to the bottom surface 102B of the cased item.

[0087] The narrowness values ​​DP1, DP2 can affect the ability of the cased articles to be palletized, such that the reduced surface area (i.e., support surface) of the top surface 102T due to the tapers TP1, TP2 may not stably support other cased articles 102 stacked thereon. When the cased articles 102 are generally symmetrical, such as in the case of cased articles including round bottles as in FIG. 25 , the larger of the narrowness values ​​DP1, DP2 is assumed for both the length and width axes of the cased articles, although in other embodiments, the tapers TP1, TP2 and the resulting narrowness values ​​DPI, DP2 can be determined for each face 102F, 102R, 102L1, 102L2 of the cased articles 102 (e.g., from three-dimensional image data from the flap detection system 170 or a combination of image data from both the flap detection system 170 and the case inspection system 180). In other embodiments, such as when the cased articles 102 include asymmetric contents (e.g., salad dressing bottles having one flat side and a side that includes a tapered bottleneck), the narrowness values ​​DP1, DP2 are provided for only one of the length and width axes, but the larger of the narrowness values ​​DP1, DP2 is assumed for both the length and width axes. In the case of a bottle, the maximum narrowness value may be approximately the expected distance EDP between the edge 2510 defined by the tray / packaging 2520 holding the bottle and the outer periphery of the bottle cap 2530 (see FIG. 25A), although in other embodiments the maximum narrowness value may be greater or less than the expected distance EDP.

[0088] Referring to FIG. 27, an exemplary image (obtained from one or more of the case inspection system 180 and flap detection system 170) illustrates the top narrowness of a cased article 102 in the form of a box. While the exemplary image is a substantially two-dimensional image of the cased article 102, in other embodiments, a three-dimensional image may be provided. In the illustrated example, the narrowness values ​​DP1, DP1 indicate a tilted / deformed box, but in other embodiments, the narrowness values ​​DP1, DP2 may indicate a decrease in value (i.e., surface area) of the top surface 102T relative to the bottom surface 102B of the cased article 102 when the top surface 102T of the cased article is wrinkled (see FIG. 23) or otherwise deformed. Here, the top edge TEF of the cased article 102 on the leading side surface 102L1 is offset by the narrowness value DP1 relative to the bottom edge BEF of the cased article 102 on the leading side surface 102L1. The upper edge TER of the cased article 102 on the trailing lateral surface 102L2 is offset in the same direction as the upper edge TEF by a narrowing value DP2 relative to the lower edge BER of the cased article on the trailing lateral surface 102L2. Narrowing of the upper edges TEF and TER in the same direction signals tilt of the cased article 102, which may result in a relocation of the center of gravity of the cased article 102 from CG1 to CG2, thereby affecting the stability of the cased article 102, such as when palletized. In one or more embodiments, the greater of the narrowing values ​​DP1 and DP2 that signal tilt of the cased article 102 is assumed for both the widthwise and lengthwise axes. For cased articles 102 in the form of a box, the maximum narrowing value may be approximately 1 inch (approximately 25 mm), although in other embodiments, the maximum narrowing value may be greater or less than approximately 1 inch (approximately 25 mm).

[0089] In the above example, if the narrowness values ​​DP1, DP2 exceed a predetermined maximum narrowness value, the cased articles 102 are rejected in the manner described herein. In a manner similar to that described above, the maximum narrowness value may be based on the stability of the cased articles when palletized. In one or more embodiments, the narrowness values ​​DP1, DP1 determined for the top 102T and / or bottom 102B of the cased articles 102 are presented to the operator via the user interface 198 by the controller 199 in any suitable manner. The narrowness values ​​(e.g., indicating one or more of tilt and support surface) may be utilized at least when generating a pallet build plan in the controller 199. The narrowness values ​​(e.g., indicating tilt) may be used to at least reject cases that may otherwise be incorrectly processed by automation within the logistics facility 190 (e.g., unable to be picked, unable to be stably supported, etc.).

[0090] Referring also to FIG. 11C , some of the characteristics of the cased articles described herein may not be mutually exclusive. For example, as can be seen in FIG. 11C , the narrowing and expansion of the cased article 102 may not be mutually exclusive (e.g., the narrowing and expansion may be mutually inclusive). In examples in which multiple mutually inclusive characteristics of the cased article are determined, the controller 199 is configured to identify the mutually inclusive characteristics in accordance with the above description. For example, a narrowing exists for the cased article 102 in FIG. 11C , but the top edge TEF substantially defines the end of the narrowing. The controller 199 is configured to distinguish between a substantially flat surface (or a substantially constant pitch) of the narrowing portion of the trailing longitudinal surface 102R and a variable pitch indicating a bulge in the top portion 102T of the cased article 102. Here, the controller 199 is configured to determine the expansion from the top edge TE identified by a change in the pitch of the trailing longitudinal surface 102R. In other embodiments, the controller 199 is configured to distinguish between the various cased item characteristics described herein in any suitable manner.

[0091] Referring to FIG. 26 , an exemplary image (obtained from one or more of the case inspection system 180 and the flap detection system 170) is provided illustrating verification of vertical articles within a cased article. The exemplary image is a substantially two-dimensional image of the cased articles 102, although in other embodiments, a three-dimensional image may be provided. Verification of the vertical articles provides one or more of the following: an indication of the number of distinct vertical articles that can be observed relative to the inspected axis (e.g., the length axis and / or the width axis); an indication of the average width 2610 of the top of a vertical article (e.g., bottle cap 2530) observed relative to the inspected axis; and an indication of the average width 2620 of the gap between the tops of adjacent vertical articles (e.g., bottle cap 2530) observed relative to the inspected axis. The above-described information obtained from verification of the vertical articles can be utilized by the controller 199 at least when generating a pallet building plan. In the illustrated example, the cased articles 102 are cases of round bottles similar to those illustrated in FIG. 25 .

[0092] Here, controller 199 is configured to determine the number of lengthwise articles in cased articles 102 from image data obtained from one or more of case inspection system 180 and flap detection system 170. (In the illustrated example, four lengthwise articles are arranged along the lengthwise axis, however, in other embodiments, three-dimensional image data from flap detection system 180 may be utilized in addition to or instead of two-dimensional image data from case inspection system 180 to determine the number of lengthwise articles along one or more of the lengthwise and widthwise axes.) It is noted that the number of lengthwise articles may be presented by controller 199 to the operator via user interface 198 in any suitable manner (note that the number of lengthwise articles of cased articles in the form of a box is shown as one lengthwise article).

[0093] The controller 199 is configured to determine an average width 2610 of a top portion of one of the lengthwise articles (such as a bottle cap 2530) observed relative to the inspected axis from image data obtained from one or more of the case inspection system 180 and the flap detection system 170. (In the illustrated example, the inspected axis is the length axis, although in other embodiments, three-dimensional image data from the flap detection system 180 may be utilized in addition to or instead of two-dimensional image data from the case inspection system 180 to determine an average width 2610 of a top portion of one of the lengthwise articles along one or more of the length and width axes.) It is noted that the average width 2610 of one of the lengthwise articles may be presented by the controller 199 to the operator via the user interface 198 in any suitable manner (note that the average width 2610 of a top portion of one of the lengthwise articles for cased articles in the form of a box is approximately equal to the entire top surface of the box).

[0094] The controller 199 is configured to determine an average gap width 2620 between the tops of adjacent lengthwise articles observed relative to the inspected axis from image data obtained from one or more of the case inspection system 180 and the flap detection system 170. (In the illustrated example, the inspected axis is the longitudinal axis, but in other embodiments, three-dimensional image data from the flap detection system 170 may be utilized in addition to or instead of two-dimensional image data from the case inspection system 180 to determine the average gap width 2620 between the tops of adjacent lengthwise articles.) It is noted that the average gap width 2620 between the tops of adjacent lengthwise articles may be presented by the controller 199 to the operator via the user interface 198 in any suitable manner (note that the average gap width 2620 between the tops of adjacent lengthwise articles for cased articles in the form of boxes is approximately equal to zero).

[0095] As described above, flap detection system 170 (using data from case inspection system 180) and profile detection system 180 determine whether cased articles 102 that have passed through profile detection system 180 are suitable for storage, handling, and palletization within logistics facility 190. For example, as described above, at least one conveyor 110, 120 advances cased articles 102 into logistics facility 190. Case inspection station 180 is positioned in communication with at least one conveyor 110, 120 such that cased articles 102 are advanced past case inspection system 180. Case inspection system 180 has at least one case inspection camera (e.g., sensors / imagers 181, 184) configured to capture a shadow image of each cased article 102 advanced past case inspection system 180. At least another camera 171-173 (e.g., of flap detection system 170) is connected to case inspection station 180 separately and distinct from at least one sensor / imager 181, 184. At least another camera 171-173 is positioned to capture other case image data for each of cased articles 102 advanced past case inspection station 180 other than the case image data captured by at least one sensor / imager 181, 184.

[0096] Here, processor 199P of controller 199 is operatively coupled to at least one conveyor 110, 120. Processor 199P is communicatively coupled to at least one sensor / imager 181, 184 to receive case image data from the at least one sensor / imager 181, 184. Processor 199P is further communicatively coupled to at least another camera 171-173 to receive other case image data for each of cased articles 102 from the at least another camera 171-173. Here, processor 199P (and thus controller 199) is configured to determine a predetermined characteristic (such as the characteristic described above) of each of cased articles 102 that determines case shape from the shadow image of each of cased articles 102 captured by the at least one sensor / imager 181, 184 to confirm that each cased article has a case shape. The predetermined characteristics of each of the cased articles 102 that determine the case configuration include one or more of the case length, case width, case height, included angle between the sides of the case, box dimensions (see FIGS. 13A-20, 25, 25A, 27, 28A, and 28B), and any other suitable physical characteristics of the cased articles, such as those described herein, that determine the case configuration.

[0097] Upon determining that each cased item 102 has a case shape, the processor 199P / controller 199 is configured to determine from other image data (e.g., from the flap detection system 170) the compatibility of each cased item 102 with predetermined case form fit characteristics (such as those described above). As described herein, the predetermined case form fit characteristics inform the compatibility of each cased item 102 within a predetermined compatibility space or location of the logistics facility 190 (e.g., a storage space or other holding location such as a storage array 190SA, a cargo hold of an autonomous guided vehicle 190ATV, or a pallet load build location in a pallet build formed within the logistics facility 190).

[0098] For example, with reference to Figures 28A and 28B, any cased item stored / handled by a logistics facility has corresponding predicted dimensions in at least case length, case width, and case height (note that the amount of narrowing and / or tapering, the number of individual items held, the gaps between the individual items, and the width of the top of the individual items also have predicted dimensions). These predicted dimensions define a predetermined case shape and form fit for the corresponding cased item 102 inserted into logistics facility 190, and note that each identical stockkeeping unit (SKU) allowed / inserted into logistics facility 190 has predicted case dimensions that define the form fit for that SKU. The predicted dimensions are measured from a predetermined reference datum of the case item 102 so that dimensional uniformity of the case items exists among case items of the same type (i.e., the same SKU). For example, as illustrated in Figure 28A, the length dimension of the case is measured from a length-determining datum plane, and the width dimension of the case is measured from a width-determining datum plane. The length-determining datum surface and the width-determining datum surface lie, for example, in a vertical plane defined by one of the lateral surfaces (e.g., side surface 102L1) and a vertical plane defined by one of the longitudinal surfaces (e.g., side surface 102R). As can be seen in Figure 28B, the height dimension of the case is measured from a height-determining datum surface defined by the bottom surface 102B (or seating surface) of the cased article 102.These datum surfaces provide position determination of the cased items by the controller 199, the palletizer 190P, and the autonomous guided vehicle 190ATV, etc., to position the cased items 102 on, but not limited to, storage shelves within the storage array 190SA, on pallets within a pallet load, on the autonomous guided vehicle 190ATV for robotic grasping of the palletizer 190P, and on a pick face builder for the formation of a pick face (e.g., any suitable case processing equipment of the logistics facility configured to form a pick face, including, but not limited to, the autonomous guided vehicle 190ATV and pick face builder described in U.S. Patent No. 9,475,649, issued October 25, 2016, entitled "Pickface Builder for Storage and Retrieval Systems," previously incorporated herein by reference in its entirety), where the pick face includes multiple cased items to be transported / handled within the logistics facility 190 as a single unit, etc.

[0099] The predicted case length, predicted case width, and predicted case height include tolerances that allow the actual dimensions of the cased items to be above and below the predicted values ​​by a predetermined amount. The tolerances may be based on the size of the storage space within the storage array 190SA, the size of the payload bay of the autonomous guided vehicle 190ATV, the stability of the cased items in the pallet case construction, the height limitations of the storage space, or any other suitable structural limitations imposed on the cased items by the structure and operation of the logistics facility 190. These predicted dimensions, including their tolerances for a given case item type (e.g., SKU), define predetermined case form fit characteristics for the cased items 102. Case item characteristics determined by the case inspection system 180 and / or flap detection system 170 inform the actual case form fit characteristics of a given cased item being inspected by the inspection system 100, and the controller 199 determines the conformance of the actual case form fit characteristics of the given cased item with the predetermined case form fit characteristics defined by the predicted dimensions.

[0100] As described herein, if one or more of the determined dimensions of the cased item 102 exceed the expected dimensions of the cased item 102 (including any tolerances), the cased item is rejected and not admitted into the storage, handling, and palletization processes of the logistics facility 190. The tolerances applied to the predicted dimensions (e.g., establishing go or no-go type criteria for admission of cased item types into logistics facility 190) are determined so that fit of cased items 102 into storage spaces or other holding locations in storage array 190SA, payload bays of autonomous guided vehicles 190ATV, pallet load build locations within pallet builds formed within logistics facility 190, and any other suitable locations in logistics facility 190 is substantially assured for cased items 102 that fall within approximately two standard deviations of the Gaussian distribution of cased items 102 handled by logistics facility 190 for a given number of cased items inspected by cased item inspection system 100, while in other aspects fit of cased items 102 is substantially assured for cased items 102 that fall within approximately three standard deviations of the Gaussian distribution of cased items handled / inspected by logistics facility 190. Here, by substantially ensuring the form fit or conformance of the cased items to within approximately 2 standard deviations (or in some embodiments, 3 standard deviations) for any number of cased items 102 inspected by the cased item inspection system 100, each cased item 102 in the logistics facility is substantially always registrable with a pick face builder, positionable on a shelf (or other cased item holding location suitable for storage), registrable for picking and placement of the cased items by the end of the arm tool of the palletizing robot of the palletizer 190P, and / or substantially always stackable within a pallet load formed by the palletizer 190P.

[0101] During operation, the flap detection system provides a binary result regarding the presence of an open flap (i.e., open flap: yes / no), while the length, width, and height of the cased item are measured by the profile detection system 180. As an example, if the dimensions of a cased item 102 are registered with the controller 199 as 8 units wide, 10 units long, and 6 units high, and the cased item inspection system 100 returns a result from inspecting the cased item 102 that the cased item 102 has a width of 8 units, a length of 13 units, and a height of 6 units, then the open flap detection result is true. It is noted that tolerances of cased item dimensions (e.g., the presence or absence of an open flap) may depend on downstream (i.e., after the cased item inspection system 100) automated cased item processing capabilities. For example, Table 1 below illustrates the pass / fail rate of cased articles passing through a cased article inspection system 100 with the dimensional tolerance of the cased articles set to 1 unit (e.g., approximately 1 inch or approximately 25 mm, where linear dimensions in Table 1 are in millimeters and angular dimensions are in degrees), where a 1 in the pass / fail column indicates a rejected cased article 102 and a 0 in the pass / fail column indicates an accepted cased article 102.

[0102] [Table 1]

[0103] As can be seen in Table 1 above, when a tolerance of, for example, 1 inch or 25.4 mm is utilized, the cased article 102 will be rejected. However, as noted above, the allowable tolerance of the cased article's dimensions (e.g., the presence or absence of an open flap) may depend on the downstream (i.e., after the cased article inspection system 100) automated cased article processing capabilities. Therefore, if the downstream automated case processing equipment is capable of processing cases with a tolerance of approximately 2 inches or 50 mm, the tolerance for the same cased article will increase as shown in Table 2 below.

[0104] [Table 2]

[0105] With respect to Table 2, it is noted that the indication of open flaps for the same cased article changes from that in Table 1 due to the requirement that a minimum number of parameters must be met for an open flap to be detected. In the examples of Tables 1 and 2, all of the parameters (note that the flap depth parameter is included in the flap length vs. case length parameter) must be met before an open flap is detected. For Table 2, as intersections increase, the number of open flaps detected decreases and the number of cased articles allowed increases.

[0106] The process may also determine, through a comparison of predicted cased article dimensions to actual (i.e., measured) cased article dimensions and the presence of open flaps, that open flaps extend along one or more of the length, width, and height of cased article 102. This information and any other suitable information may be presented to the operator via user interface 198, as described herein. Flap detection system 170 supports the detection of open flaps on any of the five visible sides of cased articles 102 that are not seated on conveyors 110, 120. In one or more embodiments, flap detection system 170 utilizes case image data to estimate the core dimensions of the cased article (e.g., length, width, and height excluding case exterior protrusions or open flaps), even in the presence of open flaps and / or case exterior protrusions. Here, flap detection system 170 includes any suitable number of sensors 171-173 (such as two or more, or utilizing the use of mirrors to view the cased article from three or more angles) so that imaging of the side of the cased article is not obstructed or otherwise blocked by the open flap. Estimation of the core dimension of cased article 102 by flap detection system 170 may verify acceptance or rejection of any given cased article by profile detection system 180. For example, if a cased article is rejected by profile detection system 180 as being out-of-range (e.g., one or more of the length, width, and / or height exceed the corresponding predetermined (e.g., expected) length, width, and height) due to an open flap (i.e., the core dimensions of the cased article are within range, but the out-of-range condition is detected by profile detection system 180 due to the presence of an open flap), flap detection system 170 verifies that the out-of-range condition is due to an open flap and whether the open flap can be processed by downstream automated equipment (i.e., after cased article inspection system 100). If a cased article with an open flap cannot be processed by downstream automated equipment, the cased article may be rejected.

[0107] 1, 1A-1C, and 22, a method for inspection of cased articles 102 is described in accordance with one or more aspects of the disclosed embodiments. According to the method, cased articles 102 are advanced on at least one conveyor 110, 120 and passed through cased item inspection system 100 (FIG. 22, block 2200). At least one sensor 171-173 captures case image data 1400 for each of cased articles 102 advanced on at least one conveyor 110, 120 and passed through cased item inspection system 100 (FIGS. 14A-14D and 22, block 2210). A processor 199P is provided (FIG. 22, block 2220), where, in one or more embodiments, the processor 199P characterizes, from the case image data, the case exterior protrusions 220 (FIGS. 2A and 2B) of the cased articles 102 as case flaps in an open state (FIG. 22, block 2230), and the processor 199P is configured to interpret the case image data 1400 and determine that the case exterior protrusions 220 are coherent planes 1410 (FIGS. 14A-14D), and is programmed with a parameter array 199A of physical property parameters describing coherence attributes of the case flaps that determine the coherent planes 1410 that define the open case flap state. In one or more embodiments, the processor 199P interprets the case image data 1400 and determines that the case exterior protrusions 220 are coherent planes 1410 (FIG. 22, block 2240). For each coherent plane 1410 determined, the processor 199P generates a physical property array 199C from the case image data 1400 (FIG. 22, block 2250) and applies the parameter array 199A to the physical property array 199C, thereby resolving the coherent plane 1410 as an open case flap.

[0108] 1, 1A-1C, 2B, 23A, and 29, a method in an inspection apparatus for inspection of cased articles is described. In the method, at least one conveyor 110, 120 advances cased articles 102 past the inspection apparatus 100 (FIG. 30, block 3000). At least one camera 171-173 captures case image data for each of the cased articles 102 advanced by the at least one conveyor 110, 120 and passing through the inspection apparatus 100 (FIG. 30, block 3010). A processor 199P is provided (FIG. 30, block 3020) that receives the case image data 1400 from the at least one camera 171-173. As described herein, the processor 199P is operably coupled to at least one conveyor 110, 120 and communicatively coupled to at least one camera 171-173, and is configured to characterize at least one of a case side recess and a case outer protrusion of the cased item as an open case flap (FIG. 30, blocks 3030 and 3045) from case image data 1400 generated from a common image of the cased item 102 captured by the at least one camera 171-173 and resolved by the processor 199P (FIG. 30, block 3040).

[0109] The processor 199P interprets the case image data (see FIG. 30, block 3040) and determines that the case outer protrusions 220 are coherent planes, and the processor is programmed with a parameter array of physical property parameters 199A that describe the coherence attributes of the case flaps that determine the coherent planes that define the open case flap state. For each coherent plane determined, the processor generates a physical property array 199C from the case image data 1400 (FIG. 30, block 3050) and applies the parameter array 199A to the physical property array 199C, thereby resolving the coherent planes as open case flaps.

[0110] In the method, at least one camera 171-173 is positioned to capture case image data 1400 of each cased article advanced on at least one conveyor 110, 120 and passing through inspection apparatus 100, whereby case image data 1400 embodies at least one of case side indentations 2300 and case outer protrusions 220 manifested in at least one exposed case side 102T, 102L, 102F, 120R, with at least one exposed case side 102T, 102L, 102F, 120R oriented in the orientation of each exposed case side of the cased article. In the method, another imaging system (e.g., profile detection system 180) is provided. The profile detection system 180 is separate and distinct from at least one camera 171-172 that images the cased articles 102 separately and distinctly from the imaging of the cased articles 102 by at least one camera 171-173 for inspection of the cased articles 102 other than detecting at least one of the indentations in the case side and the open flap of the case as described herein.

[0111] In accordance with one or more aspects of the disclosed embodiment there is provided an inspection apparatus for inspection of cased items. The inspection device includes at least one conveyor configured to advance cased articles through the inspection device, at least one camera positioned to capture case image data for each cased article advanced by the at least one conveyor through the inspection device, and a processor operably coupled to the at least one conveyor and communicatively coupled to the at least one camera to receive the case image data from the at least one camera, the processor configured to characterize an outer case protrusion of the cased article as an open case flap from the case image data, the processor configured to interpret the case image data and determine that the outer case protrusion is a coherent plane, and programmed with a parameter array of physical property parameters describing coherence attributes of the case flap that determine the coherent plane defining the open case flap state, the processor configured to generate a physical property array from the case image data for each determined coherent plane and apply the parameter array to the physical property array to resolve the coherent plane as an open case flap.

[0112] In accordance with one or more aspects of the disclosed embodiment, at least one camera is positioned to image each exposed case side of each of the cased articles advanced on at least one conveyor and passing through the inspection device to image any external case protrusions apparent on each imaged exposed case side.

[0113] According to one or more aspects of the disclosed embodiment, the imaged exposed case side is positioned such that the open case flap, revealed from the case outer protrusion visible on the imaged exposed case side, extends from the exposed case side adjacent to the conveyor seating surface on which the cased items are seated.

[0114] In accordance with one or more aspects of the disclosed embodiment, at least one camera is positioned to capture case image data for each exposed case side of each of the cased articles advanced on the at least one conveyor and passing through the inspection device, whereby the captured case image data for each of the cased articles embodies each exposed case side of the respective case exterior.

[0115] According to one or more aspects of the disclosed embodiment, the imaged exposed case side is positioned such that the open case flap, revealed from the case outer protrusion visible on the imaged exposed case side, extends from the exposed case side adjacent to the conveyor seating surface on which the cased items are seated.

[0116] In accordance with one or more aspects of the disclosed embodiment, at least one camera is positioned to capture case image data of each of the cased articles advanced on at least one conveyor and passing through the inspection device, whereby the case image data embodies the case outward protrusions with the case outward protrusions manifested on at least one exposed case side surface and with the at least one exposed case side surface positioned in an orientation of the exposed case side surface of each of the cased articles.

[0117] According to one or more aspects of the disclosed embodiment, at least one exposed case side imaged by at least one camera is positioned such that an open case flap revealed from an outer case protrusion visible on the imaged at least one exposed case side extends from the at least one exposed case side adjacent to a conveyor seating surface on which the cased items are seated.

[0118] In accordance with one or more aspects of the disclosed embodiment, the inspection apparatus further includes a separate imaging system, separate and distinct from the at least one camera, for imaging different properties of the cased items advanced on the at least one conveyor and passing through the inspection apparatus, different from the physical properties of the physical property array.

[0119] In accordance with one or more aspects of the disclosed embodiment, at least one camera captures case image data substantially simultaneously as another imaging system images different characteristics of the cased items.

[0120] In accordance with one or more aspects of the disclosed embodiment, the inspection device further includes a separate imaging system separate and distinct from the at least one camera, which images the cased articles for inspection of the cased articles other than detection of open case flaps, separate and distinct from the imaging of the cased articles by the at least one camera.

[0121] In accordance with one or more aspects of the disclosed embodiment, a separate imaging system images the cased articles for processor verification of the identity of each of the cased articles and the compatibility of each of the cased articles with the case size parameters of the verified cased articles.

[0122] In accordance with one or more aspects of the disclosed embodiment, the processor is configured such that inspection of the cased items based on images of the cased items from another imaging system is resolved separately and differently from resolution of the open case flaps from the case image data of the at least one camera.

[0123] According to one or more aspects of the disclosed embodiment, the processor is configured to determine the presence of an outer case protrusion from imaging of another imaging system separate and distinct from the capture of case image data with the at least one camera, and to resolve the outer case protrusion as an open case flap from the case image data of the at least one camera separate and distinct from the image of the other imaging system.

[0124] In accordance with one or more aspects of the disclosed embodiment, the processor is configured to determine the presence of an outer case protrusion from the case image data captured by the at least one camera independently from images of the cased items captured by a separate imaging system.

[0125] In accordance with one or more aspects of the disclosed embodiment, an inspection apparatus for inspecting cased articles is provided, the inspection apparatus including: at least one conveyor configured to advance the cased articles through the inspection apparatus; at least one camera positioned to capture case image data for each of the cased articles advanced by the at least one conveyor through the inspection apparatus; and a processor operatively coupled to the at least one conveyor and communicatively coupled to the at least one camera for receiving the case image data from the at least one camera, the processor configured to characterize, from the case image data, case outward protrusions of the cased articles that are open case flaps, the processor configured to interpret the case image data to determine that the case outward protrusions are coherent planes, and for each determined coherent plane, generate from the case image data a physical property array of physical properties of the coherent plane, such that the physical property array describes the coherent plane as a case flap and determine that the case flap is in an open flap state based on the parameter array of parametric physical properties.

[0126] In accordance with one or more aspects of the disclosed embodiment, a parameter array of parametric physical properties describes coherence attributes of the case flap that determine a coherent plane that defines an open case flap state.

[0127] In accordance with one or more aspects of the disclosed embodiment, at least one camera is positioned to image each exposed case side of each of the cased articles advanced on at least one conveyor and passing through the inspection device to image any external case protrusions apparent on each imaged exposed case side.

[0128] According to one or more aspects of the disclosed embodiment, the imaged exposed case side is positioned such that the open case flap, revealed from the case outer protrusion visible on the imaged exposed case side, extends from the exposed case side adjacent to the conveyor seating surface on which the cased items are seated.

[0129] In accordance with one or more aspects of the disclosed embodiment, at least one camera is positioned to capture case image data for each exposed case side of the cased articles advanced on the at least one conveyor and passing through the inspection device, whereby the captured case image data for each cased article embodies each exposed case side of the respective case exterior.

[0130] According to one or more aspects of the disclosed embodiment, the imaged exposed case side is positioned such that the open case flap, revealed from the case outer protrusion visible on the imaged exposed case side, extends from the exposed case side adjacent to the conveyor seating surface on which the cased items are seated.

[0131] In accordance with one or more aspects of the disclosed embodiment, at least one camera is positioned to capture case image data of each of the cased articles advanced on at least one conveyor and passing through the inspection device, whereby the case image data embodies the case outward protrusions with the case outward protrusions manifested on at least one exposed case side surface and with the at least one exposed case side surface positioned in an orientation of the exposed case side surface of each of the cased articles.

[0132] According to one or more aspects of the disclosed embodiment, at least one exposed case side imaged by at least one camera is positioned such that an open case flap revealed from an outer case protrusion visible on the imaged at least one exposed case side extends from the at least one exposed case side adjacent to a conveyor seating surface on which the cased items are seated.

[0133] In accordance with one or more aspects of the disclosed embodiment, the inspection apparatus further includes a separate imaging system, separate and distinct from the at least one camera, for imaging different properties of the cased items advanced on the at least one conveyor and passing through the inspection apparatus, different from the physical properties of the physical property array.

[0134] In accordance with one or more aspects of the disclosed embodiment, at least one camera captures case image data substantially simultaneously as another imaging system images different characteristics of the cased items.

[0135] In accordance with one or more aspects of the disclosed embodiment, the inspection device further includes a separate imaging system separate and distinct from the at least one camera, which images the cased articles for inspection of the cased articles other than detection of open case flaps, separate and distinct from the imaging of the cased articles by the at least one camera.

[0136] In accordance with one or more aspects of the disclosed embodiment, a separate imaging system images the cased articles for processor verification of the identity of each of the cased articles and the compatibility of each of the cased articles with the case size parameters of the verified cased articles.

[0137] In accordance with one or more aspects of the disclosed embodiment, the processor is configured such that inspection of the cased items based on images of the cased items from another imaging system is resolved separately and differently from resolution of the open case flaps from the case image data of the at least one camera.

[0138] According to one or more aspects of the disclosed embodiment, the processor is configured to determine the presence of an outer case protrusion from imaging of a separate imaging system that is separate and distinct from the capture of case image data with the at least one camera, and to resolve the outer case protrusion as an open case flap from the case image data of the at least one camera that is separate and distinct from the image of the separate imaging system.

[0139] In accordance with one or more aspects of the disclosed embodiment, the processor is configured to determine the presence of an outer case protrusion from the case image data captured by the at least one camera independently from images of the cased items captured by a separate imaging system.

[0140] In accordance with one or more aspects of the disclosed embodiment there is provided a method for inspection of cased items. The method includes: advancing cased articles through an inspection device using at least one conveyor; capturing case image data for each cased article advanced on the at least one conveyor through the inspection device using at least one camera; providing a processor operably coupled to the at least one conveyor and communicatively coupled to the at least one camera for receiving the case image data from the at least one camera; and characterizing, using the processor, outer case protrusions of the cased articles as open case flaps from the case image data, wherein the processor is configured to interpret the case image data and determine that the outer case protrusions are coherent planes, and the processor is programmed with a parameter array of physical characteristic parameters describing coherence attributes of the case flaps that determine the coherent planes that define the open case flap state; and for each determined coherent plane, the processor generates a physical characteristic array from the case image data and applies the parameter array to the physical characteristic array to characterize the coherent planes as open case flaps.

[0141] In accordance with one or more aspects of the disclosed embodiment, at least one camera is positioned to image each exposed case side of each of the cased articles advanced on at least one conveyor and passing through the inspection device to image any external case protrusions apparent on each imaged exposed case side.

[0142] According to one or more aspects of the disclosed embodiment, the imaged exposed case side is positioned such that the open case flap, revealed from the case outer protrusion visible on the imaged exposed case side, extends from the exposed case side adjacent to the conveyor seating surface on which the cased items are seated.

[0143] In accordance with one or more aspects of the disclosed embodiment, at least one camera is positioned to capture case image data for each exposed case side of the cased articles advanced on the at least one conveyor and passing through the inspection device, whereby the captured case image data for each cased article embodies each exposed case side of the respective case exterior.

[0144] According to one or more aspects of the disclosed embodiment, the imaged exposed case side is positioned such that the open case flap, revealed from the case outer protrusion visible on the imaged exposed case side, extends from the exposed case side adjacent to the conveyor seating surface on which the cased items are seated.

[0145] In accordance with one or more aspects of the disclosed embodiment, at least one camera is positioned to capture case image data for each of the cased articles advanced on at least one conveyor and passing through the inspection device, whereby the case image data embodies the case outward protrusions with the case outward protrusions manifested on at least one exposed case side surface and with the at least one exposed case side surface oriented in the orientation of the exposed case side surface of each of the cased articles.

[0146] According to one or more aspects of the disclosed embodiment, at least one exposed case side imaged by at least one camera is positioned such that an open case flap revealed from an outer case protrusion visible on the imaged at least one exposed case side extends from the at least one exposed case side adjacent to a conveyor seating surface on which the cased items are seated.

[0147] In accordance with one or more aspects of the disclosed embodiment, the method further includes providing a separate imaging system separate and distinct from the at least one camera, and using the separate imaging system to image different properties of the cased items advanced on the at least one conveyor and passing through the inspection device than the physical properties of the physical property array.

[0148] In accordance with one or more aspects of the disclosed embodiment, at least one camera captures case image data substantially simultaneously as another imaging system images different characteristics of the cased items.

[0149] In accordance with one or more aspects of the disclosed embodiment, the method further includes providing a separate imaging system separate and distinct from the at least one camera, and using the separate imaging system to image the cased articles for inspection of the cased articles other than detection of open case flaps, separate and distinct from the imaging of the cased articles by the at least one camera.

[0150] In accordance with one or more aspects of the disclosed embodiment, a separate imaging system images the cased articles for processor verification of the identity of each of the cased articles and the compatibility of each of the cased articles with the case size parameters of the verified cased articles.

[0151] In accordance with one or more aspects of the disclosed embodiment, the processor is configured such that inspection of the cased items based on images of the cased items from another imaging system is resolved separately and differently from resolution of the open case flaps from the case image data of the at least one camera.

[0152] According to one or more aspects of the disclosed embodiment, the processor is configured to determine the presence of an outer case protrusion from imaging of a separate imaging system that is separate and distinct from the capture of case image data with the at least one camera, and to resolve the outer case protrusion as an open case flap from the case image data of the at least one camera that is separate and distinct from the image of the separate imaging system.

[0153] In accordance with one or more aspects of the disclosed embodiment, the processor is configured to determine the presence of an outer case protrusion from the case image data captured by the at least one camera independently from images of the cased items captured by a separate imaging system.

[0154] In accordance with one or more aspects of the disclosed embodiment, there is provided a method for inspection of cased articles, the method including: advancing the cased articles through an inspection device using at least one conveyor; capturing case image data for each of the cased articles advanced by the at least one conveyor through the inspection device using at least one camera; providing a processor operatively coupled to the at least one conveyor and communicatively coupled to the at least one camera for receiving the case image data from the at least one camera; characterizing, using the processor, case outward protrusions of the cased articles that are open case flaps from the case image data; interpreting the case image data to determine that the case outward protrusions are coherent planes; and, for each determined coherent plane, generating a physical property array of physical properties of the coherent plane from the case image data, such that the physical property array describes the coherent plane as a case flap and determines that the case flap is in an open flap state based on a parameter array of parametric physical properties.

[0155] In accordance with one or more aspects of the disclosed embodiment, a parameter array of parametric physical properties describes coherence attributes of the case flap that determine a coherent plane that defines an open case flap state.

[0156] In accordance with one or more aspects of the disclosed embodiment, at least one camera is positioned to image each exposed case side of each of the cased articles advanced on at least one conveyor and passing through the inspection device to image any external case protrusions apparent on each imaged exposed case side.

[0157] According to one or more aspects of the disclosed embodiment, the imaged exposed case side is positioned such that the open case flap, revealed from the case outer protrusion visible on the imaged exposed case side, extends from the exposed case side adjacent to the conveyor seating surface on which the cased items are seated.

[0158] In accordance with one or more aspects of the disclosed embodiment, at least one camera is positioned to capture case image data for each exposed case side of the cased articles advanced on the at least one conveyor and passing through the inspection device, whereby the captured case image data for each cased article embodies each exposed case side of the respective case exterior.

[0159] According to one or more aspects of the disclosed embodiment, the imaged exposed case side is positioned such that the open case flap, revealed from the case outer protrusion visible on the imaged exposed case side, extends from the exposed case side adjacent to the conveyor seating surface on which the cased items are seated.

[0160] In accordance with one or more aspects of the disclosed embodiment, at least one camera is positioned to capture case image data of each of the cased articles advanced on at least one conveyor and passing through the inspection device, whereby the case image data embodies the case outward protrusions with the case outward protrusions manifested on at least one exposed case side surface and with the at least one exposed case side surface positioned in an orientation of the exposed case side surface of each of the cased articles.

[0161] According to one or more aspects of the disclosed embodiment, at least one exposed case side imaged by at least one camera is positioned such that an open case flap revealed from an outer case protrusion visible on the imaged at least one exposed case side extends from the at least one exposed case side adjacent to a conveyor seating surface on which the cased items are seated.

[0162] In accordance with one or more aspects of the disclosed embodiment, the method further includes providing a separate imaging system separate and distinct from the at least one camera, and using the separate imaging system to image different properties of the cased items advanced on the at least one conveyor and passing through the inspection device than the physical properties of the physical property array.

[0163] In accordance with one or more aspects of the disclosed embodiment, at least one camera captures case image data substantially simultaneously as another imaging system images different characteristics of the cased items.

[0164] In accordance with one or more aspects of the disclosed embodiment, the method further includes providing a separate imaging system separate and distinct from the at least one camera, and using the separate imaging system to image the cased articles for inspection of the cased articles other than detection of open case flaps, separate and distinct from the imaging of the cased articles by the at least one camera.

[0165] In accordance with one or more aspects of the disclosed embodiment, a separate imaging system images the cased articles for processor verification of the identity of each of the cased articles and the compatibility of each of the cased articles with the case size parameters of the verified cased articles.

[0166] In accordance with one or more aspects of the disclosed embodiment, the processor is configured such that inspection of the cased items based on images of the cased items from another imaging system is resolved separately and differently from resolution of the open case flaps from the case image data of the at least one camera.

[0167] According to one or more aspects of the disclosed embodiment, the processor is configured to determine the presence of an outer case protrusion from imaging of a separate imaging system that is separate and distinct from the capture of case image data with the at least one camera, and to resolve the outer case protrusion as an open case flap from the case image data of the at least one camera that is separate and distinct from the image of the separate imaging system.

[0168] In accordance with one or more aspects of the disclosed embodiment, the processor is configured to determine the presence of an outer case protrusion from the case image data captured by the at least one camera independently from images of the cased items captured by a separate imaging system.

[0169] In accordance with one or more aspects of the disclosed embodiment, there is provided an inspection apparatus for inspecting cased articles, the inspection apparatus including: at least one conveyor configured to advance the cased articles through the inspection apparatus; at least one camera positioned to capture case image data for each of the cased articles advanced by the at least one conveyor through the inspection apparatus; and a processor operatively coupled to the at least one conveyor and communicatively coupled to the at least one camera for receiving the case image data from the at least one camera, the processor configured to characterize at least one of a case side recess and a case exterior protrusion of the cased articles as an open case flap from the case image data generated from a common image of the cased articles captured by the at least one camera.

[0170] In accordance with one or more aspects of the disclosed embodiment, the processor is configured to interpret the case image data and determine that the case outer protrusion is a coherent plane, and is programmed with a parameter array of physical characteristic parameters that describe coherence attributes of the case flap that determine the coherent plane that defines the open case flap state.

[0171] In accordance with one or more aspects of the disclosed embodiment, the processor is configured to generate a physical property array from the case image data for each determined coherent plane and apply the parameter array to the physical property array to resolve the coherent plane as an open case flap.

[0172] According to one or more aspects of the disclosed embodiment, at least one camera is positioned to image each exposed case side of each cased article advanced by at least one conveyor through the inspection device, so as to image at least one of a case side recess and an external case protrusion that is apparent in each imaged case side from a common image of each imaged case side.

[0173] According to one or more aspects of the disclosed embodiment, at least one camera is positioned to capture case image data for each of the cased articles advanced on at least one conveyor and passing through the inspection device, whereby the case image data embodies at least one of the case side recesses and the case outer protrusions, with at least one of the case side recesses and the case outer protrusions manifested on at least one exposed case side, and with the at least one exposed case side positioned in an orientation of the exposed case side of each of the cased articles.

[0174] According to one or more aspects of the disclosed embodiment, the at least one exposed case side imaged by the at least one camera is positioned such that at least one of the case side recesses and open case flaps revealed from at least one of the case side recesses and case outer protrusions apparent on the imaged at least one exposed case side extend from the at least one exposed case side adjacent to a conveyor seating surface on which the cased items are seated.

[0175] In accordance with one or more aspects of the disclosed embodiment, the inspection device further includes a separate imaging system separate and distinct from the at least one camera, which images the cased articles separately and differently from the imaging of the cased articles by the at least one camera for inspection of the cased articles other than detecting at least one of a dent in the case side and an open case flap.

[0176] In accordance with one or more aspects of the disclosed embodiment, a separate imaging system images the cased articles for processor verification of the identity of each of the cased articles and the compatibility of each of the cased articles with the case size parameters of the verified cased articles.

[0177] In accordance with one or more aspects of the disclosed embodiment, the processor is configured such that inspection of the cased item based on an image of the cased item from another imaging system is resolved differently than resolution of at least one of the dent in the case side and the open case flap from the case image data of the at least one camera.

[0178] According to one or more aspects of the disclosed embodiment, the processor is configured to determine the presence of at least one of a case side recess and a case exterior protrusion of the cased item from imagery of a separate imaging system that is separate and distinct from the capture of case image data with the at least one camera, and to resolve the at least one of the case side recess and the case exterior protrusion as a respective case recess and open case flap from the case image data of the at least one camera that is separate and distinct from the image of the separate imaging system.

[0179] In accordance with one or more aspects of the disclosed embodiment, the processor is configured to determine the presence of at least one of a case side indentation and an outer case protrusion of the cased item from the case image data captured by the at least one camera independently from images of the cased item captured by a separate imaging system.

[0180] In accordance with one or more aspects of the disclosed embodiment, an inspection apparatus for inspecting cased articles is provided, the inspection apparatus including: at least one conveyor configured to advance the cased articles through the inspection apparatus; at least one camera positioned to capture case image data for each of the cased articles advanced by the at least one conveyor through the inspection apparatus; and a processor operatively coupled to the at least one conveyor and communicatively coupled to the at least one camera for receiving the case image data from the at least one camera, the processor configured to characterize a dented state of at least one case top surface or at least one case side surface from the case image data of the cased articles captured by the at least one camera, the processor being programmed to resolve from the image data interior variations of the at least one case top surface or at least one case side surface from a predetermined planar coherence characteristic of the case top surface or case side surface, and the processor configured to determine from the image data a physical property describing a dented state of the at least one case top surface or at least one case side surface for the presence of each resolved interior variation.

[0181] In accordance with one or more aspects of the disclosed embodiment, the processor is configured to interpret the case image data and determine that at least one case top surface or at least one case side surface has an internal variation, and is programmed with a parameter array of physical property parameters describing internal variation attributes that determine the internal variation that defines a dented condition.

[0182] In accordance with one or more aspects of the disclosed embodiment, the processor is configured to generate a physical property array from the case image data for each determined internal variation, and apply the parameter array to the physical property array to resolve the internal variation as a recession condition.

[0183] In accordance with one or more aspects of the disclosed embodiment, at least one camera is positioned to image each exposed case side of each cased article advanced by at least one conveyor through the inspection device to image dent conditions apparent in each imaged case side from a common image of each imaged case side.

[0184] In accordance with one or more aspects of the disclosed embodiment, at least one camera is positioned to capture case image data for each of the cased articles advanced on at least one conveyor and passing through the inspection device, whereby the case image data embodies the dented condition with the dented condition manifested in at least one exposed case side and with the at least one exposed case side positioned in an orientation of the exposed case side of each of the cased articles.

[0185] According to one or more aspects of the disclosed embodiment, the at least one exposed case side imaged by the at least one camera is positioned such that a concave condition revealed from a concave condition apparent in the imaged at least one exposed case side extends from the at least one exposed case side adjacent to a conveyor seating surface on which the cased items are seated.

[0186] In accordance with one or more aspects of the disclosed embodiment, the inspection apparatus further includes a separate imaging system separate and distinct from the at least one camera, which images the cased articles separately and differently from the imaging of the cased articles by the at least one camera for inspection of the cased articles other than detecting dent conditions.

[0187] In accordance with one or more aspects of the disclosed embodiment, a separate imaging system images the cased articles for processor verification of the identity of each of the cased articles and the compatibility of each of the cased articles with the case size parameters of the verified cased articles.

[0188] In accordance with one or more aspects of the disclosed embodiment, the processor is configured such that inspection of the cased item based on images of the cased item from another imaging system is resolved separately and differently from resolution of the dent condition from the case image data of the at least one camera.

[0189] In accordance with one or more aspects of the disclosed embodiment, the processor is configured to determine the presence of a cased item in a dented state from imagery from another imaging system that is separate and distinct from the capture of case image data with the at least one camera, and to resolve the dented state as a case dent from the case image data from the at least one camera that is separate and distinct from the imagery from the other imaging system.

[0190] In accordance with one or more aspects of the disclosed embodiment, the processor is configured to determine the presence of a dented cased item from the case image data captured by the at least one camera independently from images of the cased item captured by another imaging system.

[0191] In accordance with one or more aspects of the disclosed embodiment, an inbound conveyor system for introduction of cased items within a logistics facility is provided, the system including at least one conveyor configured to advance the cased items into the logistics facility, a case inspection station disposed in communication with the at least one conveyor such that the cased items advance past the case inspection station, the case inspection station having at least one case inspection camera configured to capture a shadow image of each of the cased items advanced past the case inspection station, and at least another camera connected to the case inspection station, separate and distinct from the at least one case inspection camera, the at least another camera configured to capture other case image data of each of the cased items advanced past the case inspection station other than the case image data captured by the at least one case inspection camera. and at least another camera; and a processor operably coupled to the at least one conveyor, communicatively coupled to the at least one case inspection camera to receive case image data from the at least one case inspection camera, and communicatively coupled to the at least another camera to receive other case image data for each of the cased articles from the at least another camera, the processor configured to determine, from a shadow image of each of the cased articles captured by the at least one case inspection camera, a predetermined characteristic of each of the cased articles that determines a case shape to confirm that each cased article has a case shape, and upon confirming that each cased article has a case shape, the processor is configured to determine, from the other image data, a conformance of each cased article with the predetermined case form conformance characteristic.

[0192] In accordance with one or more aspects of the disclosed embodiment, the predetermined case form fit characteristic informs the fit allowance of each cased item within a predetermined fit space or location of a storage array of a logistics facility.

[0193] In accordance with one or more aspects of the disclosed embodiment, the predetermined compatible space or location is a pallet load build location in a pallet build formed within the logistics facility.

[0194] In accordance with one or more aspects of the disclosed embodiment, the predetermined case form-fit characteristic is an inward bulge or depression of at least one side of the case shape of each cased article relative to the planar case side.

[0195] In accordance with one or more aspects of the disclosed embodiment, the predetermined characteristics of each of the cased articles that determine the case shape include one or more of the case length, the case width, the case height, the included angle between the sides of the case, and the box dimensions.

[0196] In accordance with one or more aspects of the disclosed embodiment, the processor includes an image acquisition component configured to acquire a plurality of digitized images from the case inspection station for each cased article advanced through the case inspection station, and an image combiner configured to selectively combine some of the acquired digitized images, distinct from the plurality of digitized images, into a combined image based on a sustained input beam spatial intensity decrease below a first threshold over a plurality of durations among the acquired digitized images.

[0197] In accordance with one or more aspects of the disclosed embodiment, the processor is configured to confirm the presence of the cased item based on a sustained decrease in input beam spatial intensity below a second threshold that identifies the presence of translucent shrink wrap placed on the product in the cased item.

[0198] In accordance with one or more aspects of the disclosed embodiment, the image combiner is configured to selectively combine acquired digitized images into a potential product combined image, wherein a number of digitized pixels in the image having reduced intensity below a first predetermined threshold defines an image width above a second threshold.

[0199] In accordance with one or more aspects of the disclosed embodiment, the image combiner is configured to selectively combine the acquired digitized images to form a combined image, wherein the number of digitized pixels across consecutive images having reduced intensities below a first predetermined threshold and a second threshold represents a predetermined combined image length.

[0200] In accordance with one or more aspects of the disclosed embodiment, the at least one conveyor is configured to advance the cased articles at an advancement speed, and the image acquisition component is configured to acquire digitized images at an acquisition speed proportional to the advancement speed of the cased articles.

[0201] In accordance with one or more aspects of the disclosed embodiment, the image acquisition rate is synchronized through the use of an encoder or by a stepper motor drive circuit.

[0202] In accordance with one or more aspects of the disclosed embodiment the image acquisition component comprises an image cache storage.

[0203] In accordance with one or more aspects of the disclosed embodiment, the at least one case inspection camera is configured to determine ambient light intensity from a sample buffer of cached images.

[0204] In accordance with one or more aspects of the disclosed embodiment, the processor is configured to determine, from the combined image, a first shape that best fits in the combined image, a second shape that circumscribes the combined image, and a dimension of the difference between the first shape and the second shape.

[0205] In accordance with one or more aspects of the disclosed embodiment the processor is configured to determine, from the combined image, an orientation angle of the case of articles relative to the at least one conveyor.

[0206] In accordance with one or more aspects of the disclosed embodiment, the processor is configured to determine, from the combined image, a distance of the case of articles from one side of the at least one conveyor.

[0207] In accordance with one or more aspects of the disclosed embodiment, the case inspection station is configured to identify the presence of debris on an input window of at least one case inspection camera based on common pixels of the same intensity across a plurality of digitized images.

[0208] In accordance with one or more aspects of the disclosed embodiment, there is provided a method in an inspection device for inspecting cased articles, the method including: advancing the cased articles through the inspection device using at least one conveyor; capturing case image data for each of the cased articles advanced by the at least one conveyor through the inspection device using at least one camera; and providing a processor operatively coupled to the at least one conveyor and communicatively coupled to the at least one camera, the processor configured to characterize at least one of a case side indentation and a case exterior protrusion of the cased articles as an open case flap from the case image data generated from a common image of the cased articles captured by the at least one camera.

[0209] In accordance with one or more aspects of the disclosed embodiment, a processor interprets the case image data and determines that the case exterior protrusion is a coherent plane, the processor being programmed with a parameter array of physical characteristic parameters describing coherence attributes of the case flap that determine the coherent plane that defines the open case flap state.

[0210] In accordance with one or more aspects of the disclosed embodiment, the processor generates a physical property array from the case image data for each determined coherent plane and applies a parameter array to the physical property array to resolve the coherent plane as an open case flap.

[0211] According to one or more aspects of the disclosed embodiment, at least one camera is positioned to image each exposed case side of each cased article advanced by at least one conveyor through the inspection device, so as to image at least one of a case side recess and an external case protrusion that is apparent in each imaged case side from a common image of each imaged case side.

[0212] According to one or more aspects of the disclosed embodiment, at least one camera is positioned to capture case image data for each of the cased articles advanced on at least one conveyor and passing through the inspection device, whereby the case image data embodies at least one of the case side recesses and the case outer protrusions, with at least one of the case side recesses and the case outer protrusions manifested on at least one exposed case side, and with the at least one exposed case side positioned in an orientation of the exposed case side of each of the cased articles.

[0213] According to one or more aspects of the disclosed embodiment, the at least one exposed case side imaged by the at least one camera is positioned such that at least one of the case side recesses and open case flaps revealed from at least one of the case side recesses and case outer protrusions apparent on the imaged at least one exposed case side extend from the at least one exposed case side adjacent to a conveyor seating surface on which the cased items are seated.

[0214] In accordance with one or more aspects of the disclosed embodiment, the method further includes imaging the cased articles using a separate imaging system, separate and distinct from the at least one camera, for inspection of the cased articles other than detecting at least one of the indentation in the case side and the open case flap, separate and distinct from the imaging of the cased articles with the at least one camera.

[0215] In accordance with one or more aspects of the disclosed embodiment, a separate imaging system images the cased articles for processor verification of the identity of each of the cased articles and the compatibility of each of the cased articles with the case size parameters of the verified cased articles.

[0216] In accordance with one or more aspects of the disclosed embodiment, the processor is configured such that inspection of the cased item based on an image of the cased item from another imaging system is resolved differently than resolution of at least one of the dent in the case side and the open case flap from the case image data of the at least one camera.

[0217] According to one or more aspects of the disclosed embodiment, the processor determines the presence of at least one of a case side recess and a case exterior protrusion of the cased item from imagery of another imaging system that is separate and distinct from the capture of case image data with the at least one camera, and resolves the at least one of the case side recess and the case exterior protrusion as a respective case recess and open case flap from the case image data of the at least one camera that is separate and distinct from the image of the other imaging system.

[0218] According to one or more aspects of the disclosed embodiments, a processor determines the presence of at least one of a case side indentation and an exterior case protrusion of the cased item from case image data captured by at least one camera, independently from images of the cased item captured by a separate imaging system. While a "vision system" is referenced herein, aspects of the disclosed embodiments are not limited to any single camera system or any combination thereof operating in the millimeter wave, infrared, visible, microwave, x-ray, gamma ray, etc. spectrum. While a composite camera may be utilized, separate spectrum-specific cameras may also be utilized, either separately or in combination. References to cased items containing foodstuffs (or other contents) are incidental and are not intended to limit the scope of the claims appended hereto.

[0219] It should be understood that the foregoing description is merely illustrative of aspects of the disclosed embodiments. Various substitutions and modifications may be contemplated by those skilled in the art without departing from the aspects of the disclosed embodiments. Accordingly, aspects of the disclosed embodiments are intended to embrace all such substitutions, modifications, and variations that fall within the scope of any claims appended hereto. Furthermore, the mere fact that different features are recited in mutually different dependent or independent claims does not indicate that a combination of these features cannot be used to advantage and that such combination remains within the scope of aspects of the disclosed embodiments.

Claims

1. 1. An inspection apparatus for inspection of cased articles, said inspection apparatus comprising: at least one conveyor configured to advance the cased articles past the inspection device; at least one camera positioned to capture case image data for each of the cased articles advanced on the at least one conveyor and past the inspection device; a processor operatively coupled to the at least one conveyor and communicatively coupled to the at least one camera for receiving the case image data from the at least one camera; Equipped with the processor is configured to characterize an exterior case protrusion of the cased article as an open case flap from the case image data, the processor is configured to interpret the case image data and determine that the exterior case protrusion is an alignment plane, and is programmed with a parameter array of physical characteristic parameters describing case flap alignment attributes that determine the alignment plane that defines an open case flap state; the processor is configured to generate a physical property array from the case image data for each determined alignment plane and apply the parameter array to the physical property array to resolve the alignment plane as an open case flap.

2. 2. The inspection device of claim 1, wherein the at least one camera is positioned to image each exposed case side of each of the cased articles advanced by the at least one conveyor and passing through the inspection device so as to image the external case protrusions apparent on each imaged exposed case side.

3. 3. The inspection device of claim 2, wherein the imaged exposed case side is positioned so that the open case flap revealed from the case outer protrusion visible in the imaged exposed case side extends from the exposed case side adjacent to a conveyor seating surface on which the cased item is seated.

4. 2. The inspection device of claim 1, wherein the at least one camera is positioned to capture the case image data for each exposed case side of each of the cased articles advanced on the at least one conveyor and passing through the inspection device, whereby the captured case image data for each of the cased articles embodies each exposed case side of a respective case exterior.

5. 5. The inspection device of claim 4, wherein the imaged exposed case side is positioned so that the open case flap revealed from the case outer protrusion revealed in the imaged exposed case side extends from the exposed case side adjacent to a conveyor seating surface on which the cased item is seated.

6. 2. The inspection device of claim 1, wherein the at least one camera is positioned to capture case image data of each of the cased articles advanced on the at least one conveyor and passing through the inspection device, whereby the case image data embodies the case outward protrusions with the case outward protrusions manifested on at least one exposed case side, the at least one exposed case side being oriented in the orientation of the exposed case side of each of the cased articles.

7. 7. The inspection device of claim 6, wherein the at least one exposed case side imaged by the at least one camera is positioned such that the open case flap revealed from the case exterior protrusion visible on the imaged at least one exposed case side extends from the at least one exposed case side adjacent to a conveyor seating surface on which the cased item is seated.

8. 10. The inspection apparatus of claim 1, further comprising a separate imaging system separate and distinct from the at least one camera, the separate imaging system imaging a different property of the cased articles advanced on the at least one conveyor and passing through the inspection apparatus than the physical properties of the physical property array.

9. The inspection device of claim 8 , wherein the at least one camera captures case image data substantially simultaneously with the separate imaging system imaging the different characteristics of the cased items.

10. 2. The inspection device of claim 1, further comprising a separate imaging system separate and distinct from the at least one camera, the separate imaging system imaging the cased articles for inspection of the cased articles other than detection of the open case flap, separate and distinct from imaging of the cased articles by the at least one camera.

11. 11. The inspection device of claim 10, wherein the separate imaging system images the cased articles for processor verification of each cased article's identity and conformance with the case size parameters of the verified cased article.

12. 11. The inspection device of claim 10, wherein the processor is configured such that inspection of the cased items based on images of the cased items from the separate imaging system is resolved separately and differently from resolving the open case flap from the case image data of the at least one camera.

13. 11. The inspection device of claim 10, wherein the processor is configured to determine the presence of the outer case protrusion from imaging of the other imaging system separate and distinct from the capture of the case image data with the at least one camera, and to resolve the outer case protrusion as an open case flap from the case image data of the at least one camera separate and distinct from the image of the other imaging system.

14. 11. The inspection device of claim 10, wherein the processor is configured to determine the presence of the case exterior protrusion from the case image data captured by the at least one camera independently from images of the cased article captured by the separate imaging system.

15. 1. An inspection apparatus for inspection of cased articles, said inspection apparatus comprising: at least one conveyor configured to advance the cased articles past the inspection device; at least one camera positioned to capture case image data for each of the cased articles advanced on the at least one conveyor and past the inspection device; a processor operatively coupled to the at least one conveyor and communicatively coupled to the at least one camera for receiving the case image data from the at least one camera; Equipped with the processor is configured to characterize, from the case image data, an outward case protrusion of the cased article that is an open case flap; the processor: interpreting the case image data to determine that the case exterior protrusion is a matching plane; and generating a physical property array of physical properties of the alignment plane from the case image data, such that for each determined alignment plane, the physical property array describes the alignment plane as a case flap and determines that the case flap is in an open flap state based on the parameter array of parametric physical properties; The inspection device is configured as follows.

16. 16. The inspection apparatus of claim 15, wherein the parametric array of parametric physical characteristics describes case flap integrity attributes that determine the alignment plane that defines an open case flap state.

17. 1. A method for inspection of cased articles, the method comprising: advancing the cased articles through an inspection device using at least one conveyor; capturing, with at least one camera, case image data for each of the cased articles advanced on the at least one conveyor and past the inspection device; providing a processor operatively coupled to the at least one conveyor and communicatively coupled to the at least one camera for receiving the case image data from the at least one camera; characterizing, with the processor, from the case image data, an exterior case protrusion of the cased article as an open case flap, the processor being configured to interpret the case image data and determine that the exterior case protrusion is an alignment plane, and being programmed with a parameter array of physical characteristic parameters describing case flap alignment attributes that determine the alignment plane defining an open case flap state; Including, The method of claim 1, wherein the processor generates a physical property array from the case image data for each determined alignment plane, and applies the parameter array to the physical property array to resolve the alignment plane as an open case flap.

18. 18. The method of claim 17, wherein the at least one camera is positioned to image each exposed case side of each of the cased articles advanced on the at least one conveyor and passing through the inspection device to image the outward case protrusions apparent on each imaged exposed case side.

19. 19. The method of claim 18, wherein the imaged exposed case side is positioned such that the open case flap revealed from the case exterior protrusion visible in the imaged exposed case side extends from the exposed case side adjacent to a conveyor seating surface on which the cased article is seated.

20. 18. The method of claim 17, wherein the at least one camera is positioned to capture the case image data for each exposed case side of each of the cased articles advanced on the at least one conveyor and past the inspection device, whereby the captured case image data for each of the cased articles embodies each exposed case side of a respective case exterior.

Images