Abnormality detection device during egg pack transfer and abnormality detection system for case sealing machine

Abstract

To minimize the impact on an egg pack loaded afterwards even if an egg pack is not at the desired condition inside a transport container.SOLUTION: An abnormality detection device (1) during the transfer of an egg pack according to the present disclosure comprises a transfer device (3), an imaging apparatus (4), and a control unit (20). The transfer device (3) adheres to an upper surface of a lid of an egg pack, lifts and moves the egg pack, and places the egg pack in a predetermined position of a transport container. The imaging apparatus (4) photographs an area including the predetermined position after the egg pack has been placed. The control unit (20) detects abnormalities within the area based on the captured images. The control unit (20) instructs the transfer device (3) to perform the next action based on the detection results.SELECTED DRAWING: Figure 4

Description

[Technical field]

[0001] The present disclosure relates to an abnormality detection device during egg carton transfer. [Background technology]

[0002] For example, Patent Document 1 discloses a transfer device for transferring egg cartons. This transfer device adsorbs the top surface of the lid of the egg carton to lift and move the egg carton. Then, this transfer device places the egg carton in a predetermined position in a container for transportation such as a cardboard box.

[0003] In a cardboard box, multiple egg cartons are stacked vertically, but each individual egg carton is very unstable. For example, an egg carton is composed of a body part that houses the lower side of an egg and a lid that houses the upper side of an egg. The body part has an uneven shape that conforms to the shape of an egg, and the lid also has a shape that is unique to egg cartons. Furthermore, an outwardly protruding flange is provided at the connection part between the body part and the lid. Also, the egg carton is structured so that consumers can easily open the lid. When the egg carton is lifted by adsorbing the upper surface of the lid, in some cases, the lid and the body part may partly or entirely separate. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2018-177325 A Summary of the Invention [Problem to be solved by the invention]

[0005] As described above, egg cartons have several factors that can make them unstable, making it difficult to automate their handling. For example, even if a robot completes the operation of transferring egg cartons into a transport container, the egg cartons may not actually be in the desired state, such as not being placed in the designated location, being tilted, having their lids removed, or eggs being exposed outside the pack. If an egg carton is not in the desired state inside the transport container, it will have a significant impact on the egg cartons that are loaded thereafter.

[0006] The present disclosure aims to reduce the significant impact that an undesired egg pack occurring within a shipping container will have on subsequently loaded egg packs. [Means for solving the problem]

[0007] The device for detecting abnormalities during egg carton transfer of the present disclosure includes a transfer device and a photographing device. The transfer device adsorbs the top surface of the lid of the egg carton, lifts and moves the egg carton, and places the egg carton in a predetermined position in a transport container. The photographing device photographs an area including the predetermined position after the egg carton is placed. The control device detects abnormalities within the area based on the photographed image. The control device instructs the transfer device to perform the next operation based on the detection result. Effect of the Invention

[0008] According to the present disclosure, even if an egg pack is not in a desired condition within a transport container, it can be reduced to have a significant impact on egg packs loaded subsequently.

[0009] The above and other objects, features, aspects and advantages of the present disclosure will become apparent from the following detailed description of the disclosure taken in conjunction with the accompanying drawings. [Brief description of the drawings]

[0010] [Figure 1] 1 is a side view illustrating a schematic diagram of a pack assembly production system according to an embodiment of the present disclosure. [Diagram 2] FIG. 2 is a side view showing a schematic configuration of the transfer device according to the embodiment. [Diagram 3] 2 is a plan view showing a schematic view of a part of the pack assembly production system according to the embodiment. FIG. [Figure 4] FIG. 2 is a block diagram showing an abnormality detection device during egg pack transfer according to the embodiment. [Diagram 5] 11 is a flowchart showing an example of the operation of a production system for a pack assembly. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] Hereinafter, a pack assembly production system 2 according to the present embodiment will be described with reference to FIGS.

[0012] First, the pack assembly will be described. The pack assembly is produced, for example, at a GP center (Grading and Packing Center). The pack assembly is loaded onto a truck or the like and transported to a storefront where consumers can purchase the pack assembly.

[0013] The pack assembly is in a state where a plurality of egg packs P are packed in a transport container 50. In the transport container 50, a plurality of egg packs P are arranged on one plane and stacked vertically. The transport container 50 is a dolly, a cardboard box, a plastic container, a pallet, or the like. The transport container 50 of this embodiment is a mobile rack. This mobile rack is a dolly dedicated to egg packs, is foldable, and has a plurality of shelves 51. The egg packs P are stacked in a plurality of tiers on each shelf 51.

[0014] In the transport container 50, the egg packs P are stacked such that the main body P1 of the egg pack P on the upper level and the lid P2 of the egg pack P on the lower level are in contact with each other. The egg packs P may be arranged in the same manner as the egg packs P on the lower level, or may be arranged in different manners. The egg packs P have an uneven shape in the portion that accommodates the lower part of the eggs, and the position of the egg packs P may change in the transport container 50 after stacking. In other words, the egg packs P are stacked in a very unstable state by placing another egg pack P on top of the egg pack P. For example, the main body P1 of the upper egg pack P may be placed on the inclined surface of the lid P2 of the lower egg pack P, or the lid P2 of the lower egg pack may be depressed downward due to the load of the upper egg pack P. In addition, the distance between adjacent egg packs P may change due to the provision of a deformable flange P3 described later.

[0015] The egg pack P is a container in which a number of eggs are packed and sealed. Containers for the egg pack P are well known in the art and include various types of containers made of different materials or shapes. The container includes a main body P1 and a lid P2. The main body P1 is for housing the lower side of the egg, has an uneven shape that conforms to the egg, and is generally slanted inwardly downward. The lid P2 is for housing the upper side of the egg, and is slanted inwardly upward. The lid P2 may have an uneven shape that conforms to the egg. The lid P2 has a protrusion on the upper surface side. The protrusion is provided, for example, at each corner of the top surface, and prevents the egg packs P stacked on top from shifting out of position.

[0016] The egg carton P is made of, for example, a transparent synthetic resin. The egg carton P is made to a thickness that allows it to deform under external force, and is provided with multiple ribs. When photographing such an egg carton P, it is difficult to capture the outline, and the egg carton P has a glossy surface, and the unevenness of the ribs causes the surface to be uneven, resulting in glare when photographed. Therefore, a special photographing method or image processing method is required to photograph the egg carton P.

[0017] The egg carton P has a flange P3 that protrudes outward. One side of the flange P3 is connected to the main body P1 and the lid P2 by integral molding. One side of the flange P3 may be connected with a perforation. The other side of the flange P3 is connected using tape (not shown). The other side of the flange P3 may be connected by thermal welding. The main body P1 and the lid P2 are connected in a state that allows consumers to easily separate them.

[0018] Egg cartons P are available in various sizes and shapes, but the drawing shows an egg carton P containing 10 eggs and having a flat top surface of the lid P2.

[0019] A production system 2 for producing a pack assembly is mainly composed of a transfer device 3, a photographing device 4, and a control device 20. The control device 20 has a detection unit 5 and a control unit 6. The transfer device 3, the photographing device 4, and the control device 20 constitute an abnormality detection device 1 during egg pack transfer according to this embodiment.

[0020] In this embodiment, the abnormality detection device 1 photographs the production process of a pack assembly produced at a GP center or the like, inspects the image data obtained by this photography according to a predetermined model, and outputs the inspection result. This model is obtained by machine learning, for example, and is stored in the storage device 7. The production system 2 judges whether or not there is an abnormality in the pack assembly based on the inspection result, and automatically detects whether or not the transfer device 3 is allowed to perform the next operation.

[0021] Production system 2 also includes a conveying section 10 for egg packs, a waiting section 11 for egg packs, a conveying section 12 for containers, and a waiting section 13 for containers.

[0022] The conveying section 10 for egg cartons is provided with a sealing machine (not shown) on the upstream side. The sealing machine is for connecting the other side of the flange P3 and is called, for example, a tape sealer. The sealing machine applies tape to several thousand to several tens of thousands of egg cartons P per hour. In the egg cartons P, eggs, which are natural objects, are not uniform in size or shape. Therefore, depending on the combination of eggs placed in the container, the degree to which the lid P2 closes or the degree to which the other side of the flange P3 is connected (for example, the way the tape is fastened) may not be uniform.

[0023] The transfer device 3 adsorbs the upper surface of the lid P2 of the egg pack P. The transfer device 3 lifts and moves the egg pack P. The transfer device 3 places the egg pack P at a predetermined position in the transport container 50. The transfer device 3 includes, for example, a robot head 31 and a robot arm 32.

[0024] Robot head 31 has a holding unit 33. Holding unit 33 holds a plurality of egg cartons P. Holding unit 33 is composed of a plurality of suction members 34. Each suction member 34 suctions the top side of egg carton P with lid P2 closed. Each suction member 34 is connected to a vacuum mechanism (not shown). Each suction member 34 has a bellows structure that is expandable and contractable in the vertical direction.

[0025] The robot head 31 lifts and moves multiple egg cartons P at a time. In this embodiment, the holding part 33 holds only the top surface side of the lid P2, so when the egg carton P is lifted by the holding part 33, the weight of the eggs places a large load on the connected flange P3. In addition, lateral shaking occurs as the robot head 31 moves, so the holding state of the holding part 33 is unstable.

[0026] The robot head 31 releases the holding state of the holding part 33 within the transport container 50. The egg carton P is placed directly on the bottom of the transport container 50 or on top of an egg carton P previously placed in the transport container 50.

[0027] The robot arm 32 is capable of changing the position and posture of the robot head 31. The robot arm 32 moves the robot head 31 between the standby section 11 for egg cartons and the transport container 50. The robot arm 32 may be a conventional articulated robot that can be operated arbitrarily, such as a six-axis vertical articulated robot.

[0028] The photographing device 4 photographs an area including a predetermined position. The photographing device 4 photographs the egg packs P after they are placed on the transport container 50. The predetermined position is the position where the transfer device 3 places the egg packs P on the transport container 50. The predetermined position for each transfer operation is stored, for example, in the memory of the control unit 6. The area includes the space around the transport container 50. The photographing device 4 photographs every time the transfer device 3 performs an operation of placing the egg packs P on the predetermined position. In this embodiment, the photographing device 4 is provided on the transfer device 3 and is attached at a position (not shown) that does not interfere with the transfer operation. The photographing device 4 may photograph the egg packs P from the top side, from the side side, or from an oblique direction with respect to the egg packs P. The photographing device 4 is preferably one that can move in the vertical direction according to the height at which the egg packs P are stacked, and is attached to, for example, the robot arm 32.

[0029] The detection unit 5 detects abnormalities within the area based on the captured image. The detection unit 5 inspects the image data of the egg packs P captured by the imaging device 4 against predetermined items, and outputs the results (e.g., whether or not there is an abnormality in the loading of the egg packs). The inspection by the detection unit 5 is performed, for example, according to a predetermined learning model obtained by machine learning. Examples of abnormalities include the egg packs P not being placed in a predetermined position, the egg packs P being tilted, the lids P2 of the egg packs P being detached, and the eggs being exposed outside the packs. The control device 20 is configured using a computer.

[0030] Detection unit 5 determines the state of egg packs P after transfer, specifically, whether the transfer has been successful or unsuccessful, based on the image data. If the transfer has failed, for example, there are the following first to fourth cases.

[0031] The first case is when no egg packs P are placed at the predetermined locations. The detection unit 5 can determine the first case from, for example, the number of egg packs P included in the image.

[0032] The second case is a case where the egg carton P is tilted. The detection unit 5 can determine the second case from, for example, the orientation of the egg carton P included in the image.

[0033] The third case is when the lid P2 of the egg carton P is removed. The detection unit 5 can determine the third case, for example, when the lid P2 cannot be detected or when the label attached to the lid P2 cannot be detected.

[0034] The fourth case is when the eggs are exposed outside the pack. The fourth case can occur, for example, when the lid P2 opens during transfer and the eggs fly out of the pack. The detection unit 5 can determine the fourth case when eggs are detected outside the transport container 50. In this way, the state of the egg packs P stacked in multiple layers in the transport container 50 can be determined based on the image data.

[0035] The learning model is trained in advance using teacher data. Image data is acquired for a state where the transfer is successful, that is, the state of a large number of egg packs P that are found to be normal when loaded in the transport container 50, and teacher data is created. The teacher data includes information that represents the normal state at each process of loading in the transport container 50, and image data that represents an image of the egg packs P loaded in the transport container 50. The image data of the egg packs P included in the teacher data is input to each node of the input layer, and learning is performed in which the parameters of the calculation of each node are adjusted so that a score that matches the state indicated by the information included in the teacher data is output from each node of the output layer. For example, in the learning, an error is calculated using an error function with the output value of each node of the output layer and the output value expected from the teacher data as variables, and the parameters of the calculation of each node are adjusted so that the error is minimized by the error backpropagation method.

[0036] The storage device 7 stores a learning model obtained by machine learning. The learning model is a trained model for performing a process of determining the state of the egg pack according to the image data. The learning model uses a neural network with an input layer, an intermediate layer, and an output layer. The input layer receives image data. For example, the pixel value of each pixel included in the image is input. The output layer outputs the state of the egg pack. The storage device 7 is provided with a learning model in which image data stored and accumulated for each type of container 50 and each type of egg pack P is learned. That is, the storage device 7 is provided with a learning model corresponding to each product item. The storage device 7 is also provided with a learning model in which image data stored and accumulated for each type of operation of the transfer device 3 is learned. That is, the storage device 7 is provided with a learning model corresponding to each process, and is provided with a learning model corresponding to various states of the pack assembly including the intermediate stages of making the finished product of the pack assembly. Note that the learning model does not need to correspond one-to-one to each process, and one learning model may correspond to multiple processes.

[0037] The control device 20 is composed of a dedicated computer or a general-purpose computer, including a CPU (Central Processing Unit), an internal memory, an input / output interface, an AD (analog-to-digital) converter, etc. The functions of the control device 20 are fulfilled by the cooperation of the CPU and its peripheral devices according to the program stored in the internal memory.

[0038] The control unit 6 instructs the transfer device 3 to perform the next operation based on the detection result. Specifically, the control unit 6 outputs an abnormality signal based on the detection result that is determined to be abnormal. The control unit 6 stops the transfer device 3 from starting the next operation.

[0039] The control unit 6 also controls the transfer device 3. Specifically, the control unit 6 controls the holding / releasing operation of the egg pack P in the holding unit 33. The control unit 6 controls the movement of the robot head 31 equipped with the holding unit 33 and the robot arm 32 capable of changing the position and posture of the robot head 31. The control unit 6 moves the egg pack P held by the holding unit 33 onto the shelf board 51 of the container 50. When moving the egg pack P to the space below the shelf board 51, the control unit 6 positions the tip of the robot arm 32 at a position shifted toward one end in the longitudinal direction from the center of gravity of the egg pack P, and holds the egg pack P in the holding unit 33.

[0040] The egg pack conveying section 10 conveys egg packs P and supplies them to the egg pack waiting section 11. A packaging device (not shown) that places eggs in packs is disposed upstream of the egg pack conveying section 10.

[0041] The waiting section 11 for egg packs is provided downstream of the conveying section 10 for egg packs, and is provided with a stopper 15 for restricting the movement of the egg packs P so that the transfer device 3 can hold the egg packs P.

[0042] The container conveying section 12 conveys the container 50 and supplies it to the container waiting section 13. The standby section 13 for containers is provided midway along the transport section 12 for containers, and a stopper 16 for restricting the movement of the containers 50 is provided so that the transfer device 3 can stably load the egg packs P.

[0043] 5 is a flowchart showing an example of a pack assembly production method and an abnormality detection process based on image data, which are executed by abnormality detection device 1 during egg pack transfer. First, when control unit 6 outputs a signal to transfer device 3 to start a transfer operation, transfer device 3 lifts egg pack P from egg pack standby section 11 and transfers it to a predetermined position in container 50 (step S1).

[0044] When the series of transfer operations is completed (step S2), the detection unit 5 performs a setting process to make settings for detecting abnormalities in the egg packs. The detection unit 5 may perform this setting process before step S1 or S2, or after step S5 described below. In the setting process, the detection unit 5 obtains information related to the process of the transfer device 3 from the control unit 6 (step S3), and selects a learning model corresponding to the process of the product item (step S4). The storage device 7 includes multiple learning models with different parameters, and selects the learning model to be used in step S6 from these learning models.

[0045] When the photographing device 4 receives a signal indicating that at least a series of transfer operations has been completed, it photographs the egg packs P in the state after being transferred to the container 50 (step S5). The detection unit 5 performs a judgment process to judge the state of the egg packs based on the image data. The judgment process is a process to make a judgment using a learning model (step S6). For example, the possibility that the transfer of the egg packs P to the container 50 belongs to each category of successful or unsuccessful is obtained as an estimation result, and the success or failure of the transfer is identified based on the estimation result. The judgment result is output to the control unit 6 (step S7).

[0046] In step S8, if the transfer is successful, a normal signal is output to control unit 6 and the process proceeds to the transfer of the next egg pack P, and if the transfer is unsuccessful, the process proceeds to step S9. In step S9, control unit 6 outputs an error signal and outputs an abnormality signal to transfer device 3, prohibiting the start of the transfer operation of the next egg pack P.

[0047] As described above, the abnormality detection device 1 for transferring egg packs according to this embodiment includes the transfer device 3, the photographing device 4, and the control device 20. The transfer device 3 picks up and moves the egg pack P by adsorbing the upper surface of the lid P2 of the egg pack P, and places the egg pack P in a predetermined position in the container 50 for transportation. The photographing device 4 photographs an area including the predetermined position after the egg pack P is placed. The detection unit 5 of the control device 20 detects an abnormality in the area based on the photographed image. The control unit 6 of the control device 20 instructs the transfer device 3 to perform the next operation based on the detection result. As described above, the production system 2 can automatically create a pack assembly in which egg packs P are stacked in the container 50 for transportation in a desired state. In addition, the abnormality detection device 1 can reduce a large impact on egg packs that are stacked thereafter, even if an egg pack that is not in a desired state occurs in the container for transportation.

[0048] Furthermore, photographing device 4 photographs egg packs P stacked in multiple tiers in transport container 50, with the egg packs P arranged in different arrangements on the upper tier and the lower tier. Photography device 4 photographs each time egg packs P are placed on transport container 50 by transfer device 3.

[0049] The detection unit 5 detects at least one of the following: the egg pack P is not placed in a predetermined position, the egg pack P is tilted, the lid P2 of the egg pack P is removed, and the eggs are exposed outside the pack. This makes it possible to deal with problems specific to egg packs P that are structured so that consumers can easily open the lid P2.

[0050] Regarding "whether the lid P2 of the egg pack P is detached," it is also possible to provide a separate inspection device downstream of the sealing machine to inspect whether the flange P3 of the egg pack P is securely connected. However, with an apparatus like this embodiment, it is possible to detect whether the lid P2 of the egg pack P is detached at low cost while ensuring the processing speed of the egg packs P. Also, the detection of whether the lid P2 of the egg pack P is detached can be performed together with the inspection of another item.

[0051] The area includes the space around the transport container 50. Therefore, it is possible to detect egg packs P that have fallen outside the container 50 when the egg packs P are transferred.

[0052] The camera 4 takes an image every time the transfer device 3 places an egg pack P in a predetermined position. In order to complete the pack assembly, the transfer device 3 needs to operate multiple times, but if an abnormality occurs, the operation can be temporarily stopped. This makes it possible to recover before a serious accident occurs, such as eggs cracking in the egg pack P due to an accumulation of abnormalities.

[0053] The present disclosure is not limited to the above-described embodiments. In the above-described embodiment, an example was described in which machine learning was used, but the state of the egg pack P may be detected by using general image processing without using machine learning.

[0054] The photographing device 4 may be one that photographs only the vicinity of a predetermined position, or one that photographs a wide range including the vicinity of the predetermined position. The photographing device 4 may be a fixed camera, or may be one that can change the height or direction depending on the position of the image to be acquired. The photographing device 4 may be provided in multiple locations.

[0055] The photographing device 4 may photograph after the transfer device 3 has performed multiple operations. For example, it is possible to photograph after the transfer device 3 has transferred one layer of containers 50 or one stage of egg packs P on the shelf board 51.

[0056] The abnormalities of the egg packs P detected by the detection unit 5 are not limited to those exemplified in the above embodiment. In addition, the detection unit 5 may be located in a place different from the transfer device 3, and may be provided on a cloud, for example.

[0057] Container 50 is not limited to the movable rack shown in the figure. In addition, the pack assembly may be in any state after a plurality of egg packs P are stored in container 50. For example, it may include a state in which, among the plurality of shelves 51, there is a tier on which no egg packs P are placed, or a state in which lid P2 of a cardboard box is not closed.

[0058] The transfer device 3 is not limited to a so-called six-axis vertical articulated robot. The transfer device 3 can be any robot or device capable of moving the robot head 31 along the X-axis, Y-axis, and Z-axis.

[0059] Holding unit 33 holds, for example, three egg packs P adjacent in the horizontal direction. Holding unit 33 may hold one or two egg packs P, or may hold four or more egg packs P simultaneously. Each egg pack P is held by a plurality of (for example, six) suction members 34. Note that the number and arrangement of suction members 34 may be any number. Also, the arrangement of egg packs P in container 50 is not limited to that shown in the figure.

[0060] The control device 20 of the present disclosure may be configured by a computer that is physically separate from the control device for controlling the transfer device 3.

[0061] The embodiments disclosed herein are illustrative and are not limited thereto. The present disclosure is not limited to the above-described scope, but is defined by the scope of the claims, and is intended to include all modifications within the meaning and scope equivalent to the scope of the claims. [Industrial Applicability]

[0062] The present disclosure can be used when transferring egg cartons. [Explanation of symbols]

[0063] 1. Anomaly detection device 3…Transfer device 4. Shooting device 5…Detection section 6...Control section 20...Control device 50...Transportation container P…egg carton P2…Lid

Claims

1. a transfer device that sucks the top surface of the lid of the egg carton, lifts and moves the egg carton, and places the egg carton in a predetermined position in a container for transportation; an imaging device that images an area including the predetermined position after the egg pack is placed; a control device; The control device includes: Detecting anomalies within the region based on the captured image; An abnormality detection device for detecting abnormalities during egg carton transfer that instructs the transfer device to perform the next action based on the detection results.

2. 2. The device for detecting abnormalities during egg pack transfer according to claim 1, wherein the control device detects at least one of the following: an egg pack not being placed in a designated location, an egg pack being tilted, a lid of the egg pack being removed, and an egg being exposed outside the pack.

3. The device for detecting abnormalities during transfer of egg packs according to claim 1 or 2, wherein the region includes a space around the transport container.

4. The device for detecting abnormalities during egg pack transfer according to claim 1 , wherein the photographing device photographs each time the transfer device performs the operation of placing an egg pack at the specified position.

5. When the detection result indicates that there is no abnormality in the area, the next operation is an operation of continuing the processing by the transfer device, An abnormality detection device for transferring egg packs as described in any one of claims 1 to 4, wherein if the detection result indicates that there is an abnormality within the area, the next action is an action of stopping processing by the transfer device.

6. The device for detecting abnormalities during transfer of egg packs according to any one of claims 1 to 5, wherein the photographing device is provided on the transfer device.

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