Egg tray sorting device

Abstract

The system automatically sorts the egg trays to be returned. [Solution] The system includes a transport unit that transports trays one by one after the eggs have been removed by a transfer device, an imaging unit that photographs the trays being transported by the transport unit, and an inspection unit that inspects the trays for contamination based on the images taken by the imaging unit. The system also includes a sorting unit that sorts the trays based on the inspection results from the inspection unit. The inspection unit inspects for contamination originating from the eggs at a minimum.

Description

Technical Field

[0001] The present invention relates to a classification device for egg trays.

Background Art

[0002] Conventionally, as shown in Patent Document 1, as an automated warehouse for temporarily storing eggs, a tray in which trays containing eggs are stacked (hereinafter referred to as a "stacked tray") is stored from the inbound gate and automatically stored and stored in a storage shelf using a transfer device such as a stacker crane.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] By the way, in this automated warehouse, the stacked trays discharged from the outbound gate are separated one by one by a de-stacking device and conveyed to a packaging device. Then, the eggs contained in the trays in the repacker are accommodated in egg trays. In addition, the empty trays from which the eggs have been removed are collected, stacked on a rack, etc., and then manually returned to the tray filling section of the sorting system on the inbound side. In addition, a configuration in which a conveyor for conveying the empty trays to the inbound side is provided and returned to the tray filling section, and a configuration in which a rack containing the empty trays is returned to the tray filling section by an automated guided vehicle (AGV) are also considered.

[0005] When manually returning the rack containing the empty trays to the inbound side, even if the egg trays are dirty or damaged, a person can check the condition and prevent them from being directly returned to the inbound side. On the other hand, if the system is designed to automatically return empty trays to the receiving end, such empty egg trays may also be returned to the receiving end along with the normal egg trays, which could cause problems.

[0006] The present invention aims to automatically sort egg trays before they are returned. [Means for solving the problem]

[0007] The egg tray sorting device of the present invention comprises a transport unit that transports trays one by one after eggs have been removed by a transfer device, an imaging unit that photographs the trays being transported by the transport unit, and an inspection unit that inspects the trays for contamination based on the images taken by the imaging unit. [Effects of the Invention]

[0008] According to the present invention, egg trays to be returned can be automatically sorted.

[0009] The above and other objects, features, aspects and advantages of this invention will become apparent from the following detailed description relating to this invention, which will be understood in conjunction with the accompanying drawings. [Brief explanation of the drawing]

[0010] [Figure 1] This is a schematic plan view of an egg sorting facility to which an egg tray sorting device according to one embodiment of the present invention is applied. [Figure 2] This is a schematic front view showing a repacker according to the same embodiment. [Figure 3] This is a schematic side view showing an egg tray sorting device according to the same embodiment. [Figure 4] This is a schematic side view showing the main parts of the egg tray sorting device according to the same embodiment. [Figure 5] This is a schematic front view showing the main parts of the egg tray sorting device according to the same embodiment. [Figure 6] This is a schematic plan view showing the main parts of the egg tray sorting device according to the same embodiment. [Figure 7] This is a schematic front view showing the main part of an egg tray sorting device according to a modified example of the present invention. [Figure 8] This is a schematic front view showing the main part of an egg tray sorting device according to another modification of the present invention. [Figure 9] This is a schematic plan view showing the main parts of an egg tray sorting device according to yet another modification of the present invention. [Figure 10] This is a schematic front view showing the main parts of the egg tray sorting device according to the modified example. [Modes for carrying out the invention]

[0011] Hereinafter, an embodiment of the present invention will be described with reference to Figures 1 to 6. The egg tray sorting device 1 according to this embodiment is installed in an egg sorting facility 3 equipped with a repacker 63.

[0012] The egg sorting facility 3 is equipped with an automated warehouse 4. The automated warehouse 4 includes multiple receiving gates 41, multiple shipping gates 42, multiple storage shelves 43 for storing stacking trays T1, and a stacker crane 44 for moving the stacking trays T1 between the receiving gates 41, shipping gates 42, and storage shelves 43. In Figure 1, one shipping gate 42 is shown as a representative example.

[0013] Each of the multiple receiving gates 41 is connected to a receiving-side transport unit 5, such as a conveyor, which transports stacked trays T1 to the receiving gate 41. In this case, each receiving gate 41 is connected to two receiving-side transport units 5. Each receiving-side transport unit 5 connected to the receiving gate 41 is equipped with a stacking device 51 that stacks trays T containing eggs E in a vertical direction. Furthermore, upstream of the stacking device 51 in the receiving-side transport unit 5, a sorting system 52 is provided that sorts the eggs E, for example by weight, and places them in the trays T.

[0014] The plurality of storage shelves 43 store the stacked trays T1 that have been received, sorted by variety. Each storage shelf 43 may be configured to store one stacked tray T1, or may be configured to store a plurality (for example, three) of stacked trays T1.

[0015] The stacker crane 44 transfers the stacked tray T1 from the incoming gate 41 to the storage shelf 43, and transfers the stacked tray T1 from the storage shelf 43 to the outgoing gate 42. The stacker crane 44 in this embodiment is movable in the vertical and horizontal directions and is controlled by a control device. The stacker crane 44 is controlled by the control device based on an incoming request from an incoming-side operation terminal (not shown), and moves and stores the stacked tray T1 that has entered each incoming gate 41 in the storage shelf 43 by variety. Further, the stacker crane 44 is controlled by a control device (not shown) based on an outgoing request from an outgoing-side operation terminal (not shown), and moves the stacked tray T1 stored in each storage shelf 43 to each outgoing gate 42 by variety for outgoing.

[0016] The control device is constituted by a computer having a CPU, a memory, an input / output interface, an AD converter, a display device such as a display, an input device, a communication device, etc. Then, based on a program stored in the memory, the control device causes the CPU and peripheral devices to cooperate to control each part of the automated warehouse 4 and perform operations such as the incoming operation and the outgoing operation of the stacked tray T1 in the automated warehouse 4. Note that instead of a configuration in which the control device controls the entire automated warehouse 4, control units corresponding to each part of the automated warehouse 4 may be provided to control each part.

[0017] Connected to each of the plurality of outgoing gates 42 is an outgoing-side conveyance unit 6 such as a conveyor that conveys the stacked tray T1 to the packaging system 61.

[0018] As shown in FIGS. 1 and 2, the packaging system 61 includes a step separation device 62 that separates the stacked trays T1 conveyed by the outgoing-side conveyor 6 one tray T at a time, and a repacker 63 (transfer device) disposed on the downstream side of the step separation device 62. The repacker 63 is a transfer device that transfers the eggs E contained in the tray T to a container P such as an egg pack and packs the eggs E into the container P. The repacker 63 includes a holding portion 64 that adsorbs the eggs E from above, a head portion 65 provided with a plurality of holding portions 64, and a control portion 66 that moves the head portion 65 up, down, left, and right between the tray T and the container P. The repacker 63 includes a first conveyor 71 that conveys the tray T and a second conveyor 72 that conveys the container P.

[0019] The first conveyor 71 conveys the trays T with the eggs E one by one, and conveys the trays T after the eggs E have been taken out by the repacker 63 one by one. The first conveyor 71 is, for example, a belt conveyor, and the tray T is placed directly on the upper surface T6 of the belt conveyor. Adjacent trays T are conveyed with a predetermined space therebetween. The tray T is made of plastic and has a rectangular shape in plan view. The tray T can accommodate 30 eggs E in 6 vertical rows and 5 horizontal rows, and has concavities and convexities adapted to the shape of the eggs E. The tray T also includes a plurality of holes penetrating in the vertical direction.

[0020] The second conveyor 72 conveys the empty containers P with the lids open one by one, and conveys the containers P after the eggs E have been accommodated by the repacker 63 one by one. A sealing device and an inspection device (not shown) are arranged on the downstream side of the second conveyor 72. The container P is made of plastic and has a rectangular shape in plan view. The container P can accommodate 10 eggs E in 2 vertical rows and 5 horizontal rows, and has concavities and convexities adapted to the shape of the eggs E.

[0021] The classification device 1 for egg trays T is provided on the downstream side of the first conveyor 71. As shown in FIG. 3, the classification device 1 for egg trays T includes a first conveyor 71, an imaging unit 73, an inspection unit 74, and a sorting unit 75.

[0022] The imaging unit 73 photographs the tray T after it has been transported by the first transport unit 71 and removed by the transfer device. The imaging unit 73 is located above the first transport unit 71. In this embodiment, the imaging unit 73 takes three images of each tray T. The first time, it photographs the downstream side T2 of the tray T upstream of the imaging unit 73 during transport. The second time, it photographs the top surface T6 of the tray T below the imaging unit 73. The third time, it photographs the upstream side T5 of the tray T downstream of the imaging unit 73 during transport. In addition, the imaging unit 73 in this embodiment photographs multiple trays T together. For example, it photographs the downstream side T2 of one tray T and the top surface T6 of another tray T together. It also photographs the top surface T6 of one item and the upstream side T5 of another item together. It also photographs the downstream side T2 of one tray T and the upstream side T5 of another tray T together. Below the imaging unit 73, mirrors 76 are provided on both sides of the first transport unit 71. The imaging unit 73 can capture images of the left and right sides T3 and T4 of the tray T via the mirrors 76. In addition, an illumination unit (not shown) is provided in association with the imaging unit 73 to illuminate the egg tray T during imaging.

[0023] The imaging unit 73 can also be described as follows. When the trays T transported by the first transport unit 71 are numbered 1, 2, 3, etc., from the front, the first imaging unit captures the downstream side T2 of tray T No. 1 in one shot. Next, after the first transport unit 71 has transported the trays T a predetermined distance, the imaging unit captures the top surface T6 and left and right sides T3 and T4 of tray T No. 1, and the downstream side T2 of tray T No. 2 in one shot. After that, after the first transport unit 71 has transported the trays T another predetermined distance, the imaging unit captures the upstream side T5 of tray T No. 1, the top surface T6 and left and right sides T3 and T4 of tray T No. 2, and the downstream side T2 of tray T No. 3 in one shot. Subsequently, after the first transport unit 71 transports tray T a predetermined distance, it captures images of the upstream side T5 of tray T No. 2, the top surface T6 and left and right sides T3 and T4 of tray T No. 3, and the downstream side T2 of tray T No. 4 in a single scan. The imaging unit 73 then repeats the same process.

[0024] The inspection unit 74 inspects the tray T for contamination based on the image captured by the imaging unit 73. The inspection unit 74 inspects for contamination originating from egg E. Contamination originating from egg E includes, for example, yolk stains and egg white stains. The inspection unit 74 may also inspect whether or not contamination is present, or the extent of such contamination. The inspection unit 74 may also inspect whether or not there is any damage (scratches or cracks) to the tray T, or the extent of such damage. Furthermore, the inspection unit 74 may also inspect whether or not egg E remains on the tray T.

[0025] The inspection unit 74 may have rules for inspection created by a human, or it may be a learning model generated using machine learning. One example of machine learning is a neural network having an input layer, one or more hidden layers, and an output layer, which learns using a training dataset containing images and labels in learning mode, and makes decisions in prediction mode using its parameters. Machine learning may be supervised learning or unsupervised learning.

[0026] The sorting unit 75 sorts the trays T based on the inspection results from the inspection unit 74. The sorting unit 75 sends out trays T one by one without stacking any trays T that have problems such as being dirty, damaged (scratches or cracks), or having eggs E remaining on them. On the other hand, trays T that have no problems according to the inspection results are stacked vertically. The stacked trays T are then transported further downstream and stored in racks using a transfer device such as a rack-in 81. These racks are then transported to the sorting system 52 and removed from the racks using a transfer device such as a rack-out 82. These stacked trays T1 are then supplied one by one to the conveyor by a supply device such as a tray supply device 83.

[0027] As described above, the egg tray T sorting device 1 of this embodiment includes a first transport unit 71 that transports the trays T one by one after the eggs E have been removed by the transfer device, an imaging unit 73 that photographs the trays T being transported by the first transport unit 71, and an inspection unit 74 that inspects the trays T for contamination based on the images taken by the imaging unit 73. Therefore, the egg trays T to be returned to the sorting system 52 can be automatically sorted.

[0028] The system includes a sorting unit 75 that sorts tray T based on the inspection results from the inspection unit 74, allowing items that can be reused as is to be grouped together.

[0029] Since the inspection unit 74 inspects for contamination originating from eggs E, the hygienic condition of the tray T can be maintained. In particular, because the inspection unit 74 utilizes images captured by the imaging unit 73, it can also classify defects other than contamination, such as tray T as shown in Figure 3, i.e., tray T in which eggs E that were not adsorbed by the repacker 63 remain.

[0030] Furthermore, if the tray T is rectangular in plan view, rotating the tray T on a horizontal plane would require setting a larger width for the first transport unit 71, making the mechanism more complex. However, with an embodiment like this, multiple surfaces can be observed without rotating the tray T, eliminating the need to enlarge the first transport unit 71 or provide a complex mechanism.

[0031] However, the present invention is not limited to the embodiments described above.

[0032] For example, the imaging units 73 may be positioned on the upstream and / or downstream sides in the transport direction. With such a setup, the upstream side T5 and the downstream side T2 of the tray T can be photographed without multiple exposures. For example, the upstream imaging unit 73 can photograph the upstream side T5, the downstream imaging unit 73 can photograph the downstream side T2, and the imaging unit 73 positioned above the tray T can photograph the top surface T6 of the tray T. Alternatively, the upstream imaging unit 73 can photograph the top surface T6 and the upstream side T5 of the tray T, and the downstream imaging unit 73 can photograph the top surface T6 and the downstream side T2 of the tray T.

[0033] <Modified example (Figure 7)> Furthermore, if the imaging unit 73 is positioned on the left and / or right side in the transport direction, the installation of the mirror 76 becomes unnecessary. Figure 7 shows an arrangement where the imaging units 73 are positioned on the left and right side in the transport direction. In such an arrangement, the left and right sides T3 and T4 of the tray T can be photographed even without the mirror 76. That is, one imaging unit 73 photographs the top surface T6 and the left side T3 (in the transport direction) of the tray T, and the other imaging unit 73 photographs the top surface T6 and the right side T4 (in the transport direction) of the tray T.

[0034] <Example (Figure 8)> Furthermore, even if the imaging unit 73 is positioned on the left and / or right and top sides in the transport direction, the installation of the mirror 76 is not required. Figure 8 shows an arrangement where the imaging unit 73 is positioned on the left, right and top sides in the transport direction. In such an arrangement, the left and right sides T3 and T4 of the tray T can be photographed without the mirror 76. That is, the first imaging unit 73 photographs the left side T3 of the tray T (in the transport direction), the second imaging unit 73 photographs the top surface T6 of the tray T, and the third imaging unit 73 photographs the right side T4 of the tray T (in the transport direction).

[0035] <Modified examples (Figures 9 and 10)> Furthermore, as shown in Figures 9 and 10, for example, when trays T are transported in multiple rows in parallel in the transport direction, multiple imaging units 73 are arranged in parallel. The figures show a system where trays T are transported in three rows in the width direction, and these are referred to as the first row, second row, and third row from right to left in the transport direction. From right to left in the transport direction, the first imaging unit 73 is positioned above the first row, the second imaging unit 73 is positioned above the second row, and the third imaging unit 73 is positioned above the third row. In Figure 9, only the imaging range of the second imaging unit 73 is schematically shown by a dashed line. This modified example also allows simultaneous imaging of the left and right sides T3 and T4 of adjacent trays T. In particular, it is preferable to have a system that can simultaneously image the front and rear surfaces T2 and T5 of adjacent trays T, as well as the left and right sides T3 and T4 of adjacent trays T.

[0036] Specifically, the first imaging unit 73 captures the top surface T6 of the first row tray T and the right side T4 of the second row tray. The second imaging unit 73 captures the left side T3 of the first row tray T, the top surface T6 of the second row tray T, and the right side T4 of the third row tray T. The third imaging unit 73 captures the left side T3 of the second row tray T and the top surface T6 of the third row tray T. In addition, the first and third imaging units 73 can capture the left and right sides T3 and T4 of the tray T via the mirror 76.

[0037] The illumination unit used to light the egg tray T during imaging may be white light, or light with a wavelength appropriate to the type of stain to be detected. For example, ultraviolet light may be used to check for stains that are not visible to the naked eye, such as egg whites.

[0038] The conveying section may consist of multiple connected conveyors and may be different from the conveyors of the transfer device.

[0039] The imaging unit 73 may take images from the underside of the tray T. In this case, in order to enable imaging of the tray T from below, the tray T may be transported by a conveying unit (for example, a chain conveyor) that supports a part of the underside of the tray T, or a gap may be provided between adjacent conveyors and the images may be taken through that gap. In this case, the illumination unit that illuminates the egg tray T during imaging may be located below the conveying unit.

[0040] The imaging unit 73 may obtain a reflected image of the tray T illuminated by the illumination unit, or it may obtain a transmitted image of the tray T illuminated by the illumination unit. The illumination unit that illuminates the egg tray T during imaging may be positioned above the transport unit, or it may be positioned to the side of the transport unit.

[0041] A dirt removal device (not shown) may be provided upstream of the sorting device 1 to remove dirt. The dirt removal device is provided upstream of the imaging unit 73 on the first transport unit 71 and removes dirt from the tray T using at least one of a brush and water. In this case, the tray T that has passed through the dirt removal device is inspected by the sorting device 1 with the major dirt removed first. If the trays T pass through the dirt removal device in a stacked state, it is preferable that the trays T be separated one by one upstream of the sorting device 1.

[0042] In addition to detecting egg yolk stains, egg white stains, eggshell residue, feather residue, other foreign matter, tray defects, and residual eggs on the tray due to transfer failures, the sorting device 1 may also sort the trays T by type. The inspection unit 74 can identify the shape and color of the trays and sort them by type.

[0043] The embodiments disclosed herein are illustrative and not limiting. The present invention is defined by the claims, not the scope described above, and all modifications in the meaning and scope equivalent to the claims are intended. [Industrial applicability]

[0044] This invention can be used in a sorting device for egg trays. [Explanation of Symbols]

[0045] 1… Egg tray sorting device 3…Egg sorting facility 4…Automated warehouse 41... Entrance Gate 42... Exit Gate 43...Storage shelves 44…Stacker crane 5…Inbound transport section 51... Stacking device 52… Sorting system 61…Packaging System 6…Delivery side transport section 62... Step-breaking device 63… Repacker (transfer device) 64...Holding part 65... Head part 66... ​​Control Unit 71...First Transport Unit 72... Second Transport Section 73…Imaging Unit 74…Inspection Department 75... Distribution Department 76...Mirror 81... Rack-in (transfer device) 82... Rack-out (transfer device) 83...Tray feeding device E…Egg T...Tray T1...Stackable trays T2... Downstream side T3, T4...Left and right sides T5...upstream side T6…Top surface P...Container (egg carton)

Claims

1. A conveying unit that transports the trays one by one after the eggs have been removed by the transfer device, An imaging unit for photographing the tray being transported by the transport unit, An egg tray sorting device comprising an inspection unit that inspects for contamination of the tray based on an image captured by the imaging unit.

2. The egg tray sorting device according to claim 1, further comprising a sorting unit that sorts the trays based on the inspection results from the inspection unit.

3. The egg tray sorting device according to claim 1 or 2, wherein the inspection unit inspects for at least the contamination originating from the eggs.

Images