Can bodymaker system with on-line vision system

Abstract

A can forming system includes a can bodymaker line and at least one camera. The can bodymaker line is configured to form a body of a can from a metal, such as but not limited to aluminum or an aluminum alloy. The at least one camera may have a field of view of at least a portion of the can bodymaker line. A method of forming the body of the can includes receiving visual data from at least one camera having a field of view of at least a portion of a can bodymaker line, identifying the portion of the can bodymaker line in the field of view, and determining at least one characteristic of the portion of the can bodymaker line responsive to identifying the portion of the can bodymaker line.

Description

Attorney Docket No.: 108050-1543493CAN BODYMAKER SYSTEM WITH ON-LINE VISION SYSTEMREFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of and priority to U.S. Provisional Patent Application No. 63 / 761.201, filed on February 21, 2025, and entitled CAN BODYMAKER SYSTEM WITH ON-LINE VISION SYSTEM, the content of which is hereby incorporated by reference in its entirety.FIELD OF THE INVENTION

[0002] This application relates to metalworking techniques, and more particularly to can body-making systems and methods.BACKGROUND

[0003] A can forming system generally forms cylindrical or tubular structures (hereinafter referred to as "cans") using a cupping system, a can bodymaker system, and a trimmer. The cupping system may make a blank out of material (such as metal) and then draw the blank to form a shallow cup. After the shallow cup is initially drawn, the can bodymaker system forms the shallow cup into a body of a can, often by carrying the cups on an end of a reciprocating ram through a series of dies to obtain a desired size and thickness of the body of the can. As part of forming the can body, the can bodymaker system may utilize a bottom forming tool to shape the bottom of the can (e.g., to have a dome). Downstream from the can bodymaker system, a trimmer may trim the edge of the can to produce a finished can with a generally uniform edge.

[0004] The can body exiting the can bodymaker system may have various defects indicative of process variations and / or equipment performance. As a non-limiting example, a can body may have a sugar scoop defect whereby the untrimmed edge of the can body is wavy or crooked. Such defects may be removed by the trimmer (e.g., the trimmer trims off the uneven edge), but if the underlying process and / or equipment issue is not addressed, the defect will continue to exist and / or may worsen, thereby producing and / or increasing material waste.

[0005] Due to the hostile environment of the can bodymaker system (e g., low lighting, dirty oil cans, high temperature, and high speed), the identification of the sugar scoop defect (and others) traditionally has been achieved by taking a sample can offline and testing the sample inAttorney Docket No.: 108050-1543493a bench / lab seting using contact sensors and the subjective analysis of the tester. Such traditional approaches may not reliably detect the defect (due to subjective analysis), and the offline detection has a lag time, thereby allowing for material waste to continue to accumulate. Other approaches may perform testing on finished cans (e.g., after the can has exited the trimmer) to identify defects in the finished cans, but such approaches are unable to identify defects that temporally exist and / or are removed to produce the finished can.SUMMARY

[0006] Embodiments covered by this patent are defined by the claims below, not this summary. This summary is a high-level overview of various embodiments and introduces some of the concepts that are further described in the Detailed Description section below. This summary is not intended to identify key or essential features of the claimed subject matter, nor is it intended to be used in isolation to determine the scope of the claimed subject mater. The subject mater should be understood by reference to appropriate portions of the entire specification of this patent, any or all drawings, and each claim.

[0007] According to certain embodiments, a can forming system includes a can bodymaker line for forming a body of a can. The can forming system also includes at least one camera having a field of view of at least a portion of the can body maker line.

[0008] According to various embodiments, a can bodymaker line includes at least one can bodymaker configured to form a body of a can and at least one sensor configured to obtain online visual data of at least a portion of the can body maker line.

[0009] According to some embodiments, a can bodymaker vision system includes at least one camera having a field of view of at least a portion of a can bodymaker line and a processor communicatively coupled to the at least one camera. In various embodiments, the processor may be adapted to receive visual data from the at least one camera and identify the portion of the can bodymaker line in the field of view. In some embodiments, the processor may determine at least one characteristic of the portion of the can bodymaker line responsive to identifying the portion of the can body maker line. Optionally, responsive to determining the at least one characteristic of the portion of the can bodymaker line, the processor may implement a control response.

[0010] According to certain embodiments, a can bodymaker vision system includes at least one camera having a field of view of at least a portion of a can body maker line and a processor communicatively coupled to the at least one camera. In various embodiments, the processorAttorney Docket No.: 108050-1543493may receive visual data from the at least one camera, identify at least one can in the field of view, and determine at least one characteristic of the can responsive to identifying the can. Optionally, responsive to determining the at least one characteristic of the can, the processor may implement a control response.

[0011] According to some embodiments, a method of forming a body of a can includes receiving visual data from at least one camera having a field of view of at least a portion of a can body maker line, identifying the portion of the can body maker line in the field of view, and determining at least one characteristic of the portion of the can bodymaker line responsive to identifying the portion of the can body maker line.

[0012] According to various embodiments, non-transitory computer readable storage medium comprises a plurality of instructions executable by one or more processors, which, when executed on the one or more processors, cause the one or more processors to perform actions including receiving visual data from at least one camera having a field of view of at least a portion of a can body maker line, identifying the portion of the can body maker line in the field of view, and determining at least one characteristic of the portion of the can bodymaker line responsive to identifying the portion of the can bodymaker line.

[0013] According to certain embodiments, a can forming system includes a can bodymaker line for forming a body of a can. The can forming system also includes at least one camera having a field of view of at least a portion of the can bodymaker line. The can forming system also includes a control system communicatively coupled to the at least one camera. In certain embodiments, the control system is configured to identify a can body in the can bodymaker line and identify at least one defect in the can body.

[0014] Optionally, the at least one defect includes a clip out on the can body, a split can, a pinched ear on the can body, combinations thereof, and / or other can body defects as desired.

[0015] Various implementations described herein can include additional systems, methods, features, and advantages, which cannot necessarily be expressly disclosed herein but will be apparent to one of ordinary skill in the art upon examination of the following detailed description and accompanying drawings. It is intended that all such systems, methods, features, and advantages be included within the present disclosure and protected by the accompanying claims.Attorney Docket No.: 108050-1543493BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The specification makes reference to the following appended figures, in which use of like reference numerals in different figures is intended to illustrate like or analogous components.

[0017] FIG. 1 illustrates a can forming system according to embodiments.

[0018] FIGS. 2A-C illustrate analysis of cans in the can forming system of FIG. 1 according to embodiments.

[0019] FIGS. 3A-C illustrate analysis of cans in the can forming system of FIG. 1 according to embodiments.

[0020] FIG. 4 illustrates a method according to embodiments.

[0021] FIGS. 5A-C illustrate analysis of cans in the can forming system of FIG. 1 according to embodiments.DETAILED DESCRIPTION

[0022] Described herein are can forming systems and methods with one or more vision sensors for on-line measurement of a can bodymaker line and / or before a trimming operation by a trimmer. Any number of vision sensors may be provided, and the vision sensors may be provided at various locations upstream from a trimmer, including but not limited to upstream from a can body maker, within the can body maker, and / or downstream from the can bodymaker. The vision sensors may include optical or video cameras, single or multi-stereo cameras, laser-based cameras, thermal (e.g., infrared) cameras, a line-scan camera, visible light cameras, red-green-blue depth (RGB-D) cameras, combinations thereof, and / or other suitable sensors as desired.

[0023] Compared to traditional approaches, the systems and methods described herein may provide real-time, on-line measurement and / or identification of portions of a can bodymaker line and characteristics thereof. As non-limiting examples, the systems and methods described herein may identify equipment of the can body maker line and / or one or more cans being processed by the can bodymaker line. In some embodiments, the systems and methods described herein may detect various characteristics about one or more cans, such as but not limited to an edge of a can, an angle of the edge of the can, a height of the can, a metal property of the can, combinations thereof, and / or as otherwise desired. Optionally, the systems and methods described herein may detect one or more defects in one or more cans, such as but notAttorney Docket No.: 108050-1543493limited to clip out defects, split can defects, pinched ear defects, combinations thereof, and / or other defects as desired. In some embodiments, the systems and methods described herein may enable detection of one or more defects that traditionally have not been identified on-line in the can forming system. In certain embodiments, the systems and methods described herein may relate measurements with the can body maker line and / or portions thereof.

[0024] Optionally, based on the detected characteristics, the systems and methods described herein may provide various control responses. As non-limiting examples, the systems and methods described herein may generate an alert, control equipment of the can body maker line, control equipment of the can forming system, monitor and / or predict operational parameters (e.g., alignment variation, maintenance issues, etc.), create information and / or reference knowledge about the process, analyze the data, implement machine learning techniques, determine trends in the process and / or perform trend analysis, combinations thereof, and / or as responses or actions as desired otherwise desired. In one non-limiting example, the systems and methods described herein may enable real-time, on-line edge analysis, which may enable the identification of process variations that impact line performance, such as but not limited to an identification of the sugar scoop defect.

[0025] The systems and methods described herein may improve line performance of a can bodymaker line, reduce a number of line stops per trimmer jam, and / or minimize or reduce low axial load situations. Additionally, or alternatively, by reducing downtime hours and trending analysis of defect parameters, the systems and methods described herein may reduce the amount of energy' expended to produce the same amount of good cans. Various other benefits and advantages may be realized with the systems and methods described herein, and the aforementioned benefits and advantages should not be considered limiting.

[0026] FIG. 1 illustrates an example of a can forming system 100 according to embodiments for generally producing a finished can 107 from a material 101 such as but not limited to a sheet of metal. The can forming system 100 generally includes a cupping system 102, a can bodymaker line 104, and a trimmer system 106. The spatial relationship and number of components of the can forming system 100 should not be considered limiting, and in other embodiments, the can forming system 100 may have other arrangements of equipment as desired to produce the finished can 107.

[0027] The cupping system 102 generally may make blanks out of the material 101 and then draw the blanks to form shallow cups 103. In some embodiments, the material 101 is a metal,Attorney Docket No.: 108050-1543493such as but not limited to steel, steel alloy, tin, tin alloys, aluminum, and / or aluminum alloys. In non-limiting examples, the material 101 is a Ixxx series aluminum alloy, a 2xxx series aluminum alloy, a 3xxx series aluminum alloy, a 4xxx series aluminum alloy, a 5xxx series aluminum alloy, a 6xxx series aluminum alloy, a 7xxx series aluminum alloy, an 8xxx series aluminum alloy and / or any other aluminum or aluminum alloy as desired. In certain embodiments, the material 101 may be various materials that are drawn and ironed, although they need not be. As illustrated in FIG. 1, the material 101 may be supplied in various forms, such as but not limited to a sheet.

[0028] The can bodymaker line 104 includes one or more can bodymakers 108 which form the shallow cups 103 into unfinished can bodies 105. As used herein, an “unfinished can body” refers to a can body with an untrimmed edge and is the state of a can body prior to trimming. The number, location, and type of can body makers 108 included with the can bodymaker line 104 should not be considered limiting. In some non-limiting examples, one or more of the can bodymakers 108 includes a tool pack with one or more dies, and a reciprocating ram, and each cup 103 is carried on the ram through the dies of the tool pack to obtain the unfinished can bodies having a desired size and thickness. Optionally, one or more of the can bodymakers 108 includes a bottom forming tool to shape the bottom of the unfinished can 105, such as to have an internal dome or other shape as desired.

[0029] The trimmer system 106 includes one or more trimmers for trimming the edges of the unfinished can bodies 105 (e.g., opposite from a bottom wall of the can bodies 105 and / or defining the open ends of the can bodies 105) to produce the finished cans 107. While the trimmer system 106 is illustrated as a separate system in FIG. 1, in other embodiments, the trimmer system 106 may be provided as a component of and / or system attached to and / or otherwise associated with at least one can bodymaker 108, optionally with each can bodymaker 108.

[0030] In various embodiments, the cups 103 and / or the unfinished can bodies 105 may have various defects due to variations in process parameters, equipment performance, and / or equipment arrangement. As non-limiting examples, a sugar scoop defect may be defined in the edge of the cups 103 and / or the edge of the unfinished can bodies 105. which may be indicative of misalignment of the tooling of the cupping system 102 and / or misalignment of the tooling of the can body maker line 104. In certain embodiments, the amount of material removed by the trimmer system 106 may be related to the severity of the sugar scoop defect, and the trimmer system 106 removing more material in turn produces more scrap material. Other defects mayAttorney Docket No.: 108050-1543493be present in the cups 103 and / or unfinished can bodies, and reference to the sugar scoop defect should not be considered limiting.

[0031] In various embodiments, and as illustrated in FIG. 1, the can forming system 100 includes one or more vision sensors 110 for obtaining on-line visual data about at least a portion of the can forming system 100 upstream from the trimmer system 106. In certain embodiments, the one or more vision sensors 110 may obtain on-line visual data about at least a portion of the can bodymaker line 104, such as but not limited to one or more of the cups 103, the unfinished can bodies 105, the bodymakers 108. combinations thereof, and / or as otherwise desired.

[0032] The vision sensors 110 may be various devices suitable for obtaining the at least one image of at least a portion of the can forming system 100 and / or the can bodymaker line 104, such as but not limited to various cameras and / or video cameras for capturing the at least one image as a single frame, video, and / or as otherwise desired. As non-limiting examples, the vision sensors 110 may include optical or video cameras, single or multi-stereo cameras, laserbased cameras, thermal (e.g., infrared) cameras, visible light cameras, red-green-blue depth (RGB-D) cameras, line-scan cameras, combinations thereof, and / or other devices as desired. In certain embodiments, the vision sensors 110 may be visible spectrum cameras.

[0033] Any number of vision sensors 110 may be utilized as desired. As such, while five vision sensors 110 are illustrated in FIG. 1, in other embodiments a single vision sensor 110 and / or a plurality of vision sensors 110 may be utilized.

[0034] The vision sensors 110 may be provided at various locations, angles, orientations, and / or arrangements as desired and / or such that each vision sensor 110 has a field of view of various portions of the can forming system 100. As one non-limiting example, one or more vision sensors 110 may be provided downstream from a can bodymaker 108, optionally having a field of view of at least a portion of the can body maker line 104 including the can bodymaker 108, unfinished can bodies 105 exiting the can bodymaker 108, and / or at any other location between the can bodymaker 108 and the trimmer system 106 as desired. Additionally, or alternatively, one or more vision sensors 110 may be provided upstream from a can bodymaker 108, optionally having a field of view of at least a portion of the can bodymaker line 104 including the can bodymaker 108, cups 103 being supplied to the can bodymakers 108, and / or at any other location as desired. Additionally, or alternatively, one or more vision sensors 110 may be provided within one or more can bodymakers 108. As a further non-limiting example,Attorney Docket No.: 108050-1543493when the trimmer system 106 is provided with each can bodymaker 108. the one or more vision sensors 110 may be mounted above each trimmer of the trimmer system 106. In such embodiments, the one or more vision sensors 110 may have a field of view that includes a portion of the can bodymaker 108 upstream from the trimmer and / or a workspace of the trimmer. Other locations or combinations thereof may be utilized for the one or more vision sensors 110 as desired.

[0035] Various sensor arrangements of the vision sensors 110 may be utilized as desired. FIG.1 illustrates one non-limiting example of a sensor arrangement wherein each can bodymaker 108 includes an associated vision sensor 110 for obtaining visual data upstream from each can bodymaker 108 and a single vision sensor 110 is provided downstream from the can body makers 108 for obtaining visional data downstream from the can body makers 108. Other non-limiting examples of sensor arrangements include, but are not limited to, a single vision sensor 110 provided upstream from the bodymakers 108, each can body maker 108 including an associated vision sensor 110 for obtaining visual data dow n stream from each can body maker 108, at least one can bodymaker 108 including a vision sensor 110 within the can bodymaker 108, combinations thereof, and / or as otherwise desired.

[0036] In some embodiments, the ty pe of vision sensor 110 utilized optionally may be based on the location in which the vision sensor 110 is installed to obtain the on-line visual data. As non-limiting examples, a visible spectrum camera may be provided in an environment of the can bodymaker line 104 with a controlled background and good visibility (e.g., due to minimized or reduced fumes), a thermal camera may be provided in an environment with poor visibility (e.g., due to moderate or increased fumes) and a controlled background, and a laserbased camera may be provided in an environment with poor visibility and a complex background. In other embodiments, the various types of vision sensor 110 may be utilized in environments as desired.

[0037] In embodiments where a plurality of vision sensors 110 are provided, the type of vision sensor 110 and / or the arrangement of the vision sensors 110 may be the same or different as desired. As anon-limiting example and referring to FIG. 1, the vision sensors 110 are arranged relative to a path of the cups 103 and / or the unfinished can bodies 105 such that the at least one vision sensor 110 has a detection region that includes an edge of the cups 103 and / or the unfinished can bodies 105. Optionally, the one or more vision sensors 110 may detect the edges of the cups 103 and / or unfinished can bodies 105 in at least tw o axes or directions (e.g., in a width direction and in a height direction). In other embodiments, the one or more vision sensorsAttorney Docket No.: 108050-1543493110 may detect the edges of the cups 103 and / or unfinished can bodies 105 using other techniques and / or as otherwise desired. As another non-limiting example, the can forming system 100 may include five vision sensors 110, of which four vision sensors 110 upstream from a can bodymaker 108 are laser-based or thermal cameras, and one vision sensor 110 downstream from the can body maker 108 is a visible spectrum camera. As another non-limiting example, the can forming system 100 may include two visible spectrum cameras as vision sensors 110, each of which is oriented at a different angle relative to the path of cups 103 and / or unfinished can bodies 105 for capturing different portions of the cups 103 and / or unfinished can bodies 105. Various other arrangements and / or combinations of vision sensors 110 may be utilized as desired.

[0038] In addition to the one or more vision sensors 110, the can forming system 100 may include a control system 112. The control system 112 may be a dedicated control system and / or may be integrated into other systems of the can forming system 100 as desired.

[0039] The control system 112 may include one or more processing units and / or one or more memory devices. The processing unit may be various suitable processing devices or combinations of devices including but not limited to one or more application specific integrated circuits, digital signal processors, digital signal processing devices, programmable logic devices, field programmable gate arrays, processors, controllers, micro-controllers, microprocessors, other electronic units, and / or a combination thereof. The one or more memory devices may be any machine-readable medium that can be accessed by the processor, including but not limited to any type of long term, short term, volatile, nonvolatile, or other storage medium, and is not to be limited to any particular type of memory or number of memories, or type of media upon which memory is stored. Moreover, as disclosed herein, the term "storage medium,” '‘storage” or '‘memory” can represent one or more memories for storing data, including read only memory (ROM), random access memory (RAM), magnetic RAM, core memory', magnetic disk storage mediums, optical storage mediums, flash memory' devices and / or other machine readable mediums for storing information. The term “machine-readable medium” includes, but is not limited to, portable or fixed storage devices, optical storage devices, wireless channels, and / or various other storage mediums capable of storing that contain or carry' instruction(s) and / or data.

[0040] In certain embodiments, the control system 112 optionally includes an associated user interface, including but not limited to a graphical user interface or a human machine interface, such that the control system 112 may obtain information from a user and / or provideAttorney Docket No.: 108050-1543493information to the user. In such embodiments, the user interface and / or human machine interface may be on the control system 112 itself or may be at a location remote from the control system 112.

[0041] The control system 112 may be communicatively coupled to the one or more vision sensors 110 such that the control system 112 receives the visual data from the one or more vision sensors 110. Communication between the control system 112 and the one or more vision sensors 110 may be various types of communication as desired, such as but not limited to wired communication and / or wireless communication (e.g.. near field, cellular, Wi-Fi. Bluetooth®, Bluetooth Low Energy, etc.). Optionally, the control system 112 may be communicatively coupled with other devices and / or systems as desired, such as but not limited to a user device, a remote system, equipment of the can body maker line 104 (e g., such as but not limited to one or more can bodymakers 108), other equipment of the can forming system 100 (e.g., the cupping system 102 and / orthe trimmer system 106). combinations thereof, and / or as otherwise desired.

[0042] In various embodiments, the control system 112 may identify at least a portion of the can bodymaker line 104 in the visual data and / or determine at least one characteristic of the portion of the can body maker line 104 in the visual data. Portions of the can bodymaker line 104 identified in the visual data may include, but are not limited to, a can bodymaker 108, unfinished can bodies 105 exiting the can bodymaker 108, any other location between the can bodymaker 108 and the trimmer system 106, cups 103 being supplied to the can bodymakers 108, tooling and / or equipment within one or more can body makers 108, combinations thereof, and / or as otherwise desired. In a non-limiting example, the portions of the can body maker line 104 may include an edge of a cup 103 and / or an edge of an unfinished can body 105.

[0043] The at least one characteristic may be various information about the equipment, the cups 103, and / or the unfinished can bodies 105 as desired. As non-limiting examples, the at least one characteristic may be a shape of a cup 103, a shape of an unfinished can body 105, an angle of the edge of the cup 103, an angle of the edge of the unfinished can body 105, a height of the cup 103 , a height of the unfinished can body 105 , a metal property of the cup 103 and / or the unfinished can body 105. a surface property of the cup 103 and / or unfinished can body 105, earring of the unfinished can bodies 105, alignment of equipment, combinations thereof, and / or as otherwise desired.Attorney Docket No.: 108050-1543493

[0044] The control system 112 optionally may generate various control responses based on the detection or determination of the at least one characteristic. In some embodiments, the control response may include an output to the operator on a user interface and / or remote device. In such embodiments, the alert may be various types of alerts as desired, such as but not limited to an audible alert or alarm or a visual alert or alarm based on the determined characteristic. Additionally, or alternatively, the control response may include a control of actuators and / or equipment of the can body maker line 104, such as but not limited to control of one or more can bodymakers 108. Additionally, or alternatively, the control response may include a control of actuators and / or equipment of the can forming system 100, such as but not limited to control of the cupping system 102 and / or control of the trimmer system 106. Control of equipment of the can bodymaker line 104 and / or the can forming system 100 may include, but is not limited to, halting or stopping an operation, adjusting an operation parameter, starting an operation, combinations thereof, and / or as otherwise desired. Additionally, or alternatively, the control response may include generating a prediction or estimation of a current operational state of equipment of the can bodymaker line 104. Additionally, or alternatively, the control response may include generating a prediction of a future operational state of equipment of the can bodymaker line. As a non-limiting example, the control system 112 may monitor or track a progression of a change in edge angle for predictive maintenance. Various other control responses may be generated as desired.

[0045] Optionally, the control system 112 may generate the control response (or type of control response) based on a comparison of the characteristic to a threshold. As a non-limiting example, the control system 112 may determine an angle of the edge of the unfinished can bodies 105 and may generate a control response based on the angle exceeding a threshold angle and / or based on an identified trend of a change of the angle of the edge increasing (or decreasing) above (or below) a threshold rate. As a non-limiting example, the control system 112 may determine a height of the unfinished can bodies 105 and may generate a control response based on the height exceeding a threshold height and / or based on an identified trend of a change in the height increasing (or decreasing) above a threshold rate.

[0046] Various other control responses may be implemented for the can forming system 100 and / or the can body maker line 104 based on the measured characteristic of the portion of the can bodymaker line 104. Moreover, various other processes may utilize the measured characteristic of the portion of the can bodymaker line 104 as desired.Attorney Docket No.: 108050-1543493

[0047] FIGS. 2A-C illustrate a non-limiting example of a process performed by the control system 112.

[0048] In this example, in FIG. 2A, the control system 112 may receive visual data from one or more vision sensors 110 of at least a portion of the can body maker line 104. In the example illustrated, the portion of the can bodymaker line 104 includes an unfinished can body 105 having an edge 111.

[0049] As illustrated in FIG. 2B, responsive to receiving the visual data from the one or more vision sensors 110, the control system 112 may identify the portion of the can bodymaker line 104. In FIG. 2B, the identification of the portion of the can bodymaker line 104 is represented by box 213.

[0050] In some embodiments, and as illustrated in FIG. 2C, responsive to the identification of the portion of the can bodymaker line 104, the control system 112 may determine at least one characteristic of the portion of the can bodymaker line 104. In the embodiment illustrated in FIG. 2C, the control system 112 may assign or determine a shape 215 to unfinished can body 105 and may determine a height of the shape 215 to estimate or determine a height of the unfinished can body 105.

[0051] FIGS. 3A-C illustrate another non-limiting example of a process performed by the control system 112. In each of FIGS. 3A-C, the control system 112 may receive the visual data from the one or more vision sensors 110 and may identify unfinished can bodies 105A-C. In certain embodiments, the control system 112 may identify the edges 111A-C and assign or generate aline 317A-C corresponding to the edges. In various embodiments, the control system 112 may determine an angle of each line 317A-C to determine the angle of the edge 111A-C of each can body 105A-C. In the non-limiting examples of FIGS. 3A-C, the control system 112 identified unfinished can body 105 A as having an edge angle of 1.71°, identified unfinished can body 105B as having an edge angle of 0.43°, and identified unfinished can body 105C as having an edge angle of 0.10°.

[0052] Various other processes and / or characteristics may be determined as desired, and the aforementioned examples should not be considered limiting.

[0053] FIG. 4 illustrates an example of a method for forming a can body with the can forming system 100. In certain embodiments, the method may be performed by the control system 112, although it need not be in other embodiments.Attorney Docket No.: 108050-1543493

[0054] In a block 402, the method includes receiving, by the control system 112, the visual data from the one or more vision sensors 110. Block 402 may include receiving visual data from a plurality of vision sensors 110, of which the vision sensors 110 may be various types of vision sensors 110 and / or at various arrangements relative to the can bodymaker line 104.

[0055] In a block 404, the method includes identifying at least a portion of the can bodymaker line 104 based on the visual data. In certain embodiments, block 404 may include determining one or more pieces of equipment of the can body maker line 104, one or more cups 103, one or more unfinished can bodies 105, combinations, thereof, and / or as otherwise desired. In various embodiments, determining the portions of the can bodymaker line 104 is based on contrast, texture properties, color properties, relative movement, reflectivity, combinations thereof, and / or other techniques as desired.

[0056] In a block 406, the method may include determining one or more characteristics of the portion of the can body maker line 104. As non-limiting examples, block 406 may include determining one or more of a shape of a cup 103, a shape of an unfinished can body 105, an angle of the edge of the cup 103, an angle of the edge of the unfinished can body 105, a height of the cup 103, a height of the unfinished can body 105, a metal property of the cup 103 and / or the unfinished can body 105, a surface property of the cup 103 and / or unfinished can body 105, earring of the unfinished can bodies 105. alignment of equipment, combinations thereof, and / or as otherwise desired. In one non-limiting example, block 406 may include determining the angle of the edge of a cup 103 or unfinished can body 105 by identifying the edge in the visual data, assigning or generating a line corresponding to the edge, and determining an angle of the line. In some embodiments, block 406 may include analyzing trends and measurement distribution based on the determined characteristics. In some non-limiting examples, block 104 may include determining misalignment trends, other defect trends, and / or other trends and / or measurements associated with the can bodymaker line as desired. In one non-limiting example, block 406 may include generating a normal distribution of the measured data and using this generated normal distribution in the evaluation of the can ends. Optionally, visual images (e.g., pictures, videos, etc.) and / or other measurements may be obtained at various angles of several cans for generating the normal distribution. In such embodiments, all measurements may not be obtained at a position with a highest angle (e.g., an alignment issue), so the system may generate the normal distribution and compare the distribution of measurements (e.g., to eliminate false negatives due to alignment issues or as otherwise desired).Attorney Docket No.: 108050-1543493

[0057] Various other techniques may be utilized as desired, and various other characteristics or combinations of characteristics may be determined as desired.

[0058] Optionally, in a block 408, the method includes generating a control response based on the determined characteristics. In some non-limiting examples, block 408 may include generating an output to the operator on a user interface and / or remote device. As non-limiting examples, block 408 may include generating at least one of an audible alert or alarm or a visual alert or alarm for the operator based on the determined characteristic of the portion of the can body maker line 104. In some embodiments, block 408 may include controlling actuators and / or equipment of the can body maker line 104, such as but not limited to control of one or more can bodymakers 108. Additionally, or alternatively, block 408 may include controlling actuators and / or equipment of the can forming system 100, such as but not limited to controlling the cupping system 102 and / or control of the trimmer system 106. Additionally, or alternatively, block 408 may include generating a prediction or estimation of a current operational state of equipment of the can bodymaker line 104. Additionally, or alternatively, block 407 may include generating a prediction of a future operational state of equipment of the can body maker line.

[0059] FIGS. 5A-C illustrate additional non-limiting examples of processes performed by the control system 112. In each of FIGS. 5A-C, the control system 112 may receive the visual data from the one or more vision sensors 110 and may identify unfinished can bodies 105. In certain embodiments, the control system 112 additionally or alternatively may identify portions 213 of the can bodymaker line 104. FIGS. 5A-C illustrate the identification of defect regions 519A-C in the unfinished can bodies 105 having one or more defects, such as but not limited to a pinched ear defect 521 (FIG. 5A), a clip out defect 523 (FIG. 5B). and / or a split can defect 525 (FIG. 5C). The particular pinched ear defect 521, clip out defect 523, and split can defect 525 illustrated should not be considered limiting, and in other embodiments, additional and / or fewer defects and / or defect regions may be identified in the unfinished can bodies 105 as desired. The control system 112 may identify defects using various techniques as desired. As non-limiting examples, the control system 112 may identify defects based on an absence of material in a region of the can body 105 expected to have material, a presence of material in a region of the can body 105 expected to have an absence of material, a profile deviation from a predefined and / or predetermined profile, surface patterns or defects, contrast, texture properties, color properties, relative movement, reflectivity, combinations thereof, and / or other techniques as desired.Attorney Docket No.: 108050-1543493

[0060] Various other control responses and / or combinations thereof may be generated in block 408 as desired. Moreover, various other processes may utilize the measured characteristic of the portion of the can body maker line 104 as desired.

[0061] A collection of exemplary embodiments is provided below, including at least some explicitly enumerated as an ‘'Illustration” providing additional description of a variety of example embodiments in accordance with the concepts described herein. These illustrations are not meant to be mutually exclusive, exhaustive, or restrictive; and the disclosure not limited to these example illustrations but rather encompasses all possible modifications and variations within the scope of the issued claims and their equivalents.

[0062] Illustration 1. A can forming system comprising: a can bodymaker line configured to form a body of a can: and at least one camera having a field of view of at least a portion of the can bodymaker line.

[0063] Illustration 2. The system, method, or instructions of any preceding or subsequent illustration or combination of illustrations, further comprising a trimmer dow nstream from the can body maker line, the trimmer configured to trim an edge of the can.

[0064] Illustration 3. The system, method, or instructions of any preceding or subsequent illustration or combination of illustrations, further comprising a control system communicatively coupled to the at least one camera, wherein the control system is configured to: receive visual data from at least one camera having a field of view of at least a portion of the can bodymaker line; identify the portion of the can bodymaker line in the field of view'; and determine at least one characteristic of the portion of the can bodymaker line responsive to identifying the portion of the can bodymaker line.

[0065] Illustration 4. The system, method, or instructions of any preceding or subsequent illustration or combination of illustrations, wherein the at least one characteristic comprises at least one of angle of a can edge, earring, and / or a height of the can.

[0066] Illustration 5. The system, method, or instructions of any preceding or subsequent illustration or combination of illustrations, wherein the portion of the can bodymaker line comprises at least one can.

[0067] Illustration 6. The system, method, or instructions of any preceding or subsequent illustration or combination of illustrations, wherein the portion of the can bodymaker line comprises an edge of the at least one can.Attorney Docket No.: 108050-1543493

[0068] Illustration 7. The system, method, or instructions of any preceding or subsequent illustration or combination of illustrations, wherein the control system is configured to determine the at least one characteristic by: identifying an edge of a can; generating a line conforming to the identified edge of the can; and determining an angle of the line.

[0069] Illustration 8. The system, method, or instructions of any preceding or subsequent illustration or combination of illustrations, wherein the control system is further configured to generate a control response responsive to the determination of the at least one characteristic.

[0070] Illustration 9. The system, method, or instructions of any preceding or subsequent illustration or combination of illustrations, wherein the control response comprises at least one of: an alert or notification; a control of equipment of the can bodymaker line; a control of equipment of the can forming system downstream from the can body maker line; and / or a prediction of a current or future operational state of equipment of the can body maker line.

[0071] Illustration 10. The system, method, or instructions of any preceding or subsequent illustration or combination of illustrations, wherein the at least one camera is within a can bodymaker, upstream from the can bodymaker, or downstream from the can bodymaker.

[0072] Illustration 11. The system, method, or instructions of any preceding or subsequent illustration or combination of illustrations, wherein the at least one camera comprises at least one of a laser-based camera, a thermal camera, a visible light camera, an optical camera, a video camera, a line-scan camera, or an RGB-D camera.

[0073] Illustration 12. A can bodymaker line comprising at least one can bodymaker configured to form a body of a can; and at least one sensor configured to obtain on-line visual data of at least a portion of the can bodymaker line.

[0074] Illustration 13. The system, method, or instructions of any preceding or subsequent illustration or combination of illustrations, wherein the at least one sensor comprises at least one of a laser-based camera, a thermal camera, a visible light camera, an optical camera, a video camera, a line-scan camera, or an RGB-D camera.

[0075] Illustration 14. The system, method, or instructions of any preceding or subsequent illustration or combination of illustrations, wherein the at least one sensor is upstream from the at least one can bodymaker, downstream from the at least one can bodymaker, or w ithin the at least one can bodymaker.Attorney Docket No.: 108050-1543493

[0076] Illustration 15. The system, method, or instructions of any preceding or subsequent illustration or combination of illustrations, further comprising a control system communicatively coupled to the at least one sensor, wherein the control system is configured to: receive visual data from at least one sensor; identify at least a portion of the can bodymaker line in the visual data; and determine at least one characteristic of the portion of the can body maker line responsive to identifying the portion of the can body maker line.

[0077] Illustration 16. The system, method, or instructions of any preceding or subsequent illustration or combination of illustrations, wherein the portion of the can bodymaker line comprises at least one of equipment of the can bodymaker line or at least one can on the can bodymaker line.

[0078] Illustration 17. The system, method, or instructions of any preceding or subsequent illustration or combination of illustrations, wherein the portion of the can bodymaker line comprises at least one can on the can bodymaker line, and wherein the control system is further configured to identify an edge of a can in the visual data.

[0079] Illustration 18. A can bodymaker vision system comprising: at least one camera having a field of view of at least a portion of a can bodymaker line; and a processor communicatively coupled to the at least one camera, wherein the processor is configured to: receive visual data from the at least one camera; identify the portion of the can body maker line in the field of view; determine at least one characteristic of the portion of the can bodymaker line responsive to identifying the portion of the can bodymaker line; and responsive to determining the at least one characteristic of the portion of the can bodymaker line, implement a control response.

[0080] Illustration 19. The system, method, or instructions of any preceding or subsequent illustration or combination of illustrations, wherein the control response comprises at least one of: an alert or notification; a control of equipment of the can bodymaker line; a control of equipment of the can forming system downstream from the can bodymaker line; and / or a prediction of a current or future operational state of equipment of the can body maker line.

[0081] Illustration 20. The system, method, or instructions of any preceding or subsequent illustration or combination of illustrations, wherein the portion of the can bodymaker line comprises at least one can.

[0082] Illustration 21. The system, method, or instructions of any preceding or subsequent illustration or combination of illustrations, wherein the at least one characteristic comprises at least one of an angle of a can edge, earring, and / or a height of the can.Attorney Docket No.: 108050-1543493

[0083] Illustration 22. The system, method, or instructions of any preceding or subsequent illustration or combination of illustrations, wherein the portion of the can bodymaker line comprises an edge of the at least one can.

[0084] Illustration 23. The system, method, or instructions of any preceding or subsequent illustration or combination of illustrations, wherein the processor is configured to determine the at least one characteristic by: identifying an edge of a can; generating a line conforming to the identified edge of the can; and determining an angle of the line.

[0085] Illustration 24. A can bodymaker vision system comprising: at least one camera having a field of view of at least a portion of a can bodymaker line; and a processor communicatively coupled to the at least one camera, wherein the processor is configured to: receive visual data from the at least one camera; identify at least one can in the field of view; determine at least one characteristic of the can responsive to identifying the can; and responsive to determining the at least one characteristic of the can, implement a control response.

[0086] Illustration 25. A method of forming a body of a can, the method comprising: receiving visual data from at least one camera having a field of view of at least a portion of a can bodymaker line; identifying the portion of the can bodymaker line in the field of view; and determining at least one characteristic of the portion of the can bodymaker line responsive to identifying the portion of the can body maker line.

[0087] Illustration 26. The system, method, or instructions of any preceding or subsequent illustration or combination of illustrations, further comprising generating a control response responsive to determining the at least one characteristic.

[0088] Illustration 27. A non-transitory computer readable storage medium comprising a plurality of instructions executable by one or more processors, which, when executed on the one or more processors, cause the one or more processors to perform actions including: receiving visual data from at least one camera having a field of view of at least a portion of a can body maker line; identifying the portion of the can body maker line in the field of view; and determining at least one characteristic of the portion of the can bodymaker line responsive to identifying the portion of the can body maker line.

[0089] Illustration 28. The non-system, method, or instructions of any preceding or subsequent illustration or combination of illustrations, wherein the instructions further comprise instructions causing the one or more processors to generate a control response responsive to the determining of the at least on characteristic.Attorney Docket No.: 108050-1543493

[0090] Illustration 29. A can forming system comprising a can bodymaker line for forming a body of a can. at least one camera having a field of view of at least a portion of the can bodymaker line, and a control system communicatively coupled to the at least one camera, wherein the control system is configured to identify a can body in the can bodymaker line and identify at least one defect in the can body.

[0091] Illustration 30. The system, method, or instructions of any preceding or subsequent illustration or combination of illustrations, wherein the at least one defect includes a clip out on the can body, a split can, a pinched ear on the can body, combinations thereof, and / or other can body defects as desired.

[0092] Illustration 31. A method or instructions to perform the actions of the system of any preceding or subsequent illustration or combination of illustrations. The subject matter of embodiments of the present disclosure is described here with specificity to meet statutory requirements, but this description is not necessarily intended to limit the scope of the claims. The claimed subject matter may be embodied in other ways, may include different elements or steps, and may be used in conjunction with other existing or future technologies. This description should not be interpreted as implying any particular order or arrangement among or between various steps or elements except when the order of individual steps or arrangement of elements is explicitly described. Directional references such as “up," “down," “top," “bottom,” “left,” “right,” “vertical,” “horizontal,” “lateral,” “longitudinal,” “front,” and “back,” among others, are intended to refer to the orientation as illustrated and described in the figure (or figures) to which the components and directions are referencing.

[0093] The terms “comprising,” “having,” “including,” and “containing” are to be constmed as open-ended terms (i.e., meaning “including, but not limited to,”) unless otherwise noted. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, or gradients thereof, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g.. “such as”) provided herein, is intended merely to better illuminate embodiments of the invention and does not pose a limitation on the scope of the invention unless otherwise claimed. No language in the specification should be constmed as indicating any non-claimed element as essential to the practice of the invention.Attorney Docket No.: 108050-1543493

[0094] The above-described aspects are merely possible examples of implementations, merely set forth for a clear understanding of the principles of the present disclosure. Many variations and modifications can be made to the above-described embodiment(s) without departing substantially from the spirit and principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of the present disclosure, and all possible claims to individual aspects or combinations of elements or steps are intended to be supported by the present disclosure. Moreover, although specific terms are employed herein, as well as in the claims that follow, they are used only in a generic and descriptive sense, and not for the purposes of limiting the described embodiments, nor the claims that follow.

Claims

Attorney Docket No.: 108050-1543493CLAIMSThat which is claimed:

1. A can forming system comprising:a can bodymaker line configured to form a body of a can; andat least one camera having a field of view of at least a portion of the can bodymaker line.

2. The can forming system of claim 1 , further comprising a trimmer downstream from the can body maker line, the trimmer configured to trim an edge of the can.

3. The can forming system of claim 1, further comprising a control system communicatively coupled to the at least one camera, wherein the control system is configured to: receive visual data from at least one camera having a field of view of at least a portion of the can bodymaker line;identify the portion of the can bodymaker line in the field of view; and determine at least one characteristic of the portion of the can bodymaker line responsive to identifying the portion of the can bodymaker line.

4. The can forming system of claim 3, wherein the at least one characteristic comprises at least one of an angle of a can edge, earring, and / or a height of the can.

5. The can forming system of claim 3, wherein the portion of the can bodymaker line comprises at least one can.

6. The can forming system of claim 5, wherein the portion of the can bodymaker line comprises an edge of the at least one can.

7. The can forming system of claim 3, wherein the control system is configured to determine the at least one characteristic by: identifying an edge of a can; generating a line conforming to the identified edge of the can; and determining an angle of the line.Attorney Docket No.: 108050-15434938. The can forming system of claim 3, wherein the control system is further configured to generate a control response responsive to the determination of the at least one characteristic.

9. The can forming system of claim 8, wherein the control response comprises at least one of:an alert or notification;a control of equipment of the can bodymaker line;a control of equipment of the can forming system downstream from the can bodymaker line; and / ora prediction of a current or future operational state of equipment of the can body maker line.

10. The can forming system of claim 1, wherein the at least one camera is within a can bodymaker, upstream from the can bodymaker, or downstream from the can bodymaker.

11. The can forming system of claim 1, wherein the at least one camera comprises at least one of a laser-based camera, a thermal camera, a visible light camera, an optical camera, a video camera, a line-scan camera, or an RGB-D camera.

12. A can bodymaker line comprising:at least one can bodymaker configured to form a body of a can; andat least one sensor configured to obtain on-line visual data of at least a portion of the can bodymaker line.

13. The can bodymaker line of claim 12, wherein the at least one sensor comprises at least one of a laser-based camera, a thermal camera, a visible light camera, an optical camera, a video camera, a line-scan camera, or an RGB-D camera.

14. The can bodymaker line of claim 12, wherein the at least one sensor is upstream from the at least one can bodymaker, dow nstream from the at least one can bodymaker, or within the at least one can body maker.Attorney Docket No.: 108050-154349315. The can bodymaker line of claim 12, further comprising a control system communicatively coupled to the at least one sensor, wherein the control system is configured to: receive visual data from at least one sensor;identify at least a portion of the can bodymaker line in the visual data; and determine at least one characteristic of the portion of the can bodymaker line responsive to identifying the portion of the can bodymaker line.

16. The can bodymaker line of claim 15, wherein the portion of the can bodymaker line comprises at least one of equipment of the can bodymaker line or at least one can on the can bodymaker line.

17. The can bodymaker line of claim 15, wherein the portion of the can bodymaker line comprises at least one can on the can bodymaker line, and wherein the control system is further configured to identify an edge of a can in the visual data.

18. A can bodymaker vision system comprising:at least one camera having a field of view of at least a portion of a can bodymaker line;anda processor communicatively coupled to the at least one camera, wherein the processor is configured to:receive visual data from the at least one camera;identify the portion of the can body maker line in the field of view ; determine at least one characteristic of the portion of the can bodymaker line responsive to identifying the portion of the can body maker line; and responsive to determining the at least one characteristic of the portion of the can bodymaker line, implement a control response.

19. The can bodymaker vision system of claim 18, wherein the control response comprises at least one of:an alert or notification;a control of equipment of the can bodymaker line;a control of equipment of the can forming system downstream from the can bodymaker line; and / orAttorney Docket No.: 108050-1543493a prediction of a current or future operational state of equipment of the can bodymaker line.

20. The can bodymaker vision system of claim 18, wherein the portion of the can bodymaker line comprises at least one can.

Images