Produce orientor using 3D depth imaging for asymmetric apples
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Solution Overview
Problem
Existing automatic orienting systems for produce items, such as apples, fail to correctly orient asymmetrical apples, leading to incomplete core removal and increased waste, as they assume symmetry based on stem and blossom alignment, which is not valid for all apple varieties.
Innovation Solution
The use of depth imaging cameras and a programmable robotic manipulator to create a three-dimensional characterization of the apple's surface, comparing it to stored models using algorithms like Iterative Closest Point (ICP) or Principal Axis of Curvature (PAC) to accurately locate and align the stem and blossom, regardless of the apple's shape, ensuring proper orientation for efficient processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If prior art automatic orienting apparatus assumes apple symmetry based on stem and blossom alignment, then simple and fast orientation is achieved, but asymmetric apples are incorrectly oriented leading to incomplete core removal
Solution Approach 1:
The patent replaces mechanical orientation assumptions with optical sensing systems (cameras) and computational algorithms. Depth imaging cameras capture three-dimensional surface characteristics, and image processing algorithms analyze the data to locate stem and blossom indents accurately, replacing the mechanical assumption of symmetry with optical-digital detection methods.
Solution Approach 2:
The patent creates a digital three-dimensional model (copy) of the apple's surface characteristics using depth imaging cameras. This digital copy allows the system to analyze apple geometry and orientation without physical manipulation, enabling accurate identification of asymmetric apples and proper orientation determination before processing.
2Productivity
If asymmetric apples are processed with traditional orientors, then processing continues without interruption, but core removal is incomplete and quality deteriorates
Solution Approach 1:
The patent performs preliminary detection and classification of apple symmetry using depth imaging and image processing before the apples enter the processing line. Asymmetric apples are identified and oriented correctly in advance, ensuring that when they reach the coring stage, the coring tube is properly aligned with the apple's core, guaranteeing complete core removal.
Solution Approach 2:
The system uses feedback from depth imaging cameras and image processing algorithms to continuously monitor and adjust apple orientation. The digital model of each apple provides real-time information about its geometry, allowing the system to verify correct orientation before processing and ensure reliable core removal for both symmetric and asymmetric apples.
3Manufacturing precision
If depth imaging cameras and image processing algorithms are used to accurately locate stem and blossom, then orientation precision is improved, but device complexity increases
Solution Approach 1:
The patent introduces an intermediary computational layer between the physical apple and the orientation mechanism. Depth imaging cameras capture surface data, image processing algorithms create a digital three-dimensional model and locate stem and blossom indents, and this digital information guides the physical manipulator. This intermediary digital model simplifies the control problem by translating complex physical geometry into actionable orientation data.
4Reliability
If asymmetric apples are separated and disposed of, then processing quality is maintained, but material waste and processing cost increase
Solution Approach 1:
The patent explicitly addresses asymmetric apples by using image processing algorithms that can detect and accommodate asymmetric geometry. Instead of discarding asymmetric apples, the system creates accurate digital models of their asymmetric surfaces, locates their stem and blossom indents, and determines the correct orientation for each unique asymmetric shape, enabling successful processing of previously unusable apples.
Data Source
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AI summary
A method of automatically orienting symmetric and asymmetric produce items, such as apples for example, is provided. Individual items of produce are manipulated by a programmable manipulator within the view of one or more depth imaging cameras. Digital three dimensional characterizations of the surface of the produce items are generated by the depth imaging camera or cameras and are utilized by a computer connected to the depth imaging camera or cameras to locate the stem and blossom of each produce item. Asymmetric produce items, such as apples with dropped shoulders as well as symmetric produce items can be properly oriented and processed automatically.