Note: Descriptions are shown in the official language in which they were submitted.
CA 02495948 2005-02-02
Automated OuaGtv Assurance
Field of thQ Invention
The present invention relates to a method and apparatus, and method of doing
business tl~re~by, for automating quality control functions in processed food
production
and preparation of beef, poultry and other food segments and portions, and
more
particularly to automated means and method for dimensional suing, weighing and
temperature testing and spatial characteristic determination of food and other
products.
Baekground of the Invention
To fiu~lher efficiency in modern food product processing and packaging
operations, and in food portion control, efforts have been made to replace
formerly
manually conducted operations with automated procedures and methods. Such
methods
and products are particularly desirable in quality assurance operations and
procedures to
ensure that regulated and mandated quality standards are consistently adhered
to
throughout production operations.
For e~nple, in L~.S. patent application publication No.: LJ.S. 2003/0024'744
~F'ebruary 6, 2003 ) to Ring, there is disclosed a data acquisition and/or
control method
and device which employs a conveyor weigh scale, or "weigh scale control",
which is
said to automatically determine a crucial sample period for accurately
weighing various
CA 02495948 2005-02-02
food productsa T'he described method also employs an algorithm for data
acquisition and
control in a food product weighing operation In this method, a conveyor weigh
scale
senses a dynamic weighs of a product as it passes over a weigh scale, which
can be
expressed as a weight waveform of sensed weight over time as the product
passes over
the scale. As described, an accurate weight reading for the moving product is
made
during a brief sample period within the waveform where weight readings are
most
constant and representative of the static weight of the produ~~t. 'Chic
rnethad is said to be
art advantage over conventional continuously moving produ~~t scales which use
laser
sensor or photosensitive components, such as an optical or other external
triggering
device. ~'hese devices are used to detect the entry of a product into a weigh
scale, and
then actuate the scale which uses fixed timing numbers to estimate the
position of the
sample period on a weight waveform to make weight measurements.
The improvement associated with this method is said to be the provision of a
software algorithm for a weight scale associated with a continuously moving
conveyor
which is capable of positioning the sample period on each product weight
waveform and
in which the weight and speed of the product passing over the scale does not
at~ect the
positioning of the sample period. fihe algorithm calculates the sample period
using
waveform slope characteristics.
The weight measurement method described above is also said to be useful with
such conventional food processing methods, such as illustrated, for example,
in U.S.
Patent IVos. 3, X04, 26~; 5 and 5,724, $'~4 which is a slicing machine with a
conveyor
drivelclass~er system that is responsive tc~ a weigh scale to direct products
within a
weight tolerance, to an "accept conveyor, and out-ofrweight tolerance products
to a
a
CA 02495948 2005-02-02
"rgjest" sonvgyor' Thg slicing machine produces a series of stacks of food
loaf sliees
which move outwardly of the machine on an input conveyor which, as described,
continuously :senses the weight of the sliced product appearing on the scale,
which, in
turn, outputs a continuous succession or' weight readings of samples at
regular time
intervals to de~~ne corresponding waveforms, and which are characterized as
dynamic
weight measures of product. The assemblage enables rapid weight measurement on
the
order of eve-hundred samples per second, with a rapid conveyor product speed
of over
one-hundred product stacks per minute. The system is applicable to all
different types of
commercial food product loaves, such as ham, beef pork, fish in a variety of
shapes anti
sizes, and in dliff'erently shaped stacks of food product.
Other conventional food processing measurement systems include two-
dimensional (2-D) imaging systems to determine length and width, and used, for
example, in oyster measurements and in sizing other food objects. ~'hese
systems
typically prod~.uce a ~-D image which corresponds to an amount of light and
corresponding current, which is picked up by pixels of a charge-coupled device
(CCD)
camera, and which is positioned to recesve it»ages tconr a particulcr area.
These systems are
also able to olntain individual weight data per pmduct, such as the weight of
an oyster, by
carrelating a :ample group weight of food products with pixel data using an
equation
relating to 2-I~ image and volume.
Further refinements to such methods ofdetermining food product volume employ
three-dimensional (3-D) optical valume measurement such as disclosed in U.S.
Patent
No.: 6,369,401 to Lee. ~~n this method, ane or more lines ol'radiation are
projected from
a radiation source, such as a laser light source, onto a food object, and
thereafter detecting
CA 02495948 2005-02-02
lines of radiation rgflested from the ohjgsts R~flsstgd radiation is soatpared
with that
reflected from a reference surface to determine the height, length and width
ofan object
at a location corresponding to at least one line of radiation impinging on the
object. As
fiurther disclosed in this method, several laser lines are impinged onto a
surface area on
which a food product object is located, and onto a reference surface of which
no food
product object is located. A light sensitive device, such as a camera, having
a plurality of
pixel elements that can receive light firom a plurality of surface locations,
which is light
reflected fi~om the food product object, or surface, is used to determine
light intensity
received, and displacement of laser lines relative to a reference location.
Flaw umage data liom the camera is received by a central processing unit
(CPtn,
which determines the binary image ofprojected area to determine length and
width
dimensions. T'he ~i'~J also uses laser line displacemern data to determine
object height at
the various locations of the object, all of which data is then used by the
C~'~L1 to calculate
the product or object volume.
Another food product data processing/process control system and method is
discloses in International latent Application I~o. ~'C~/~'rB~9/(~07~6 to
VVhitehouse. In
this system, a food product traverses an inspection region on a conveyor belt,
and a
transducer determines shape, size and cross-section of the product in the
inspection
region. Data generating transducers can he rotated about an object or product
to be
measured so a3 to inspect the whole of the product surface for accurate size
and shape
measurements, with signals generated when a length ofproduct ewers and leaves
an
inspection region, and with computation means capability to produce product
arrival and
product deparbare signals.
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As also diselossd; data ge~rating laser displacement transducers may bs
mounted
in a ring pattern around or at an inspection site or region, and situated to
direct their
beams through a gap between two in line conveyors, with the ring being driven
by a
servo motor, and with output data of the transducers logged by a computer
means.
In yet another example of conventional product characteristic data gathering
in
commercial fcrod processing techniques, Li.~. Patent application publication
No. U.S.
2UU2%U01444~4 (February ~, 20U~) to I~eirranlc descr'bes a method and
apparatus for
automated poultry egg classification. A conveying system is used transport
eggs to an
inspection station where, among other characteristics, egg temperature is
measured by a
thermal codling system which measures temperature by detecting corresponding
infrared
radiation, thereby generating corresponding signals which are sent to a
controller, or
CPU.
Currer,~tly, in conventional poultry, meat and processed food plant operations
in
general, qual'tty control and assurance techniques are oftentimes labor
intensive. For
example, in a typical poultry plant operation, a sample of all boneless breast
meat product
is tested for si:zx, weight, temperature and other characteristics and/or
dei'ects or standard
deviations by amethod(s) which require at least some aspect of manual labor or
exertion to
produce measurable data, e.g. a quality assurance data point.. Lisually, to
obtain weight
measurements, an employee is required to extract a sample of product i~rom a
product
process line and place it on a scale for weighing. Tine product weight can
then be
recorded in a log, or other database, such as a computer database program.
Product thickness, or other dimensions of width and tength~re also typicahy
manually mea;cured, such as, for exampleR by using calipers, which data is
also manually
CA 02495948 2005-02-02
logged; or otherwise fed to a database: '1'he temperature ofgaeh product
sample is also
manually chec;iced and recorded. Such labor intensive efforts are undesirable
in that up to
two minutes o~r more is required to check each product sample, thereby
resulting in
significantly less data gcnerat~:d thin if pertirrmed by automatic machine
~~esns. Additionally, such
human intervention with quality assurance checking procedures im~ariably
results in
inconsistent or even fabricated data generation leading to unnecessarily
unreliable quality
assurance measures.
It is therefore desirable, and an object ofthe present invention, to provide a
completely automated method and system to generate all data contemplated as
required
for any processed food product quality as: urance pral;ram or ut!~er product
standardization or portion control operation.
Sammarv of the Invention
In asr~;~rdan~ with those objects and desires set forth above; the present
invention
provides a method and apparatus, and method of doing business thereby, of
automating
quality control and assurance in commercial food processing, packaging and
handling. In
this inventive product measuring system total ~~r~~lu~ or o~~ect
~neastarement~ e.~; length
width, height, weight, spatial characteristicswolume and temperature
measurement
functions and other product/object characteristic determinations are combined
in an
automated means, in which one or more sample food products on an automated
conveying means is transported to one or a phlraiity of inspection sites or
regions, which
can be located in a llouS111~ means. In accordance with this invention" once
transported to
the desired loc:ation(s), a product sample may traverse one or more inspection
regions,
(i
CA 02495948 2005-02-02
wherein it is preferred that out of a pluraiit~~ oi~ possible ~nspectic~n
means at least one
detection means is provided which is effective to measure product dimensions
and spatial
characteristics, e.g., the height, length and width, volume and generally the
3-D
topography and the unique spatial characteristics ofa sample product; another
detection
means measw:~e is provided to measure the weight of said sample product; and
an
additional detection means is present to measure the temperature of the sample
product.
Multiple deta~tion means are contemplated for use in a variety of embodiments
of this
invention to measure and/or detect any desired characteristic of a food
product or any
object traversiing an inspection region. The system can also be optionally
provided with
accept output conveyor means and reject output conveyor means, for example,
for
defective products, or products falling outside of standardization parameters,
as desired.
the inventive system is also contemplated for use with one or more executable
programs
to generate, process and store data in a database and to operate all
contemplated functions
of the inventic>n, bar code generating means to codify product measurement
characteristics and any other conventional data processing technology.
The present invention as to its manner of operation and further objects and
advantages is best understood by referertw;e to the (allowing lJetailed
Description of
('referred Embodiments, accompanied by reference to the drawing.
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Hrief Description of the Drawing
dig. 1 is a perspective schematic view ofan embodiment ofthe inventive
measuring method and system for automated dycsamie product
configuration/dimensional
deterrninatior~, weight and temperature determination.
Detailed Description of Preferred
~mbQdunents o~ tire ~reseut ~ovention
T'he present invention provides an automated f=ood product and object
measuring
system which is particularly suited for use in food plant product quality
assurance and
control operations. In this invention, a conveyor means, such as a servo-
computer
operated conveyor belt, t~~ansports one or more, or a plurality of products,
to one or more
inspection or measurement regions to be measured for, e.g. quality control
purposes,
product standardization and packaging, ar for any reason contemplated. fine
product may
be a poultry part or food portion, such as a boneless chicken breast, or a
beef or pork
section or portiion, a whole fish, or any food or prepared food product
contemplated, such
as chicken or beefpiea, prepared casseroles and the dike, or any non-food
product desired
for characteristics measurement andlar identification.
In this e:xemplifed embodiment, once entering an inspection region by way of
conveyor means, the product is subjected to a first detection means for
dimensional or
spatial dimensional or otherwise total topological and/or 2-13 or ~-D
detection and
determination uicluding, far example, the product's height, length and width,
and spatial
and/or topological characteristicsx a second detection means for product
weight
determination., a.nd then a third detection means for product temperature
determination,
8
CA 02495948 2005-02-02
all of which aolleeted information can ba automatically stored in a database.
The order of
placement of detection means can be that of any order as desired and is not
critical to the
practice of this invention However, in a preferred embodiment, there is
thought to be an
advantage to <:onducting a spatial or topological determination prior to a
temperature
determination, as the temperature of an object can then be measured at an
optimum local
of an object, fir example, the thickest portion of an object as desired. fihe
inventive
measuring system provides for an e~cient, human-intervention-free and accurate
snap-
shot product review at any point desired an a food product production line,
with a
concomitant reduction in labor required for its undertaking, and an
elimination of a
specially traizu;d labor force required for product quality control and
assurance
operations. The inventive system by way of its conveyed continuous operation
also
enables a significant increase over conventional manual operations in product
satnple(s)
review and quality control data collection.
Taming now to Fig. l, there is shown a perspective schematic view ofa
preferred
embodiment of the inventive product sample measuring/quantifying system for
automated dyriunic product configurationldimensional determination, weight and
temperature determination. In Fig. 1, a conveyor means l, such as a standard
conveyor
belt, transports one or more, or a plurality, of' food pmduc;t samples 2, such
as a poultry
portion or beefor pork food portion for hwnan, and/or animal consumption, to
one or
more inspection regions. An operator can manually place a food product 2 on
the
conveyor mean; 1, or it may be deposited from a hopper means (not shown) or by
any
suitable conventional deposit means desired or contemplated. The speed of
conveyor
means 1 can be set and controlled by a computer means (not shown) or other
Central
9
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Processing Unit (~PLJ'~; with stop/start and food product entry and depart
functions
automated and controlled as well by the computer means or CQ~J, or other
control
function means.
l~pon lbeing conveyed to a fast inspection region 12, a 1=urst detection means
3 is
similarly situated and is ei~ective to detect and make 3->=~ measurements
and/or determine product configuration f~f'the sample product. first detection
means 3
can be any known or conventional device, pre~erabiy such as a scanning device,
iaor
example, a laser scan, to determine the height, length and width ofthe sample
product at
any cross-sectional plane ofthe pmduct to provide an accurate spatial,
topological, two-
or three-ciimetasional product configuration output profile and volume of the
product.
Irregularly shaped food products such as boneless chicken parts have a varying
topography and are preferably checked and measured far total length, mean and
average
height and wie~th through several cross sectional portions or pre~orms ofthe
sample. If
preferred, two-dimensional measurements are also contemplated.
ScannE~rs contemplated as use#'ul in this example as a first detection means,
and in
this invention in general, can be any conventionally available teclumlogy,
such as, for
example, two and three-dimensional optical sizing systems employing camera
means
positioned in inspection region 12 to receive images from the inspection
region. Such
devices are wE;l1 known, of which examples are discussed in 1.1.5. ~'atent ~o.
6,369,401,
the disclosure of which is incorporated herein by reference. -~r»~ther example
of
conventional 2-D or 3-D spada~ imaging methodology or technology useful in
this invention
includes that di.isclosed in the C~pton non-contact whole field 3-D lVloire
measurement
machine series, such as first described in Takeda, "Faurier Transform
profilometry for
CA 02495948 2005-02-02
the automatic measurement of 3-D object shapes"; University of
El~trocommunications
0982), all o:f which is incorporated by reference herein. In this system an
optical sensor
head which acquires images is provided, and which are based on 3-D
calculations. In
operation, a grating pattern is projected onto an object to be topologically
characterized
from a grating projector by way of a stn~be means, e.g., a Xenon strobe, with
deformed
grating patterns ut the surtace ot~ the object ;u be measured by~ being picked
up and entered into a
computer by way ofdetection from a change-coupled deviice (CCI~) camera which
digitizes the gating images and general Bl~l imaiges on the object. As is
known a CC>~
camera contains light sensitive integrated circuits which store and display
the data for an
image in such. a way that each picture element (pixel) in the image is
converted into an
electrical charge ofwhich its intensity is related to a color of°the
color spectrum. For
example, in a system supporting h~,~~~ c.;olors, there will be a separate
value for each
color that can be stored and recovered. ''his method and system is known for
its
improved shutter speed and effectiveness in imaging and use with moving
objects to
produce accur,~te shape and color measurements with wide held, high resolution
and high
speed measurements via the use of high speed, strobe aided cameras. The system
is also
equipped with a laser pointer for auto-focusing and controlling the
orientation ofthe
camera, a lighting means, e.g. a white light lamp to illuminate an object
targeted for
measurement and for illuminating ink lines and reference marks as desired. An
optical
probe means for uniaxial point measurement, or a snap-shot one point 3-D
measurement,
at any point desired in an object is another feature. As also discussed, a
grating shifting
mechanism can be employed to improve data spatial resolution.
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As ~ntioned; in ap~ratioa a grating pattern is projestai onto a surface to be
measured which is de~'orm~ed according to an object's particular topography.
The
deformed grating pattern taken into a computer by the CC~ camera is saved as a
digital
image. Vi~ith av flat sur#'ace to be measured located at a reference position,
for example,
the most desirable focus position, the deformed image received by the camera
will be ane
ofsubstantially straight lines which may have a particular pitch
characteristic. 1~or a non
flat surface at a reference position to be measured, the deformed image
received by the
camera will be; one of non-straight lines and a changed grating pitch, with a
change of
light intensity ofthe grating image, which is measured and processed. 'l'hus,
for example,
the first image of a flat or substantially flat object, such as a conveyor
belt surface, is
used a reference wave with a certain frequency in camparison with a second
image of a
deformed wave with its phase modulated. 'f he phase diff=erence can then be
calculated,
for example, by use of an algorithm, such as the Maire 3-l~ algorithm as based
on the
Talreda publication, between the reference and deformed waves for individual
pixels of
the CCD camera, with a depth (Z coordinate) and X and Y coordinates obtained.
Many
other 2-D or ?~-D irnaging/topologicat measuring methods and systems are
known, any of
which are contemplated for use herein.
By way ova series ofsnap shots of cross-sectional segments ova sample product,
providing height, length and width data ofa varying topography of a products'
configuration, the product's volume may be determined, as well as its spatial
characteristic:, such a detailed topographic map, fxom which a host of desired
information can be extracted, including, for example, maximum thickness a~
length
along any axis of' interest. Other information operations which might be
performed
12
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in6lude, for exampl8, praduw~t outline template ehesk~ing, shape irregularity
moment
such as t~or unusual protuberances, shape; checking, and thinness and
thickness checking
over selected areas, all of which can be automatically calculated and
determined by
computer means or a CPt,1 station. As can be seen, an enormaus amount
ot~reliable data,
and sample product information, can be gathered and logged or processed in a
rapid
amount of time to control product output quality as precisely as desired or
required.
Further proceeding into another inspection region, inspection region 14 in
Fig, l,
by means of conveyor means 1, product sample 2 is next subjected to a weight
detection
or determination means 4 which is effective to determine total product sample
weight.
Weight detection means 4 situated in inspection xegian I 4 can be of any known
conventional technology, such as a load call or other device effective for
dynamic weight
measurement of products on a continuously moving weigh conveyor. Examples of
such
conventional continuous weighing technology suitable for use in the present
invention is
provided, for example, in L1.S. Patent Application Publication Na. U.S.
2UU3/0024744.
Any of the many conventional load cell weighing systems or indicators are
suitable for
use in this nnvention, including, for example, that provided by Weigh-Tronix,
for
weighing muxed items of varying size and weight, i.e. irregularly shaped and
configured
food product samples, in high speed conveyed weight validation. Other
preferred
suitable examples useful herein include such load cell-based process weighing
systert~s as
provided by BI,H Vishay weight indicators and products, and that of
Sensortronics and
RL Scales, Inc. s which provide load cell weighing systems for use in
automatic check out
counters, as well as in pickingishipping systems and general industrial
applications, any
1~
CA 02495948 2005-02-02
of which such conventional weighing tcshnolagy is contemplated for usg in this
invention.
Having uindtrrgone dimensional/spatiaUtopological configuration; volume anti
weight analysis, product samples ne~ct are transported in dig. 1 by conveyor
means 1 into
a third inspection region 6 for temperature determination/analysis or
temperature
verification. As shown in dig. 1, a temperature detection means 5 is situated
in or
contemporaneous to inspection region lh, and is e~'ective for continuous
dynamic
temperature measurement of food product samples continuously traversing region
16. In
this preferred embodiment, a temperature prove means fa, Sb is indicated for
use, which
may be a computer engaged probe insertable in any cross sectional portion of a
sample
product, such ;~s one of irregular topographical product configuration, to
pmvide an
average or mean temperature per piece or product sample, and to ensure
accurate
temperature measurement. As is known, dwell times of such temperature
measurement
products can be set as desired to further ensure accurate product temperature
measurement cm a continuously moving conveyed sample produc.-lion line.
Also suitable for use in this inven Lion are non-contact temperature
measurement
devices, such as radiation thermo-detection means which are capable of
providing
accurate and reliable temperature determinations and values at a distance over
a
continuously nwving conveyed line. Such instruments, as known, employ optical
components which can focus infrared radiation onto a solid-state detection
where it is
converted into an electrical signal and read out as temperature on a digital
display. Some
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eommgrsial sxamples include; For sxa~lg, ~quipment produced by Raytelc as the
Thermalert gees Of products.
The corweying means of the invention can be any movable belt or moving surface
means compos~rd o~ for example, antibacterial materials to avoid food product
contamination, and can be actuated and speed controlled by a servo or computer
means.
The conveyor means in accordance with the invention may be continuously
conveyed in
product m~easureme~~t operation, or, for example, stopped, started, or moved
or pulsed at
intermittent speeds, dek ending on the measuring or detection operation
desired or
contemplated, the desired speed of data generation, or any other production or
business
reason contemplated. The conveyor means is also preferably constructed of
materials
conducive and complimentary to detection measurement, such as light pulsed
measurement and the like of product sample characteristics and with surface
reference
characteristics stored in a database in a computer means. It is also
contemplated that the
system be equipped with pane or more conveying means for accepted sample
products and
for rejected sample products, with rejected samples being diverted to a
conveyor or area
by an acuateable component or means, such as a pop-up roller or automatically
insertable
panel or gate means, or other directing member means. The conveyor means can
extend
through one or more detection regions in a perpendicular or angled fashion,
and be ofa
substantially flat surface v3r concave or convex in portions depending upon
such factors
as, for example, detection means employed, physical characteristics of a
sample being
measured, and the shape of a sample product to be measured.
CA 02495948 2005-02-02
Any conventional d~ataction means is contemplated far use in thg presant
invention, and which can be placed in any order in conjunction with the
conveyer means.
For example, in some food dye colored products, a color detection means may be
desired,
or in other applications useful to grade fish species via their natural color
characteristics
such as salmon or beef sources or to detect blood spots in poultry and f sh.
$eef
marbling may be detected in such a continuous operation to grade certain cuts,
or to
determine fat percentage in ground beef. Ivloisture content detection means
may be
employed, for example, along with weight and temperature measurements to gauge
product shrinl~:age in processing and packaging operations.
Further, all of the data generated may be used in conjunction with bar code,
or
other coding technology, to grade specific ar desired food lots and
quantities, and/or used
in conjunction with a user's computer network to receive product parameters,
such as QA
data, to report pmduct line status to a control computer and to proved real
time product
reports.
In another aspect and embodiment of the present invention, it is further
contemplated that the automated quality assurance method and apparatus my be
employed in conjunction with one or more business methods, particularly
methods of
conducting food production operations, and stand alone quality assurance
business
method applications.
It will further be appreciated by those persons skilled in the art that the
embodiments described herein are merely exemplary of the principles ofthe
invention,
and that many modifications and variations are possible without departing tom
the spirit
and scope of the invention and claims.
16
