CONVEYER APPARATUS FOR INSPECTING AND PROCESSING PELLET-SHAPED ARTICLES

A conveyer apparatus may inspect and process pellet-shaped articles having a first side with a first characteristic and a second side having a second characteristic. The conveyer apparatus may include: a conveyer configured to convey pellet-shaped articles, a first pre-processing camera configured to generate a first pre-processing image of each of the pellet-shaped articles, a controller configured to receive the first pre-processing image and determine whether the first side or the second side of each of the pellet-shaped articles is facing the first lateral side of the conveyer path, a first processing device and a second processing device configured to process the first side of each of the pellet-shaped articles to produce a third characteristic, a first post-processing camera and a second post-processing camera, a post-processing light source configured to illuminate pellet-shaped articles with ultraviolet light; and an ejection unit configured to eject individual ones of the pellet-shaped articles.

FIELD OF THE TECHNOLOGY

The present technology relates to methods and apparatuses for transporting, inspecting, and processing pellet-shaped articles, e.g., tablets, caplets, lentil-shaped articles, etc.

BACKGROUND OF THE TECHNOLOGY

Inspecting and processing of pellet-shaped articles, such as marking, and/or laser drilling of pellet-shaped articles, is known in the art. Inspection units are typically configured to inspect and remove pellet-shaped articles from a conveyer mechanism that have been improperly processed in a previous processing operation. Processing operations may include marking the pellet-shaped articles with indicia, coloring the pellet-shaped articles, laser drilling holes in the pellet-shaped articles, and/or coating the pellet-shaped articles. These processing operations are typically completed upstream from the inspection unit such that the inspection unit may inspect if these processes have been properly completed.

It is important for the manufacturer to carefully inspect the pellet-shaped articles for defects, such as an improperly printed or coated side of the article, before the pellet-shaped article is distributed to the consumer so as to ensure the quality of the product and hence protect the safety of the consumer. Moreover, such defective articles must be separated from acceptable articles based on the inspection results.

The pellet-shaped articles may also have distinct and defined sides, each requiring a different processing operation to be performed. Therefore, it may be desirable to identify and process each side of the pellet-shaped article accordingly.

Furthermore, in pellet-shaped articles that have distinct and defined sides, e.g., different colors, it may be necessary to distinguish the different sides, even when the color of each respective side is only slightly different, at least visually. That is because it may be intended for only one side having a given color to be processed, e.g., by having a hole drilled.

Additionally, it may also be desirable to confirm that the hole itself was drilled to specification and on the intended side of the pellet-shaped article. It may also be desirable to confirm that a side of the pellet-shaped article that should not have been processed has actually not processed.

Known methods for identifying the side of the pellet-shaped article to be processed and then confirming that that side was processed, processed correctly, and the side not to be processed was not processed include illuminating the pellet-shaped articles with white light, imaging the pellet-shaped articles, and then analyzing the images. However, white light has drawbacks in that it may be difficult to distinguish sides of the pellet-shaped articles when the colors of the respective sides are visually similar. Also, the hole may be very small compared to the overall size of the pellet-shaped articles, and it may be difficult to accurately determine the presence or absence of a hole using white light imaging because the shadow cast by the hole that the system uses to identify it will be small. Accordingly, when there is a possibility of a hole being drilled into the dark-colored side of a pellet-shaped article, whether intended or not, the system might erroneously identify the granularity in the dark-colored side of the pellet-shaped article as a hole. In other words, there is a risk when using white light imaging that the system will indicate the presence of a hole on the dark-colored side even though there is no hole. BRIEF SUMMARY OF THE TECHNOLOGY

One aspect of the present technology is to provide a conveyer apparatus that overcomes one or more of the shortcomings of the prior art, e.g., to more accurately and efficiently process pellet-shaped articles.

Another aspect of the present technology is to provide a method for inspecting and processing pellet-shaped articles overcomes one or more of the shortcomings of the prior art, e.g., to more accurately and efficiently process pellet-shaped articles.

Another aspect of the present technology is to provide methods and apparatuses to inspect and process either or both sides of pellet-shaped articles transported on a conveyer depending on the orientation of the sides of the pellet-shaped articles.

Another aspect of the present technology is to provide methods and apparatuses to inspect and process pellet-shaped articles transported on a conveyer in a vertical or on-edge orientation.

Another aspect of the present technology is directed to a conveyer apparatus for inspecting and processing pellet-shaped articles. The conveyer apparatus comprises: a conveyer configured to convey a plurality of pellet-shaped articles; a controller configured to determine whether a first side or a second side of each of the pellet-shaped articles is facing a first lateral side of the conveyer path; a first processing device configured to process the first side of each of the pellet-shaped articles to produce a third characteristic in response to a first instruction from the controller; a first post-processing camera; a post-processing light source configured to illuminate the pellet-shaped articles with ultraviolet (UV) light, wherein the first post-processing camera is configured to generate a first post-processing image of each of the pellet-shaped articles illuminated with UV light, and wherein the controller is configured to detect presence or absence of the third characteristic. The apparatus may, in addition, include an ejection unit configured to eject individual ones of the pellet-shaped articles from the conveyer.

Another aspect of the present technology is directed to a conveyer apparatus for inspecting and processing pellet-shaped articles, each of the pellet-shaped articles including a first side with a first characteristic and a second side opposite the first side and having a second characteristic that is different from the first characteristic. The conveyer apparatus comprises: a conveyer including a plurality of carrier links configured to circulate along a conveyer path to convey a plurality of pellet-shaped articles along a portion of the conveyer path, each carrier link having a pocket configured to receive a pellet-shaped article in an orientation with the first side or the second side of the pellet-shaped article facing a first lateral side of the conveyer path and the other of the first side or the second side of the pellet-shaped article facing a second lateral side of the conveyer path; a first pre-processing camera located on the first lateral side of the conveyer path, the first pre-processing camera being configured to generate a first pre-processing image of whichever of the first side or the second side of each of the pellet-shaped articles is facing the first lateral side of the conveyer path as the pellet-shaped articles are conveyed past the first pre-processing camera; a controller configured to receive the first pre-processing image of each of the pellet-shaped articles from the first pre-processing camera and determine whether the first side or the second side of each of the pellet-shaped articles is facing the first lateral side of the conveyer path based on whether the first pre-processing image contains the first characteristic or the second characteristic; a first processing device located on the first lateral side of the conveyer path and a second processing device located on the second lateral side of the conveyer path, each of the first processing device and the second processing device being configured to process the first side of each of the pellet-shaped articles to produce a third characteristic on the first side of each of the pellet-shaped articles as the pellet-shaped articles are conveyed past the first processing device and the second processing device in response to a first instruction from the controller that is based on a determination by the controller that the first side of each of the pellet-shaped articles faces the first lateral side or the second lateral side of the conveyer path; a first post-processing camera located on the first lateral side of the conveyer path and a second post-processing camera located on the second lateral side of the conveyer path; a post-processing light source configured to illuminate the pellet-shaped articles with ultraviolet (UV) light as the pellet-shaped articles are conveyed past the first post-processing camera and the second post-processing camera; and an ejection unit configured to eject individual ones of the pellet-shaped articles from a corresponding one of the carrier links, wherein the first post-processing camera is configured to generate a first post-processing image of whichever of the first side or the second side of each of the pellet-shaped articles is facing the first lateral side of the conveyer path and illuminated with UV light and the second post-processing camera is configured to generate a second post-processing image of whichever of the first side or the second side of each of the pellet-shaped articles is facing the second lateral side of the conveyer path and illuminated with UV light, wherein the controller is configured to receive the first post-processing image and the second post-processing image of each of the pellet-shaped articles from the first post-processing camera and the second post-processing camera, respectively, and detect presence or absence of the third characteristic on the first side of each of the pellet-shaped articles in the first post-processing image or the second post-processing image, and wherein the ejection unit is configured to eject individual ones of the pellet-shaped articles from a corresponding one of the carrier links in response to a second instruction from the controller that is based on the controller detecting that the third characteristic is absent from the first side of an individual one of the pellet-shaped articles.

In examples of the aspects in the preceding paragraphs: (a) the first characteristic may be a first color and the second characteristic may be a second color that is different from the first color, (b) the first color may be lighter than the second color, (c) the first processing device may be a first laser configured to drill a hole into each of the pellet-shaped articles and the second processing device may be a second laser configured to drill a hole into each of the pellet-shaped articles, (d) the first laser and the second laser may be configured to drill the hole at a centroid of the first side of each of the pellet-shaped articles and coaxial to an axis perpendicular to a plane between the first side and the second side of each of the pellet-shaped articles, (e) the hole may be a blind hole, (f) the third characteristic may comprise at least one of the size, the shape, the depth, and the position of the hole drilled into the first side of each of the pellet-shaped articles, (g) the controller may be configured to compare at least one of the size, the shape, the depth, and the position of the hole to a hole specification and determine whether the hole drilled into the first side of each of the pellet-shaped articles is within the hole specification, (h) the controller may be configured to instruct the ejection unit to eject an individual one of the pellet-shaped articles if the controller determines that at least one of the size, the shape, the depth, and the position of the hole is not within the hole specification, (i) the controller may be configured to not instruct the first processing device and the second processing device to process the second side of each of the pellet-shaped articles, (j) the ejection unit may be configured to eject individual ones of the pellet-shaped articles from a corresponding one of the carrier links in response to a third instruction from the controller that is based on the controller detecting that the third characteristic is present on the second side of an individual one of the pellet-shaped articles, (k) a second pre-processing camera may be located on the second lateral side of the conveyer path, the second pre-processing camera being configured to generate a second pre-processing image of whichever of the first side or the second side of each of the pellet-shaped articles is facing the second lateral side of the conveyer as the pellet-shaped articles are conveyed past the second pre-processing camera, (l) the controller may be configured to receive the second pre-processing image of each of the pellet-shaped articles from the second pre-processing camera and determine whether the first side or the second side of each of the pellet-shaped articles is facing the first lateral side of the conveyer path based on whether the second pre-processing image contains the first characteristic or the second characteristic, (m) the controller may be configured to receive the second pre-processing image of each of the pellet-shaped articles from the second pre-processing camera, and the controller may be configured to determine from the first pre-processing image and the second pre-processing image whether at least one of the following: each of the pellet-shaped articles is within a predetermined size specification, each of the pellet-shaped articles is within a predetermined shape specification, and each of the pellet-shaped articles is within a predetermined position specification in the pocket of a corresponding one of the carrier links, (n) the controller may be configured to not instruct the first processing device and the second processing device to process said pellet-shaped article and to instruct the ejection unit to eject said pellet-shaped article, if the controller determines that an individual one of the pellet-shaped articles is not within at least one of the predetermined size specification, the predetermined shape specification, and the predetermined position specification, (o) the post-processing light source may be configured to emit light only in the UV spectrum, (p) a pre-processing light source may be configured to illuminate the pellet-shaped articles with ultraviolet (UV) light as the pellet-shaped articles are conveyed past the first pre-processing camera, (q) the pre-processing light source may be configured to emit light only in the UV spectrum, (r) a pre-processing light source may be configured to illuminate the pellet-shaped articles with white light as the pellet-shaped articles are conveyed past the first pre-processing camera, (s) the pre-processing light source may be configured to emit only white light, (t) a post-processing shield may be configured to block ambient light from the first post-processing camera and the second post-processing camera, (u) a pre-processing shield may be configured to block ambient light from the first pre-processing camera, (v) a feed hopper configured to feed the pellet-shaped articles into the carrier links, (w) the controller may be configured to analyze one or more of each pre-processing image and each post-processing image of each of the pellet-shaped articles by: assigning a number to each pixel in each pre-processing image and each post-processing image based on the color or light intensity detected by the controller, replacing pixels with a number above a threshold with a pixel of a first color, and replacing pixels with a number below the threshold with a pixel of a second color that is different from the first color, and/or (x) the first characteristic may be visually distinguishable from the second characteristic.

Another aspect of the present technology is directed to a system for analyzing images of pellet-shaped articles transported by in carrier links of a conveyer along a conveyer path having a first lateral side and a second lateral side, each of the pellet-shaped articles including a first side with a first characteristic and a second side opposite the first side and having a second characteristic that is different from the first characteristic, the system comprising: a processor configured to: receive a first pre-processing image of each of the pellet-shaped articles from a first pre-processing camera and determine whether the first side or the second side of each of the pellet-shaped articles is facing the first lateral side of the conveyer path based on whether the first pre-processing image contains the first characteristic or the second characteristic; instruct a first processing device located on the first lateral side of the conveyer path or a second processing device located on the second lateral side of the conveyer path to process the first side of each of the pellet-shaped articles to produce a third characteristic on the first side of each of the pellet-shaped articles as the pellet-shaped articles are conveyed past the first processing device and the second processing device based on a determination that the first side of each of the pellet-shaped articles faces the first lateral side or the second lateral side of the conveyer path; receive a first post-processing image and a second post-processing image of each of the pellet-shaped articles from a first post-processing camera and a second post-processing camera, respectively, and detect presence or absence of the third characteristic on the first side of each of the pellet-shaped articles in the first post-processing image or the second post-processing image; and instruct an ejection unit to eject individual ones of the pellet-shaped articles from a corresponding one of the carrier links if the processing system detects that the third characteristic is absent from the first side of an individual one of the pellet-shaped articles.

In examples of the aspect of the preceding paragraph: (a) the first post-processing image and the second post-processing image may depict each of the pellet-shaped articles illuminated with ultraviolet (UV) light from a post-processing light source, and/or (b) the processing system may be configured to analyze one or more of each pre-processing image and each post-processing image of each of the pellet-shaped articles by: assigning a number to each pixel in each pre-processing image and each post-processing image based on the color or light intensity detected by the controller, replacing pixels with a number above a threshold with a pixel of a first color, and replacing pixels with a number below the threshold with a pixel of a second color that is different from the first color.

Other aspects, features, and advantages of this technology will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, which are a part of this disclosure and which illustrate, by way of example, principles of this technology.

DETAILED DESCRIPTION

Depicted inFIG.1is a conveyer apparatus100for transporting, inspecting, and processing (e.g., marking or drilling with a laser or printing) pellet-shaped articles. In the depicted example, the conveyer apparatus100may include a conveyer101that transports the pellet-shaped articles50along a portion of a conveyer path CP. The conveyer apparatus100may also include carrier links105that circulate along the conveyer path CP, each carrier link105having a pocket106to transport individual pellet-shaped articles50along the conveyer path CP. It should be understood, however, that alternative examples of the technology may include carrier links105having multiple pockets such that each carrier link is able to transport multiple pellet-shaped articles.

An example of a pellet-shaped article50is shown inFIGS.4A,4B, and4C.FIG.4Ashows a side view of the pellet-shaped article50with a first side52, a second side54opposite the first side, and a belly band56located between the first side52and the second side54. The first side52and the second side54may have a first characteristic and a second characteristic, respectively, that are different from one another. This is indicated inFIG.4Aby stippling on the second side. The first and second characteristics may be different colors and/or textures, for example, and the first side52may be colored differently from the second side54. The color of the first side52may be lighter than the color of the second side54. In this example, each of the first side52and the second side54are approximately equal in volume, and each of the first side52and the second side54forms half of the belly band56such that the belly band56is half the color of the first side52and half the color of the second side54. The belly band56may also be colored the same as one of the first side52and the second side54, or the belly band56may be colored differently from both sides.FIG.4Bshows a top view of the pellet-shaped article50such that the first side is visible, as well as the belly band56.FIG.4Cshows a cross-sectional view taken through line4C-4C ofFIG.4B. The profile of the first side52, the second side54, and the belly band56can be seen in this view. In further examples, there may be no belly band56. Each of the first side52and the second side54may be in the shape of a spherical cap, except that where the pellet-shaped article50has the belly band56, a portion of each side may also be shaped to form the belly band56.

Returning toFIG.1, the pellet-shaped articles may be fed onto the conveyer101by a feed hopper102. The feed hopper102may be designed to hold a large number of pellet-shaped articles50supplied thereto in bulk. As the carrier links105of the conveyer101pass the feed hopper102, individual ones of the pellet-shaped articles50may be taken into pockets106of the carrier links105for inspecting and processing by the conveyer apparatus100. The pellet-shaped articles50may be fed onto the carrier links105in a vertical or on-edge orientation such that a plane defined through the belly band is parallel to the conveyer path CP. In other words, either the first side52or the second side54may be visible when viewed from a position transverse to the conveyer path CP, as can be seen inFIG.3depicting a side schematic view of the conveyer apparatus100.FIG.2depicts a top schematic view of the conveyer apparatus100. In this view, similar toFIG.4A, the first side52, the second side54, and the belly band56are shown. This orientation may be advantageous in that the first side52and the second side54of the pellet-shaped article50may be inspected simultaneously and, if desired, processed simultaneously as shown inFIG.2and described in greater detail below.

It should also be understood that, as shown inFIGS.2and3, the pellet-shaped articles50may be fed onto the conveyer101with the first side52and the second side54oriented randomly relative to the conveyer path CP. This may occur as a result of the pellet-shaped articles50being contained loosely in the feed hopper102in bulk and fed onto the conveyer101. As will be discussed below, the randomness of the feeding of the pellet-shaped articles50to the conveyer101may necessitate that the conveyer apparatus100determine the orientation of the first side52and the second side54to be processed accordingly. An advantageous feature of this arrangement is that in examples of the present technology, the pellet-shaped articles50need not be or are not inverted or flipped as they are transported on the conveyer101along the conveyer path CP. In other words, the orientation of the first side52and the second side54of the pellet-shaped articles does not change as the pellet-shaped articles50pass along the conveyer path CP, but respective sides can be processed and inspected as needed regardless of orientation.

According to an example of the present technology, the pellet-shaped articles transported on the conveyer may pass a first inspection unit150as shown inFIG.1. The first inspection unit150may include at least one camera for pre-processing inspection of the pellet-shaped articles50. The features and functions of the first inspection unit150will be discussed in greater detail below.

After passing the first inspection unit150, the pellet-shaped articles may then be processed by a processing unit160as shown inFIG.1. The processing unit160may include a first laser162and a second laser164to process the pellet-shaped articles50. The features and functions of the processing unit160will be discussed in greater detail below.

Once processed, the pellet-shaped articles may pass a second inspection unit170as shown inFIG.1. The second inspection unit170may include at least one camera for post-processing inspection of the pellet-shaped articles50. The features and functions of the second inspection unit170will be discussed in greater detail below.

Once the pellet-shaped articles50have passed the second inspection unit170, they may pass an ejection unit90as shown inFIG.1. The ejection unit90may be included in the conveyer apparatus100to eject pellet-shaped articles from the conveyer101that have been found by the inspection units to be defective and/or defectively processed.

After the pellet-shaped articles50pass the ejection unit90, they may continue on the conveyer101for further inspection, processing, storage, packaging, etc.

FIG.17shows a flowchart of a method for transporting, inspecting, and processing pellet-shaped articles50. At S100, the pellet-shaped articles50are fed onto the conveyer101in an on-edge orientation as described above. The conveyer101then transports the pellet-shaped articles50to the first inspection unit150.

At S102the first inspection unit150may detect a characteristic of at least one side of the pellet-shaped article being inspected. As shown inFIG.2, the first inspection unit150may include a first camera or a first pre-processing camera152and a second camera or a second pre-processing camera154, each of which generates an image of a characteristic of the side that is visible to that camera. Thus, if the first side52is visible to the first pre-processing camera152, then the first pre-processing camera152may detect the color or the texture that represents the first characteristic, and the second pre-processing camera154may detect the color or the texture that represents the second characteristic of the second side54, or vice versa. Based on the characteristic in the image from each of the first pre-processing camera152and the second pre-processing camera154, a controller200(described in detail below) may determine the orientation of each pellet-shaped article50as shown at S104. The orientation of the first side52and the second side54may be important as it may be desirable to process only one of the first side52and the second side54of each pellet-shaped article50or to process respective sides of each pellet-shaped article50differently.

Furthermore, by detecting the characteristic of each side of each pellet-shaped article50, the conveyer apparatus100can more accurately determine the orientation of each pellet-shaped article50. This may be advantageous in the situation where a pellet-shaped article50was produced incorrectly such that both sides have the same color or texture. The images from the first pre-processing camera152and the second pre-processing camera154may also depict other defects in the pellet-shaped articles50, such as being damaged or misshapen. The images from the first pre-processing camera152and the second pre-processing camera154may also depict that a given pellet-shaped article50did not seat properly in the pocket106of the carrier link105. If any of these conditions is detected, the controller200may determine that the pellet-shaped article50is defective such that it is not processed or inspected further and ejected.

Alternatively, the first inspection unit150may include only one camera, the first pre-processing camera152for example, to detect the side of the pellet-shaped article50visible to the camera, and then the controller200may use a single image of one side of the pellet-shaped article50to determine the orientation of the first side52and the second side54. Thus, if only the first pre-processing camera152is included and this camera generates an image of the first characteristic, then the controller200may determine that the first side52is oriented on that side of the conveyer101and the second side54is oriented toward the opposite side, or vice versa.

The conveyer apparatus100may also include one or more light sources positioned proximal to the first pre-processing camera152(and the second pre-processing camera154) to illuminate the pellet-shaped articles50for imaging at this stage. The light source(s) may emit white light or the light source(s) may emit light only in the UV spectrum. White light may be sufficient because it permits differentiation of the two differently colored sides of each pellet-shaped article, so its orientation can be determined. UV light may be an advantageous alternative for use at this stage because it produces greater contrast on the surface of the pellet-shaped articles50so that the defects described above can more easily be identified through analysis with the controller200.

A shield may also be positioned around the first pre-processing camera152and the second pre-processing camera154, if included, to prevent ambient light from reaching these cameras during inspection and contaminating the images.

Once the controller200has determined the orientation of each pellet-shaped article50, it will be processed accordingly by the processing unit160as indicated by S106ofFIG.17. The processing unit160may, in various examples of the technology, include at least two processing devices, each being located opposite one another relative to the conveyer101. The processing devices may include lasers (for lasering hole(s), logo(s), alphanumeric character(s), etc.), printers, composition-scanning devices, etc. As can be seen inFIGS.1and2, the processing unit160may include a first processing device in the form of a first laser162and a second processing device in the form of a second laser164.

According to one example of the technology, the first side52of each pellet-shaped article50is to be laser-drilled with a hole53and the second side54is not processed. The controller200may instruct the first laser162and the second laser164accordingly based on the image from the first pre-processing camera152alone or based on images from the first pre-processing camera152and the second pre-processing camera154. It should also be understood that the processing unit160may, according to another example of the technology, drill both sides of individual pellet-shaped articles substantially simultaneously or drill and print respective sides of individual pellet-shaped articles50substantially simultaneously. The mark may include at least one of a symbol, an alphanumeric character, and artwork. The hole53may be cylindrical or conical in shape. The hole53may be a blind hole or it may be a through-hole. The hole may be laser-drilled at a centroid of the first side52of each of the pellet-shaped articles50and coaxial to an axis perpendicular to a plane between the first side52and the second side54of each of the pellet-shaped articles50. The hole53and the mark each may include a third characteristic and a fourth characteristic, respectively, defining some feature thereof. The third and fourth characteristics may include one or more of a dimension or size of the hole53or the mark, the shape of the hole53or the mark, the depth of the hole53or mark, and the position of the hole53or mark on the pellet-shaped article.

Since the pellet-shaped articles50may be positioned on the conveyer101in either orientation, the first laser162and the second laser164may each be programmed to laser-drill the hole53. Thus, depending on the orientation of the pellet-shaped articles50on the conveyer, the first laser162may laser-drill the hole53on the first side52of one of the pellet-shaped articles because the first side is oriented towards the first laser162. Then, the subsequent pellet-shaped article50may have its second side54facing the first laser162such that the second laser164will laser-drill the hole53on the first side52of that pellet-shaped article50. Therefore, it should be understood that either laser is capable of drilling either side of each pellet-shaped article according to the orientation detected and determined by the first inspection unit150.

Alternatively, the processing unit160may include dedicated processing devices on either side. For example, the processing unit160may include four lasers with two located on either side of the conveyer path CP. Each of the pair of lasers on either side of the conveyer path CP may be programmed such that one is dedicated to laser-print the mark and the other is dedicated to laser-drill the hole. Thus, the pellet-shaped articles50can be properly processed regardless of orientation and without the need for lasers that perform multiple processing functions.

Once processed by the processing unit160, the pellet-shaped articles pass to the second inspection unit170as shown at S108inFIG.17. The second inspection unit170may then inspect the hole53of each pellet-shaped article50. The second inspection unit170may include a third camera or a first post-processing camera172and a fourth camera or a second post-processing camera174to identify which side of each pellet-shaped article50it is facing and inspect the processing operation performed thereon. As described above, the first inspection unit150may, in an alternative example, include only one camera, i.e. the first camera, to determine the orientation of pellet-shaped articles, however in such an example of the technology the second inspection unit170would include two cameras, i.e., the first post-processing camera172and the second post-processing camera174, so that either or both sides of the pellet-shaped articles50may be inspected after processing.

The conveyer apparatus100may also include one or more light sources positioned proximal to the first post-processing camera172and the second post-processing camera174to illuminate the pellet-shaped articles50for imaging at this stage. The light source(s) may emit white light or the light source(s) may emit light only in the UV spectrum. UV light may be advantageous at this stage because it produces greater contrast on the surface of the pellet-shaped articles50so that the defects described above can more easily be identified through analysis with the controller200.

A shield may also be positioned around the first post-processing camera172and the second post-processing camera174to prevent ambient light from reaching these cameras during inspection and contaminating the images.

According to one example, when a pellet-shaped article passes through the second inspection unit170each camera identifies the side of the pellet-shaped article based on whether the first characteristic or the second characteristic is detected. Then, for example, if the first characteristic is detected by the first post-processing camera172, then the second inspection unit170determines that the first side52is facing the first post-processing camera172. Accordingly, the controller200can compare the third characteristic in the image of the first side52of the pellet-shaped article50to a hole specification as shown at S110ofFIG.17. Concurrently, the second post-processing camera174may be inspecting the opposite side of the pellet-shaped article50. If the second post-processing camera174detects the second characteristic, then the second inspection unit170determines that the second side54is facing the second post-processing camera174. Accordingly, if desired, the controller200can compare the fourth characteristic of the second side54of the pellet-shaped article to a mark specification as shown at S110ofFIG.17.

If the first post-processing camera172detects that the third characteristic of the hole53is within the hole specification and, if desired, the second post-processing camera174detects that the fourth characteristic of the mark is within the mark specification, then the pellet-shaped article may continue on the conveyer101according to S114ofFIG.17. If one or both of the hole and, if desired, the mark are not within their respective specification, then the controller200may determine that that pellet-shaped article50is defective and instruct the ejection unit90to eject that pellet-shaped article50from the conveyer101as in S112ofFIG.17. Also, if the controller200identifies a hole53in the second side54of a pellet-shaped article50based on images from the first post-processing camera172and the second post-processing camera174(i.e., where a hole should not be in that example), then the controller200may determine that the pellet-shaped article50is defective and instruct the ejection unit90to eject it.

The ejection of defective pellet-shaped articles may be performed by single ejecting each defective pellet-shaped article with the ejection unit90. Ejecting only the pellet-shaped articles50determined to be defective is advantageous in that waste is avoided. Single ejection may be accomplished by an ejection system described in U.S. Pat. No. 8,381,896, which is incorporated herein by reference in its entirety. According to another example of the technology, an additional ejection unit may be included along the conveyer path CP of the conveyer apparatus100immediately following the first inspection unit150so as to allow for the ejection of pellet-shaped articles50found defective by the controller200after imaging by the first pre-processing camera152or the second pre-processing camera154.

FIG.5shows a control system of a conveyer apparatus according to an example of the present technology. In addition to the first inspection unit150, the processing unit160, the second inspection unit170, and the ejection unit90, the conveyer apparatus100may also include the controller200. The controller200may include a processor, e.g., in the form of a central processing unit or CPU202, RAM204and a memory device206. The memory device206can be magnetic, flash based, solid state, or other storage technology.

Furthermore, inFIG.5the controller200may be a computing device (which may also be referred to, for example, as a “computing device,” “computer system,” or “computing system”). The controller200may include one or more of the following: one or more processors, e.g., the CPU202, (which may be referred to as “hardware processors” or individually as a “hardware processor”); one or more memory devices,206, as well as the RAM204. The controller200may also include one or more network interface devices; one or more display interfaces; and one or more user input adapters. Additionally, in some examples, the controller200may be connected to or include a display device. As will explained below, these elements (e.g., processor(s)202, RAM204, memory device(s)206, network interface devices, display interfaces, user input adapters, display device) are hardware devices (for example, electronic circuits or combinations of circuits) that are configured to perform various different functions for the controller200. In some examples, these components of the controller200may be collectively referred to as computing resources (e.g., resources that are used to carry out execution of instructions and include the processors (one or more processors202), storage (one or more RAM204and/or memory devices206), and I/O (network interface devices, one or more display interfaces, and one or more user input adapters). In some instances, the term processing resources may be used interchangeably with the term computing resources.

In some examples, multiple instances of the controller200may be arranged into a distributed computing system, as described. For example, the controller200may also be a distributed system that includes one or multiple processors. In an example using multiple processors, one of the processors may analyze pre-processing images and another one of the processors may analyze the post-processing images.

In some examples, each or any of the processors is or includes, for example, a single- or multi-core processor, a microprocessor (e.g., which may be referred to as a central processing unit or CPU), a digital signal processor (DSP), a microprocessor in association with a DSP core, an Application Specific Integrated Circuit (ASIC), a Field Programmable Gate Array (FPGA) circuit, a graphics processing unit (GPU), or a system-on-a-chip (SOC) (e.g., an integrated circuit that includes a CPU and other hardware components such as memory, networking interfaces, and the like). And/or, in some examples, each or any of the processors202uses an instruction set architecture such as x86 or Advanced RISC Machine (ARM).

In some examples, each or any of the memory devices206is or includes a flash memory (based on, e.g., NAND or NOR technology), a hard disk, a magneto-optical medium, an optical medium, cache memory, a register (e.g., that holds instructions), or other type of device that performs the volatile or non-volatile storage of data and/or instructions (e.g., software that is executed on or by processors202). Memory devices206are examples of non-transitory computer-readable storage media. The RAM204may be a random access memory (RAM) (such as a Dynamic RAM (DRAM) or Static RAM (SRAM)).

In some examples, each or any of the network interface devices includes one or more circuits (such as a baseband processor and/or a wired or wireless transceiver), and implements layer one, layer two, and/or higher layers for one or more wired communications technologies (such as Ethernet (IEEE 802.3)) and/or wireless communications technologies (such as Bluetooth, WiFi (IEEE 802.11), GSM, CDMA2000, UMTS, LTE, LTE-Advanced (LTE-A), LTE Pro, Fifth Generation New Radio (5G NR) and/or other short-range, mid-range, and/or long-range wireless communications technologies). Transceivers may comprise circuitry for a transmitter and a receiver. The transmitter and receiver may share a common housing and may share some or all of the circuitry in the housing to perform transmission and reception. In some examples, the transmitter and receiver of a transceiver may not share any common circuitry and/or may be in the same or separate housings.

In some examples, data is communicated over an electronic data network. An electronic data network includes implementations where data is communicated from one computer process space to computer process space and thus may include, for example, inter-process communication, pipes, sockets, and communication that occurs via direct cable, cross-connect cables, fiber channel, wired and wireless networks, and the like. In certain examples, network interface devices may include ports or other connections that enable such connections to be made and communicate data electronically among the various components of a distributed computing system.

Alternatively, or additionally, in some examples, the controller200includes one or more of: a processing system that includes the processor(s)202; a memory or storage system that includes the memory devices206and the RAM204; and a network interface system that includes the network interface devices. Alternatively, or additionally, in some examples, the controller200includes a system-on-a-chip (SoC) or multiple SoCs, and each or any of the above-mentioned elements (or various combinations or subsets thereof) is included in the single SoC or distributed across the multiple SoCs in various combinations. For example, the single SoC (or the multiple SoCs) may include the processor(s)202and the network interface devices; or the single SoC (or the multiple SoCs) may include the processor(s)202, the network interface devices, and the memory devices206and/or the RAM204; and so on. The controller200may be arranged in some examples such that: the processor(s)202include a multi or single-core processor; the network interface devices include a first network interface device (which implements, for example, WiFi, Bluetooth, NFC, etc.) and a second network interface device that implements one or more cellular communication technologies (e.g., 3G, 4G LTE, CDMA, etc.); the memory devices206and the RAM204. As another example, the controller200may be arranged such that: the processor(s)202include two, three, four, five, or more multi-core processors; the network interface devices include a first network interface device that implements Ethernet and a second network interface device that implements WiFi and/or Bluetooth; and the memory devices206include the RAM204and a flash memory or hard disk.

The controller200may be included to perform functions such as the determination of the orientation of the pellet-shaped articles on the conveyer S104and the determination of whether the hole and, if desired, the mark are within their respective specification S110. Thus, the first inspection unit150and the second inspection unit170may communicate images of the pellet-shaped articles50to the controller200, which in turn performs the determination functions discussed above. Once the orientation of an individual pellet-shaped article is determined, the controller200may also instruct the processing unit160as to which processing function(s) are to be performed. Also, the second inspection unit170may communicate images of the pellet-shaped articles50to the controller200to determine whether the processing functions were performed properly. Based on the orientation of the pellet-shaped articles determined previously, the controller200may then compare the hole and the mark, for example, to the hole and mark specifications. Then, based on that comparison, the controller200may instruct the ejection unit90to eject individual pellet-shaped articles50if they are determined to be defectively processed.

Alternatively, the conveyer apparatus100may utilize “smart” cameras in the inspection units150,170to perform the determination functions. Rather, than a controller200that is in communication with the functional elements as discussed above, so called “smart” cameras may individually include controllers to perform these functions within the cameras themselves. In such a case, the first inspection unit150and the second inspection unit170may be in communication with the processing unit160and the ejection unit90to provide these elements with instructions based on the determinations performed at the inspection units.

In further examples, the analysis of pre-processing images at S104and/or of post-processing images at S110may be performed remotely from the conveyer apparatus100, such as in the cloud, at an external data center, or by a control system that is located near the conveyer apparatus100, e.g., within the same building, but physically separate from the conveyer apparatus100.

The effect of illuminating pellet-shaped articles50with UV light during imaging stages, as described above, is depicted inFIGS.6-15C.FIG.6shows a cross-section of a hole53in the first side52of a pellet-shaped article50. The incident UV light55impacts a rough surface51of the first side52that has not been processed, e.g., by drilling with a laser, and the UV light55reflected the rough surface51of the first side52scatters differently than light reflected from the smoother surface of the hole53. The difference in the way UV light55is reflected from the hole53versus the rough surface51around it may allow for a sharper contrast in post-processing images. That sharper contrast may permit more precise measurement and detailed analysis of the post-processing images by the controller200when it compares the hole53against the hole specification, for example, to determine whether a given pellet-shaped article50is defective.

The sharper contrast provided by the reflected UV light55can also highlight differences between the first side52and the second side54of a pellet-shaped article50because the first side52and the second side54may have different surface textures, in addition to being different colors, by virtue of being different materials (seeFIG.4C). Also, the sharper contrast provided by the reflected UV light55can also highlight boundaries of the pellet-shaped articles50more clearly to determine whether there may be any surface imperfections, whether they may be misshapen, or whether they are seated properly or improperly in a corresponding one of the pockets106. This may be beneficial at the pre-processing imaging stage, as well as the post-processing imaging stage, to ensure that the pellet-shaped articles50are not defective in any respect before or after processing.

FIGS.16A-16Dshow variations of the hole53that can be detected by imaging under UV light and subsequent analysis.FIG.16Ashow a hole53on the first side52of the pellet-shaped article50that is within specification. It is positioned at approximately the centroid of the first side52and extends into the pellet-shaped article50along an axis perpendicular to a plane between the first side52and the second side54of the pellet-shaped article50.FIG.16Bshows a defective hole53located on the belly band56of the pellet-shaped article50.FIG.16Cshows a hole53positioned at approximately the centroid of the first side52and extending into the pellet-shaped article50along an axis perpendicular to a plane between the first side52and the second side54of the pellet-shaped article50, but unlikeFIG.16A, the hole53is oversized and extends completely through the pellet-shaped article50.FIG.16Dshows a defective hole53similar toFIG.16Cin that it is too large, and even though it is a blind hole, it is still too deep.

The sharper contrast provided by UV light during the imaging stages is advantageous because it allows the controller200to more easily determine the parameters of a given hole53from corresponding pre- and/or post-processing images, and thus whether it is within specification, as inFIG.16A, or not, as inFIGS.16B-16D. Furthermore, the sharper contrast can also permit the controller200to detect a pellet-shaped article50that is errantly positioned in its pocket106before processing to avoid it being processed incorrectly, as inFIG.16B. While that pellet-shaped article50might be ejected before errant processing, it might be able to be recycled if it is not processed at all, whereas if it were processed incorrectly, it might be discarded completely. This can save costs for the manufacturer because fewer pellet-shaped articles50are wasted due to errant processing.

FIG.7-15Cshow various pellet-shaped articles50and how the controller200may manipulate images thereof to assess whether a given pellet-shaped article50is within specification.FIGS.7-9Cshow a pellet-shaped article50with a very light colored or white first side52and a darker second side54.FIGS.10-12Cshow a pellet-shaped article50with a light colored first side52and a darker second side54. In this example, the color of the first side52is visually closer to the color of the second side54than is the case of the pellet-shaped article50ofFIGS.7-9C.FIGS.10-12Cshow a pellet-shaped article50with a light colored first side52and a darker second side54, and the pellet-shaped article50in this example is a longitudinally compressed tablet (LCT). Again, in this example, the color of the first side52is visually closer to the color of the second side54than is the case of the pellet-shaped article50ofFIGS.7-9C. In the latter two examples where the color of the first side52is visually closer to the color of the second side54, illuminating the pellet-shaped articles50provides easier distinguishment between the first side52and the second side54because the UV light highlights the differences in surface texture with sharper contrast for analysis by the controller.

FIG.7shows the lighter-colored first side52and the darker-colored second side54of the pellet-shaped article50.FIGS.8A and9Ashow the lighter-colored first side52and the darker-colored second side54of the pellet-shaped article50, respectively, when the pellet-shaped article50is seated in the pocket106of the carrier link105. These images depict the carrier link105and the pellet-shaped article50illuminated by UV light in a raw form as imaged by respective ones of the first post-processing camera172and the second post-processing camera174, which is evident from the texture of the first side52and the second side54being visible. To create even further contrast for analysis by the controller200, the raw images ofFIGS.8A and9Aare binarized to createFIGS.8B and9B, respectively. Binarization may be performed by controller200by assigning a number to each pixel based on the color or intensity of light (e.g., as measured in candelas) detected by the controller200. The binarized images are then created by replacing pixels with a number above a certain threshold with a pixel of a first color (e.g., black) and replacing pixels with a number below a certain threshold with a pixel of a second color (e.g., white). The binarized images ofFIGS.8B and9Band their even sharper contrast can then be analyzed by the controller200to determine whether the pellet-shaped article50and its hole53are within specification.FIGS.8C and9Cshow direct side views of the first side52and the second side54to more clearly depict the color and texture of each side.

It should also be noted that examples above described that the hole53may be drilled only on the first side52and not the second side64of each pellet-shaped article50.FIGS.9A-9Cshow a pellet-shaped article50with hole53on the second side54to depict how this system can use the contrast provided by UV light and binarization to make an errant hole53easily detectible by the controller200.

FIGS.10-12CandFIGS.13-15Cshow similar images toFIGS.7-9C. However, as noted above, the respective colors of the first side52and the second side54are visually closer in these examples.FIGS.10-12CandFIGS.13-15Cindicate how the contrast provided by UV light and binarization still provide clear visual boundaries for analysis by the controller200, which might not be possible if traditional white light illumination had been used.

It should also be understood that while the improved contrast offered by UV light illumination and binarization is discussed in the context of post-processing images, those benefits are similarly applicable to pre-processing images.

While the technology has been described in connection with various examples of the technology, it is to be understood that the technology is not to be limited to the disclosed examples, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the technology. Also, the various examples described above may be implemented in conjunction with other examples, e.g., aspects of one example may be combined with aspects of another example to realize yet other examples. Further, each independent feature or component of any given assembly may constitute an additional example.