Abstract:
A visual inspection, mapping and orientation method and system ( 500 ) for golf balls ( 20 ) is disclosed. The visual inspection and mapping equipment locates unique features on the surface of the golf bail ( 20 ) and then uses the features to orient the golf ball ( 20 ) in a particular manner in preparation for providing one or more indicia ( 32 ) on the golf ball ( 20 ). The present invention eliminates the need to manually inspect and orient golf balls ( 20 ) so that the indicia ( 32 ) can be provided in the same location on each of a multitude of golf balls ( 20 ).

Description:
CROSS REFERENCES TO RELATED APPLICATIONS  
       [0001]     The present Application claims priority to U.S. Provisional Patent Application No. 60/613,582, filed on Sep. 27, 2004. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT  
       [0002]     Not Applicable  
       BACKGROUND OF THE INVENTION  
       [0003]     1. Field of the Invention  
         [0004]     The present invention relates to finishing a golf ball. More specifically, the present invention relates to a method and system for orienting a golf ball for printing of an indicia on a predetermined location of the surface of the golf ball.  
         [0005]     2. Description of the Related Art  
         [0006]     Golf balls have indicia such as logos, brand names, numbers, and the like to identify the golf ball as well as its source of origin, and to advertise a particular brand or event. Many golf balls have multiple indicia, such as a brand name (for example, TOP-FLITE or CALLAWAY GOLF), a logo or sub-brand name, a number, and other features. Often, it is desirable to have the particular indicia oriented the same way on all of the balls of a particular type or brand. For example, if an arrow or other indicia is printed on a ball, it might be desirable to always have it pointing in a particular direction, for example, at the pole or the equator of the ball.  
         [0007]     Currently, orienting the golf balls in a particular orientation based on a cover surface feature is achieved manually, and this is very time consuming and labor intensive. For example, if it is desirable to stamp particular indicia facing a particular dimple or location on the ball, the ball must be manually oriented and placed in the stamping machine. Visual inspection systems have been used to orient golf balls using other stamped indicia. For example, a visual inspection system may use the brand name to orient a ball such that an additional logo can later be stamped on the ball in a particular location that is not on or near the brand name.  
         [0008]     As previously noted, it is known to use visual inspection systems to orient a golf ball using other logos or stamps on the ball. It is also known to use visual inspection systems to inspect golf balls and reject them in-line, thus allowing the indicia to be removed before curing and reprinted. See, for example, U.S. Pat. No. 6,462,812 to Heene et al. However, the visual inspection system operates to inspect the printed indicia for quality, not to orient a ball based on specific cover surface features on the ball.  
         [0009]     There are currently no visual inspection systems that orient golf balls in a desired orientation based upon cover surface features on the golf ball. Accordingly, it would be desirable to develop a visual inspection system wherein surface features on a ball, such as a particular dimple, the equator line, mold identification marks or stamps, and the like, can be used to map the golf ball and orient it in a desired orientation for stamping of indicia.  
       BRIEF SUMMARY OF THE INVENTION  
       [0010]     On aspect of the present invention is a method for orienting a golf ball for a placement of an indicia thereon. The method begins with transferring a golf ball to a first vision station. The golf ball has a surface with an identifiable surface feature. Next, the golf ball is retained within a first pair of clamps, each clamp of the pair of clamps engages a portion of the surface of the golf ball. Next, the golf ball is rotated about a central axis at the first vision station. Next, a first viewable portion of the surface of the golf ball is mapped with at least one camera at the first vision station. Next, the golf ball is transferred to a second vision station. Next, the golf ball is oriented ninety degrees relative to an orientation of the golf ball at the first vision station. Next, the golf ball is rotated about a central axis at the second vision station. Next, a second viewable portion of the surface of the golf ball is mapped with at least one camera at the second vision station. Next, a digital map of the surface of the golf ball is created by a microprocessor. Next, the location of the identifiable surface feature of the golf ball is located from the digital map of the surface of the golf ball. Next, the golf ball is transferred to a third vision station. Next, the location of the identifiable surface feature of the golf ball is confirmed at the third vision station. Next, the golf ball is transferred to an orienting station. Next, the golf ball is oriented with reference to the at least one identifiable surface feature for printing of an indicia on a predetermined location of the surface of the golf ball. Next, the golf ball is transferred to a printing station. Finally, an indicia is printed on the predetermined location of the surface of the golf ball at the printing station.  
         [0011]     The at least one identifiable surface feature is preferably selected from the group of a deep dimple, a plurality of deep dimples, an equator of the golf ball, a pole of the golf ball, a position mid-way between a pole of the golf ball and an equator of the golf ball, an unique contour of the surface of the golf ball, or a specific dimple pattern.  
         [0012]     The surface of the golf ball preferably includes a plurality of dimples and land area. Alternatively, the surface of the golf ball includes a plurality of tubular lattice structures.  
         [0013]     Another aspect of the present invention is a method for orienting a golf ball for a placement of an indicia on a predetermined location on the surface of the golf ball. First, the golf ball is transferred to an orientation apparatus. The golf ball has at least one identifiable surface feature. Next, an entire surface of the golf ball is scanned to create a digital map of the entire surface of the golf ball. Next, the location of the at least one identifiable surface feature is determined from the digital map of the entire surface of the golf ball. Next, the golf ball is oriented relative to the location of the at least one identifiable surface feature for printing of an indicia on a predetermined location of the surface of the golf ball. Finally, an indicia is printed on the predetermined location of the surface of the golf ball.  
         [0014]     Yet another aspect of the present invention is a system for orienting a golf ball for placement of an indicia thereon. The system includes a conveyer, an orientation apparatus, a digital map creating means, a location determining means, a orienting means and a printing means. The conveyor for transfers the golf ball to the orientation apparatus. The location determining means determines the location of the at least one identifiable surface feature on the surface of the golf ball from the digital map of the entire surface of the golf ball. The orienting means orients the golf ball relative to the location of the at least one identifiable surface feature for printing of an indicia on a predetermined location of the surface of the golf ball. The printing means prints an indicia on, the predetermined location of the surface of the golf ball.  
         [0015]     The location determining means preferably includes at least one camera and a microprocessor for comparing the digital map of the entire surface of the golf ball to a real-time image of at least a portion of the golf ball.  
         [0016]     The printing means is preferably a pad-printing machine.  
         [0017]     Yet another aspect of the present invention is a system for orienting a golf ball for placement of an indicia thereon. The system includes a conveyor, an orientation apparatus, a plurality of cameras, a microprocessor, a location determining means, an orienting means, and a printing means.  
         [0018]     Having briefly described the present invention, the above and further objects, features and advantages thereof will be recognized by those skilled in the pertinent art from the following detailed description of the invention when taken in conjunction with the accompanying drawings. 
     
    
     BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS  
       [0019]      FIG. 1  is a side view illustrating a preferred embodiment of a system of the present invention.  
         [0020]      FIG. 2  is a cross-sectional view illustrating a golf ball having a core and a cover layer having dimples, wherein one or more of the dimples extends more deeply into the cover.  
         [0021]      FIG. 2A  is a diametrical cross-sectional view of the golf ball of  FIG. 2 .  
         [0022]      FIG. 3  is a top view illustrating a logo on a golf ball having dimples wherein a logo is oriented such that the arrow portion of the logo points to a deep dimple;  
         [0023]      FIG. 4  is a perspective view of a golf ball illustrating three deep dimples in one hemisphere of a golf ball;  
         [0024]      FIG. 5  is a perspective view of a golf ball illustrating a mold mark in the cover of a golf ball; and  
         [0025]      FIG. 6  is a two-dimensional view of the surface of a golf ball that has been mapped by the camera of the inspection system of the invention.  
         [0026]      FIG. 6A  is another two-dimensional view of the surface of a golf ball that has been mapped by the camera of the inspection system of the invention.  
         [0027]      FIG. 7  is a schematic side view of a printing station.  
         [0028]      FIG. 8  is a flow chart of a specific method of the present invention.  
         [0029]      FIG. 9  is a flow chart of a general method of the present invention.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0030]      FIG. 1  is a side view illustrating a system generally designated  400 . The system  400  receives golf balls from a source  100 , such as a bulk hopper and/or conveyor, or any other source known in the art that will feed the golf balls to the visual inspection system. In the embodiment shown, golf balls  110  are fed to the source  100  where they are then picked up by the visual inspection system to begin the process of mapping and orienting the ball. The source  100  accumulates the balls after the balls are covered and prepared for printing of indicia. Each ball is clamped and moved or spun in front of one or more vision cameras. The camera (or cameras) maps the entire surface of the golf ball. The mapped images of the golf ball surface are used to identify and document the key features on the cover that are used to later orient the golf ball. The ball is then rotated into the desired final orientation, preferably using precision servo motors or another precision device known in the art, based on the location of the mapped surface features. The indicia are then stamped on the balls in the desired location. The invention makes it possible to stamp the desired indicia in the same location on each ball.  
         [0031]     In the embodiment shown in  FIG. 1 , there is a golf ball inspection system  400 . There are preferably five sets of clamps ( 320 ,  330 ,  340 ,  350  and  360 ), but any desired amount can be used, as long as the mapping and orientation is accomplished. In the embodiment shown, each set of clamps ( 320 ,  330 ,  340 ,  350  and  360 ) has a golf ball ( 120 ,  130 ,  140 ,  150  and  160 ). A golf ball  120  is clamped by the first set of clamps  320 . The golf ball  120  is then moved into the first station  230  by rotating the clamps  320 . Each of the other clamps  330 ,  340 ,  350  and  360  also rotates at the same time, moving the respective golf balls one station forward. In stations  230  and  240 , camera  170  scans golf balls  130  and  140  simultaneously and maps the surfaces of the balls as they are spun. A mirror assembly (not shown) allows camera  170  to scan the golf balls in the first and second stations ( 230  and  240 ) at the same time. Lights  200  and  210  are used to make it easier for the camera  170  to scan and record the surface of the balls. The balls are then moved one position forward. Golf ball  130  is scanned again (this time in position  240 ), along with new golf ball  120 , which moves into position  230 . The golf balls are scanned in two positions because portions of the ball are obscured by the upper and lower clamp pads. As a golf ball, such as golf ball  130 , moves from station  230  to station  240 , it is rotated ninety degrees to allow the camera to scan the remaining portions of the ball. Golf ball  140  is moved into position  350  and oriented. The system software combines the images from positions  230  and  240  to obtain the full image or map of the ball exterior. The golf ball then moves on through the remaining stations.  
         [0032]     In the embodiment shown, golf ball  150  is moved into position  360  and oriented, and the ball is scanned by camera  180  to confirm that the orientation is as desired. At the same time, golf ball  160  is moved out of position  360  and either picked up by a robot (not shown) and moved to the printing or stamping device, or it is removed and returned to be oriented again. In one embodiment, a golf ball that is not correctly oriented can be automatically returned to the source for re-introduction into the orientation system. For example, in the embodiment shown, golf ball  300  is shown on rails  310  returning to the source  100  to be scanned and oriented again. Alternatively, the golf balls that are removed can be diverted to a storage device, such as a storage bin or container, until they can be introduced into the orientation system at a later time.  
         [0033]      FIGS. 6 and 6 A each show a two-dimensional view of the surface of a golf ball that has been mapped by the camera  170  of the inspection system  400 . Deep dimples  142  are shown in golf ball surface  144 , and deep dimples  242  are shown in surface  244 . In each of the golf balls mapped, there were six deep dimples total.  
         [0034]     Examples of identifiable surface features that may be used in the mapping and orienting of the golf ball include, but are not limited to, dimples having a unique or different orientation from the remainder of the dimples, such as deep dimples; equator lines; mold identification marks; letters or symbols in dimples or other locations on the ball; and the like. Preferably, dimples having an orientation that differs from the majority of the dimples, such as deep dimples, are used. As used herein, “deep dimple” refers to a dimple that has a dimple configuration wherein at least the depth of the dimple is greater than the depth of the remaining more traditional dimples. The deep dimple may be deep enough that it is to or into the next layer, such as an inner cover layer, a mantle or the core. The deep dimple is noticeably different from the other dimples and can be mapped and used to orient the golf ball. There can be any number of deep dimples in a golf ball. Preferably, there are deep dimples in both hemispheres of the golf ball, and more preferably, the number of deep dimples in the two hemispheres is the same. In some embodiments, the number of deep dimples is at least one, preferably at least two, and more preferably at least three deep dimples per hemisphere, although any number desired can be used. Different types or shapes of deep dimples may be used in combination if desired. For example, both circular and non-circular deep dimples may be used in the same golf ball. There may be additionally one or more mold marks in the cover. Alternatively, a pole location, an equator line, or some feature therebetween may be used as the identifiable feature on the surface of the golf ball  20 .  
         [0035]     Other identifiable surface features are disclosed in the following U.S. Patents, all of which are hereby incorporated by reference in their entirety: U.S. Pat. No. 5,356,150 to Lavallee et al., for a Golf Ball; U.S. Pat. No. 6,503,158 to Murphy et al., for Dual Non-Circular Dimple for Golf Balls; U.S. Pat. No. 6,620,060 to Ogg et al., for a Golf Ball; U.S. Pat. No. 6,648,778 to Sullivan et al., for a Low Spin Golf Ball Utilizing Perimeter Weighting; U.S. Pat. No. 6,695,721 to Tavares et al., for a Golf Ball Having Elongated Dimples and Method for Making the Same; U.S. Pat. No. 6,767,295 to Kennedy, mi for a Golf Ball With Undercut Dimples; U.S. Pat. No. 6,802,787 to Ogg for a Golf Ball Having a Sinusoidal Surface; U.S. Pat. No. 6,872,154 to Shannon et al., for a Golf Ball; U.S. Pat. No. 6,905,427 to Kennedy, III et al., for a Golf Ball; and co-pending U.S. patent application Ser. No. 10/709018, filed on Apr. 7, 2005, to Ogg et al., for an Aerodynamic Surface Geometry Of A Golf Ball.  
         [0036]      FIG. 2  illustrates a golf ball  20  having a deep dimple  22  and more traditional dimples  24  on the surface of the golf ball.  FIG. 4  illustrates a golf ball  40  having three deep dimples  42 ,  44  and  46  located on the surface of the golf ball. In the embodiment shown, the deep dimples  42 ,  44  and  46  are equally spaced in a triangular pattern, but any desired pattern and spacing may be used.  
         [0037]     In one embodiment, it is desirable to print an indicia  32  on the ball such that it is pointing in a certain direction. For example, as shown in  FIG. 3 , a golf ball  30  having a chevron or arrow-like logo printed on the cover wherein the point of the chevron is pointed directly toward a deep dimple  34 . The system  50  of the present invention allows the golf ball  30  to be oriented such that the point of the chevron is always pointing in the same direction, for example, at the deep dimple  34 , as shown.  
         [0038]      FIG. 5  illustrates a golf ball  50  having a mold mark  52  as an identifiable surface feature in a dimple  54 . The mold mark  52  is slightly raised and is visible to the cameras.  
         [0039]      FIG. 7  illustrates a printing station  500  for printing an indicia  32  on a golf ball  20 . An example of such a printing station  50  is disclosed in U.S. Pat. No. 6,462,812 to Heene et al., for a Golf Ball Indicia Verification System, which is hereby incorporated by reference in its entirety.  
         [0040]      FIG. 8  is a flow chart of a specific method  600  of the present invention. At block  605 , a golf ball  20  is transferred to a first vision station of the system  50 . At block  610 , the golf ball  20  is rotated within a pair of clamps about a central axis and the surface of the golf ball  20  is digitally mapped using a camera. At block  615 , the golf ball  20  is transferred to a second vision station and reoriented ninety degrees to map the portion of the surface that was previously covered by the clamps at the first vision station. At block  620 , the golf ball  20  is rotated and digitally mapped using a second camera. At block  625 , a digital map of the entire surface of the golf ball is created from the images provided by the cameras at the first vision station and the second vision station. At block  630 , a location of an identifiable surface feature is determined from the digital map of the surface of the golf ball  20 . At block  635 , an indicia  32  is printed on a predetermined location of the golf ball  20  in relation to the identifiable surface feature.  
         [0041]     A general method  700  of the present invention is illustrated in the flow chart of  FIG. 9 . At block  705 , the entire surface of the golf ball is digitally mapped using a plurality of cameras in electrical communication with a microprocessor. At block  710 , the digital map is analyzed to determine the location of at least one or more identifiable surface features of the golf ball  20 . At block  715 , the golf ball  20  is oriented relative to the identifiable surface feature for printing of an indicia  32  on a predetermined location of the surface of the golf ball  20 . At block  720 , the indicia is printed on the predetermined location of the surface of the golf ball  20 .  
         [0042]     From the foregoing it is believed that those skilled in the pertinent art will recognize the meritorious advancement of this invention and will readily understand that while the present invention has been described in association with a preferred embodiment thereof, and other embodiments illustrated in the accompanying drawings, numerous changes, modifications and substitutions of equivalents may be made therein without departing from the spirit and scope of this invention which is intended to be unlimited by the foregoing except as may appear in the following appended claims. Therefore, the embodiments of the invention in which an exclusive property or privilege is claimed are defined in the following appended claims.