Patent Description:
Food product machines, particularly high speed slicers, produce groups of food products. Those groups may be stacked vertically or may be shingled. Food patty forming machines product food product including formed meat patties. The food products may be conveyed away from the food product machine by a main conveyor. The groups of food products may then be supplied to packaging equipment, such as a fill and package apparatus, in a food product stream to be packaged for shipment. The food products as received from the food product machine may not be in a preferred predefined position or orientation on the conveyor to facilitate optimum or efficient downstream processing, such as packaging.

Sliced food products may be formed from a slicer such as disclosed in <CIT>, <CIT>, and commercially available as a FX180® slicer machine. The slicer may also be such as disclosed in <CIT>, and commercially available as a PowerMax4000™ slicer available from Formax Inc. of Mokena, IL, USA. Formed food products may be made by a patty forming machine such as disclosed in, for example, <CIT>; <CIT>; <CIT>; and <CIT>, and <CIT>, and <CIT>, or those commercialized by Formax, Inc. of Mokena, IL, including the F-<NUM>™, ULTRA26™, Maxum700®, F-<NUM>™, F-<NUM>™, or F-<NUM>™ patty forming machines.

In one type of fill and package apparatus for sliced food products, a slicer delivers groups of slices or "drafts" onto a conveyor. The drafts are conveyed spaced-apart in a stream to a staging conveyor where the stream is converted to lateral rows of drafts. Such a staging conveyor is described in <CIT>, and commercially available as the A*<NUM> Autoloader from Formax, Inc. of Mokena, IL, U. Alternatively, the drafts may be placed on the conveyor by the slicing machine in lateral rows of drafts alleviating the need of a staging conveyor. Fill and package apparatus for sliced or formed food products are disclosed in <CIT> or <CIT>.

In one type of fill and package apparatus for formed food products, the patty forming machine delivers a formed food product or a stack of food products onto an output conveyor. When formed food products are provided as a stack of food products, a food product forming machine may eject a number of food products on top of one another before the food products are advanced by the output conveyor. Also, a paper interleaving device such as disclosed in <CIT>, and commercially available from Formax Inc. , may be placed at the output of the food product forming machine to interleave paper between each food product in a food product stack. Whether the food products lay individually or in stacks on the output conveyor, the food products may be arranged in transverse rows.

The food product groups must be maintained within close tolerances, particularly as to weight; under-weight groups constitutes a potential fraud on the ultimate users and overweight groups may represent an appreciable loss of revenue to the plant operator. Even with the most sophisticated and technologically advanced controls, the slicing machines and like food product machines that produce the groups of food products may not always maintain those groups within the preset tolerance limits. This is particularly true when the food product machine first starts in operation and again whenever there is any change in operation, such as a change from one food loaf to another in the operation of a food loaf slicer or a change of bacon slabs in a bacon slicer. Moreover, even those food products that are within the preset tolerance, known as "accept" groups, must be transported to a packaging station or other utilization location.

To minimize waste, it is desirable to correct any out-of-tolerance or "reject" food product groups. A check weight conveyor, such as disclosed in <CIT> and <CIT>, and <CIT>, and <CIT>, may be used to divert rejected food products to an off-weight stream or food product correction stream or location. When rejected food products are taken out of the main food product stream a food product vacancy is created in the food product stream.

The present inventors have recognized that in order to maintain a highly efficient utilization of the packaging equipment and other downstream operations, it is desirable to maintain a food product stream with a reduced number or no food product vacancies. Moreover, the present inventors recognize that it would be desirable to fill such vacancies with substitute or corrected-weight food products from a second location. The present inventors have recognized it would be desirable to fill the vacancies with food products that were diverted from the main food product stream and corrected at a correction station.

The present inventors recognize it is advantageous to re-orientate or reposition food products received from a food product machine on a conveyor. The present inventors recognize it would be desirable to provide a device capable of precisely orientating or positioning one or more food products on a moving conveyor. The present inventors recognize that it would be desirable to provide a device capable of precisely orientating or positioning food products on a moving conveyor to facilitate efficient and optimum or efficient downstream processing, such as packaging. The present inventor recognizes that it is desirable for a fill and package apparatus to efficiently and economically fills and packs food products into packaging, including both sliced and formed food products.

Further, reference is made to <CIT>, <CIT>, <CIT>, <CIT>, <CIT> and International Organization for Standardization: "Manipulating robots- Vocabulary", Technical Report, XP055423952.

Therefore, it is an object of the invention to provide an improved food handling system.

This object is achieved by a food handling system according to claim <NUM> and a method of moving food products according to claim <NUM>.

The invention includes a food handling system having a positioning system, optionally a vacancy reduction system, and optionally a shuttle system for packaging.

The positioning system includes a main conveying surface, an electronic sensor, a controller and a robot. The main conveying surface is configured to move food products. The electronic sensor is configured to capture position data about one or more food products on the main conveying surface within a sensor range of the sensor. The controller is signal-connected to the electronic sensor and the robot. The controller is configured to receive data captured by the sensor and is configured to instruct the robot to move a food product to a destination position. The robot is configured to reposition one or more food products on the conveying surface according to instructions sent by the controller.

The vacancy reduction system includes the main conveyor, a food product parking station, a vacancy detector, a robot, and a controller. The vacancy detector is configured to detect a vacant food product position on the main conveyor. The robot has a working range for moving between the parking station and the main conveyor. The controller is signal-connected to the vacancy detector. The controller is configured to receive a signal from the vacancy detector indicating a vacant food product position on the conveyor. The controller is signal-connected to the robot and has control instructions for instructing the robot to move the food product from the food product parking station to the vacant food product position on the main conveyor.

The shuttle system for filling packages with food products includes a main conveyor, a supply of open top containers, an electronic sensor, a controller, a shuttle robot. The main conveyor configured to move food products in a longitudinal direction. The supply of open top containers displaced along a longitudinal direction and movable in the longitudinal direction into a filling station. The electronic sensor is configured to capture location data about one or more food products on the main conveying surface within a sensor range of the sensor. The controller is signal-connected to the electronic sensor and the robot. The controller is configured to receive data captured by the sensor and configured to instruct a shuttle robot to move one or more food products from the main conveyor to a destination position off the main conveyor. The shuttle robot has a working area encompassing at least between a portion of the main conveyor and a portion of the filling station and configured to move food products from the main conveyor to an open top container in the filling station.

In one embodiment, the robot comprises a gripper for holding the food product.

The gripper has at least two gripping arms. The gripper has an open position for releasing a food product, and a closed position for holding and transporting a food product. The gripping arms may have lower supports for supporting the bottom of a food product when the grippers are in a closed position.

In one embodiment, the vacant open top container comprises a plurality of vacant open top containers. During a fill cycle the shuttle robot has at least one pickup position at an end of the continuously moving main conveyor, and a plurality of drop positions located above the plurality of respective open top containers in the filling station.

In one embodiment, the device comprises a rotatable slicing blade, a conveying assembly, and a support for holding a loaf in a cutting path of the rotatable slicing blade, the slicing blade arranged to rotate in the cutting path to slice drafts from the loaf, the drafts being plural slices formed in a pile on the conveying assembly and the piles are transported onto the main conveyor.

In one embodiment device comprises a patty-forming machine, the patty-forming machine having a machine frame, a mold plate having at least one cavity and mounted to reciprocate in a longitudinal direction with respect to the frame to position the cavity between a fill position and patty knock out position, a food product delivery channel for delivering food product into the cavity, the food product delivery channel mounted stationary with respect to the frame and having a fill opening into the cavity when the mold plate is in the fill position, one or more knockout plungers for expelling the formed food product from the mold plate onto an output conveyor when the mold plate is in the knockout position.

In one embodiment, the open top containers are carried by an elongated web of film and formed as concave depression therein.

In one embodiment, a sealing station is located downstream of the filling station, the sealing station for applying a cover to the open top containers.

In one embodiment, the device has a container-forming station for forming the open top containers.

In one embodiment, the shuttle robot is for filling one or more open top containers from a group of succeeding open top containers while the succeeding group of open top containers are advanced into the filling station.

Numerous other advantages and features of the invention will become readily apparent from the following detailed description of the invention and the embodiments thereof, from the claims, and from the accompanying drawings.

A preferred embodiment refers to a positioning system for positioning food products, comprising a main conveying surface configured to move food products; and an electronic sensor configured to capture position data about one or more food products on the main conveying surface within a sensor range of the sensor; a controller signal-connected to the electronic sensor and the robot and configured to receive data captured by the sensor and configured to instruct a robot to move a food product to a destination position; and the robot configured to reposition one or more food products on the conveying surface according to instructions sent by the controller.

Preferably, the sensor comprises a camera.

Further, the robot preferably has a longitudinal working range for positioning a one or more food products to a destination position either upstream or downstream from an original position of the food product with respect to a conveying direction of the conveying surface.

Further, the robot preferably has a lateral working range for positioning one or more food products to a destination position transverse from an original position of the food product in relation to a conveying direction of the conveying surface.

The sensor preferably captures an orientation of one or more food products on the conveying surface within the sensor range.

The controller preferably comprises instruction for determining whether a food product is in a mis-orientated position on the conveying surface by comparing a measured orientation with a predefined orientation or a predefined orientation range; and, the controller comprises instructions for directing the robot to move a particular food product from the misorientated position to a corrected orientation; and wherein the robot has a rotatable ripper for rotating an orientation of one or more food products about at least one axis of rotation.

The controller preferably comprises instruction for determining whether a food product is in a misaligned position on the conveying surface; and, die controller comprises instructions for directing the robot to move a particular food product from the misaligned position to an aligned position.

Preferably, each food product has a transverse position and a longitudinal position on the conveying surface, and wherein sensor is capable of generating a signal representing a captured position including the transverse and the longitudinal position of one or more food products on die conveying surface within die sensor range, and wherein the controller has position determining instructions configured to compare the captured position with a predefined position to determine whether die product is mis-positioned; and the controller is configured to send corrected food product movement instructions to the robot to move an mis-positioned food product to a corrected food product position.

The controller preferably comprises a datastore having at least one predefined transverse centerline value representing a transverse position on which selected food products are to be aligned to form a transverse row on the conveying surface; the controller comprises a misaligned food product calculating instruction for determine whether a measured food product position value received from the sensor is outside of the transverse centerline value; and wherein the controller is configured to instruct the robot to move one or more misaligned food products into an alignment position on the transverse centerline.

The controller preferably comprises a datastore having at least one predefined longitudinal centerline value representing a longitudinal position on which the food products are to be aligned to form a transverse row on the conveying surface; and the controller comprises a misaligned food product calculating instruction for determine whether a measured food product position value received from the sensor is outside of the longitudinal centerline value; and wherein the controller is configured to instruct the robot to move misaligned food products into an alignment position on the longitudinal centerline.

The robot is preferably configured to repositioning food products on the conveying surface while the conveying surface is moving.

The robot is preferably configured to re-orientate food products while the conveying surface is moving.

The positioning system preferably comprises a high speed food product slicing machine for cutting off a series of slices from a food loaf, the slicing machine is located upstream from the sensor range and produces food products received by the conveying surface.

The positioning system preferably comprises a food patty forming machine located upstream from the sensor range, the patty forming machine for producing food products received by the conveying surface.

The positioning system preferably comprises an off-weight conveyor located adjacent to the main conveying surface for receiving food products that are not correctable by robot manipulation.

The positioning system preferably comprises a shuttle robot configured to move between a pickup area on the main conveyor and a drop area on the off-weight conveyor.

The positioning system preferably comprises a correction station adjacent to an off-weight conveyor; and the correction station configured to align a position of a food product or configure to add or subtract food product from a food product so that the food product matches a predefined weight.

The positioning system preferably comprises an off-weight conveyor, the off-weight conveyor comprising a downstream end, an upstream end, and a longitudinal portion; the downstream end is adjacent to a downstream end of the main conveyor, the longitudinal portion runs upstream from the downstream end of the of-weight conveyor along the main conveyor, and the upstream end of the off-weight conveyor crosses the main conveyor is adjacent to a correction station on a side of the main conveyor opposite the longitudinal portion.

Further, the invention relates to a method of aligning food products on a conveyor, according to claim <NUM>.

The step of detecting is preferably defined in that the position is an orientation of the food product; and wherein the step of moving includes rotating a misorientated food product from an original orientation on the conveyor to a destination orientation on the conveyor with the robot.

The step of detecting is defined in that the position is a vertical alignment position of food products in a food product stack; and wherein the step of moving includes positioning, with the robot, food products within the food product stack to bring the food product stack into a predefined vertical alignment.

Further, after the step of detecting, the method preferably comprises the following steps: sending a measured position value corresponding to the food product position detected by the sensor to a controller; determining with the controller whether the food product is mis-positioned by comparing the measured position value one or more predefined position values.

Further, the step of detecting is preferably defined in that the position is an orientation of the food product; and wherein the step of sending is defined in that the measured position value is a measured orientation value corresponding to the food product orientation; and wherein the step of determining is determining with the controller whether the food product is misorientated by comparing the measured orientation value with one or more predefined orientation values; and wherein the step of moving includes rotating a misorientated food product from an original orientation on the conveyor to a destination orientation on the conveyor with the robot.

Further, the step of providing preferably comprises providing a stream of food products on a moving conveyor; and wherein the step of detecting comprises detecting a position of each food product within a row width with the sensor; wherein sending comprises sending a position value corresponding to a position of each food product in the row width to a controller; and wherein the step of determining comprises determining a properly aligned position for each misaligned food product within the width row; and wherein the step of moving comprises moving each a misaligned food product from an original position on the conveyor to a destination position corresponding to the properly aligned position on the conveyor with a robot.

Moreover, the moving step preferably comprises the steps of: lifting the food product from the original position on the conveyor, and placing the food product down on a destination position on the conveyor with the robot.

After the step of detecting and before the step of moving, the method further comprises the steps of: determining whether a food product is robot- correctable food product with a controller; and wherein the step of moving is further defined in that only robot-correctable mis-positioned or mis-orientated food products are moved by the robot.

After the step of detecting, the method may further comprise the steps of: sending to a controller the measured position value corresponding to the food product portion as measured by the sensor; determining whether a food product is robot-correctable food product by determining whether the position value is within a predefined correctable position range; and routing a non-robot-correctable food products to a correction station; and manually correcting the non-robot-correctable food products that are manually correctable.

Further, an optional aspect relates to a food product position vacancy reduction system, comprising: a main conveyor configured to move food products, a food product parking station configured to holding food products; a vacancy detector configured to detect a vacant food product position on the main conveyor; a robot having a working range for moving between the parking station and the main conveyor; a controller signal-connected to the vacancy detector and configured to receive a signal from the vacancy detector indicating a vacant food product position on the conveyor, and the controller signal-connected to the robot and having control instructions for instructing the robot to move the food product from the food product parking station to the vacant food product position on the main conveyor.

The system preferably comprises: a food product detector configured to detect a food product parked on the food product parking station; and the controller is signal- connected to the food product detector.

The food product parking station preferably comprises a conveying surface.

The parking station preferably comprises a plurality of parking positions for holding food products, wherein the controller has vacancy detecting instructions for determining when a first parking position is vacant based on a signal from the food product detector; and wherein the controller having advancing instructions for signaling to the conveying surface to advance so that the first position is occupied by a food product.

Further, the system preferably comprises a weighing conveyor that determines the weight of one or more food products; a classifying conveyor downstream of the weighing conveyor, the classifying conveyor has an accept position that directs food products to the main conveyor, and a reject position that directs food products to an off-weight path.

Moreover, the system preferably comprises a correction station upstream of the parking station for adding or subtracting food product from a food product so that the food product matches a predefined weight.

Further, the system preferably comprises a correction station upstream of the parking station and downstream of the off-weight path, the off-weight path being an off- weight conveyor, the correction station for adding or subtracting food product from a food product so that the food product matches a predefined weight or orientation.

Moreover, an optional aspect relates to a method of reducing food product position vacancies, comprising the steps of: providing a main stream of food products on a main conveyor; observing the main stream for a vacant food product position with a vacancy detector signal connected to a controller; and placing a food product in the vacant food product position with a robot according to instructions from the controller.

After the step of observing further, the method preferably comprises the steps of: providing food products in a food product parking station, and wherein the placing step further comprises the step of moving the food product from the food product parking station to the vacant food product position with the robot.

After the step of providing further, the method preferably comprises of: detecting a off-weight food product within die main stream with a weighing conveyor; directing the off-weight food product to an off-weight correction path.

After the step of directing, the method preferably comprises the step of: correcting the off-weight food product by adding or subtracting food product to reach a predefined weight thereby transforming the off-weight food product into a corrected food product; and wherein the placing step further comprises the step of moving the corrected food product to the vacant food product position with a robot.

While this invention is susceptible of embodiment in many different forms, there are shown in the drawing and will be described herein in detail specific embodiments thereof with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the specific embodiments illustrated.

As shown in <FIG>, a system according to the invention includes a slicing machine <NUM> which cuts slices from one or more loaves and deposits the slices on an output conveyor assembly <NUM>, forming shingled or stacked drafts, or food products. The drafts can be piles, bunches or groups of thin sliced product. The slicing machine <NUM> can be of a type as described in <CIT>; <CIT>; and <CIT>; as well as <CIT> and <CIT>.

The slicing machine <NUM> can also be a FORMAX FX180 machine, commercially available from Formax, Inc. of Mokena, Ill.

In one embodiment shown in <FIG>, the output conveyor assembly <NUM> includes a check weight conveyor <NUM>, such as disclosed in <CIT> and <CIT>, and <CIT>, and <CIT>, wherein unacceptable drafts can be rejected and diverted. In another embodiment as shown in <FIG>, the conveyor assembly <NUM> includes an optical grading system <NUM>, such as disclosed in <CIT>.

In another embodiment, the conveyor assembly 3C comprises a classifying conveyor <NUM> as shown in <FIG>. The weighing conveyor <NUM>, and the optical grading system <NUM>, and the classifying conveyor <NUM> are located upstream of a main conveyor <NUM> and an alignment robot <NUM>.

An off-weight conveyor <NUM> is at least partially adjacent to the main conveyor <NUM> as shown in <FIG>. The off-weight conveyor <NUM> connects to a weight correction station <NUM>. The weight correction station <NUM> connects to a parking station <NUM>.

The system comprises an alignment and orientation camera or sensor <NUM> that has a sensor range area <NUM> focused on an area upstream and / or within a working diameter or area <NUM> of an alignment robot <NUM>. The alignment robot is located above the main conveyor <NUM>. A shuttle robot <NUM> is located above or adjacent to a downstream end portion of the main conveyor <NUM> and a fill station <NUM> and has a shuttle working diameter or area <NUM>. A shuttle camera or sensor <NUM> having at least one sensor range <NUM> focused on a downstream end of the main conveyor. A packaging machine <NUM>, such as a Multivac R530, available from Multivac, Inc. of Kansas City, Mo. , is located below the main conveyor <NUM>.

In one embodiment, the system comprises a staging conveyor located between the machine <NUM> and the robot <NUM>. Drafts are conveyed spaced-apart in a stream to a staging conveyor where the stream is converted to lateral rows of drafts. Such a staging conveyor is described in <CIT> and is commercially available as the A*<NUM> Autoloader from Formax, Inc. of Mokena, Ill. Alternatively, the drafts may be placed on the conveyor by the slicing machine in lateral rows of drafts alleviating the need of a staging conveyor.

At the fill station <NUM> of the packing machine <NUM>, the shuttle robot <NUM> delivers food products from an upstream main conveyor <NUM> into containers <NUM>. The containers <NUM> may be formed in a group of rows of pockets <NUM> formed in a lower web <NUM> of film by the packaging machine <NUM>. Downstream of the fill station <NUM>, in the direction D, is a sealing station <NUM>. The containers or pockets <NUM> that are filled with food product, are sealed by an upper web of film in the sealing station <NUM>.

The machine <NUM> may also be a food product forming machine such as disclosed in, for example, <CIT>; <CIT>, <CIT>; <CIT>; and <CIT>, and <CIT>, and <CIT>. The food product forming machine delivers a formed food product or a stack of food products onto an output conveyor <NUM>. Therefore the shingled or stacked drafts <NUM> may also be formed food products <NUM>, both of which may be referred to as food products <NUM>. The formed food product 150a may be such as those shown in <FIG> or may be of another formed shape. Whether the food products <NUM> lay individually or in stacks on the conveyor <NUM>, the food products may be arranged in rows transverse to the conveying direction.

A controller <NUM>, such as an electronic circuit, a programmable logic controller (PLC), a microprocessor, a CPU, computer, or other control device, is signal-connected to the shuttle robot <NUM>, the alignment robot, the packing machine <NUM>, the machine <NUM>, a sensor or camera <NUM>, the sealing station <NUM>, and at least one of a vacancy detector 214a and vacancy detector 214b.

The controller may comprise a datastore being a electronic or computer hardware or software memory or harddrive containing predefined values, such as food product orientation values, food product longitudinal position values, food product lateral position values, transverse centerline value representing a transverse position on which selected food products are to be aligned, longitudinal centerline values representing a longitudinal position on which the food products are to be aligned, food product position values. These values may be userdefined or predefined for various types of food products. The controller an instruction storage area for storing preprogrammed, user defined, or other instructions that the controller uses to process and/analyze the data according to machine operation programming.

<FIG>, <FIG>, and <FIG> show the off-weight conveyor <NUM> comprises an adjacent longitudinal portion <NUM>, a downstream end portion <NUM>, and an upstream end portion <NUM>. The off weight conveyor <NUM> is connected to a correction station <NUM>, which may be a weight correction station. The weight correction station <NUM> is connected to a food product parking station <NUM>.

In one embodiment, the longitudinal portion <NUM> is adjacent and parallel to the main conveyor <NUM>. The weight correction station <NUM> and the parking station <NUM> are adjacent and parallel to the main conveyor <NUM> on a side of the conveyor <NUM> opposite the longitudinal portion <NUM>. The parking station is downstream <NUM> from the weight correction station <NUM>. The correction station <NUM> is connected to the longitudinal portion <NUM> by the upstream end portion <NUM>. The upstream end portion <NUM> curves from its connection point with the longitudinal portion to be positioned perpendicularly to the conveying direction. The upstream end portion extends under the main conveyor <NUM> and curves to connect with the correction station <NUM>. Thus, the upstream end portion <NUM> forms a U shape as it extends under the main conveyor. In another embodiment, portions of the off-weight conveyor <NUM> may not curve to connect to one another, but rather may connect at an angle including a right angle. In another embodiment, the upstream end portion <NUM> may cross the main conveyor <NUM> non-perpendicularly. Moreover, the upstream end portion may cross above the main conveyor <NUM>.

The downstream end portion <NUM> is located between a pickup location <NUM> at a downstream end of the main conveyor <NUM> and the fill station <NUM> (<FIG>). The downstream end portion connects to the longitudinal portion <NUM> and curves from its connection point with the longitudinal portion to be positioned perpendicularly with the conveying direction. The downstream end portion <NUM> is vertically positioned below a conveying surface of the main conveyor <NUM> and above the filling station <NUM>, as best shown in <FIG>. In another embodiment, the downstream end portion <NUM> is vertically positioned co-planer with the conveying surface. In another embodiment, the downstream end portion <NUM> may be positioned non-perpendicularly with respect to the conveying direction.

<FIG> shows an alignment robot <NUM> downstream from the food product machine <NUM> and the output conveyor <NUM>. In one embodiment, the camera or sensor <NUM> is upstream of the alignment robot <NUM>. The sensor range area <NUM> of the sensor or camera <NUM> is focused on an area upstream and or within the working diameter or area <NUM> of an alignment robot <NUM>. The camera <NUM> and the alignment robot are signal-connected to a controller <NUM>. In one embodiment, the alignment robot <NUM> may be a picker robot or a delta robot, such as disclosed in <CIT>, <CIT>, and <CIT>.

A device of the basic delta robot concept is disclosed in <CIT>.

In another embodiment, the alignment robot <NUM> may be a four arm picker/delta robot such as the Quattro™ <NUM> robot manufactured by Adept Technologies Inc. having its corporate headquarters located in Livermore, California in <NUM>.

As shown in <FIG>, the alignment robot <NUM> is located above the main conveyor <NUM> and the off weight conveyor <NUM>. In one embodiment the robot has a base <NUM>. Four motors are mounted in the base <NUM> and move four first arms <NUM>, <NUM>, <NUM>, <NUM>. A pair of pull rods are pivotably attached to each first arm. Pull rods 202a and 202b connect to first arm <NUM>; pull rods 204a and 204b connect to first arm <NUM>; pull rods 201a and 201b (not shown) connect to first arm <NUM>; pull rods 203a (not shown) and 203b connect to first arm <NUM>. Each pair of pull rods pivotably connect to a movable plate <NUM>. The first arms, the connector arms and the movable plate comprise an arm system <NUM> of the robot. A gripper <NUM>, such the one shown in <FIG>, may be attached to the movable plate <NUM> for gripping and moving a food product.

The robot can be placed in a frame construction (not shown) above the conveyor <NUM>. In one embodiment, the arm system <NUM> is able to rotate with at least three degrees of freedom in Cartesian X, Y and Z directions.

In one embodiment, the robot <NUM> has the working area or diameter <NUM> (<FIG>, <FIG>, <FIG>) of <NUM> along the Cartesian x and y axes. The robot <NUM> has a working height, in the vertical direction or the Cartesian z axis, in the range of <NUM> to <NUM>. The robot has the ability to rotate the movable plate <NUM> one hundred and eighty degrees in one direction and one hundred and eighty degrees in the opposite direction. The robot has a maximum linear movement speed of <NUM> meters per second and a rate of acceleration of <NUM> meters per second squared.

In one embodiment, as shown in <FIG>, and <FIG>, the alignment and orientation sensor or camera <NUM> is located upstream of the alignment robot <NUM> and downstream of the output conveyor assembly <NUM>. Regardless of where the camera <NUM> is located, the sensor range area <NUM> of the camera <NUM> is focused on an area upstream and/or within the working diameter or area <NUM> of an alignment robot <NUM>. The camera <NUM> is signal-connected to the controller <NUM>. The camera <NUM> is mounted on a support structure (not shown) above or adjacent to the conveyor <NUM>.

The camera <NUM> and controller <NUM> comprises a vision system. In one embodiment, the camera <NUM> is that described in <CIT>.

The vision system is controlled by the controller <NUM>. The controller <NUM> may be an electronic circuit, a programmable logic controller (PLC), a microprocessor, a CPU or other control device. In one embodiment, the camera <NUM> and the controller <NUM> may comprise a single unit.

In one embodiment, the camera <NUM> is an ELECTRIM EDC-1000N black and white <NUM> X <NUM> pixel digital camera <NUM> with a <NUM> lens. The controller <NUM> includes a digital frame grabber PC-<NUM> printed circuit board, and a PC-<NUM> CPU main processor board. In this embodiment, the vision system may also include a light source to provide illumination of the food product <NUM>.

In operation, the camera <NUM> scans each food product <NUM> or each row of food products <NUM> as they pass under the camera <NUM> on the conveyor <NUM> and within the sensor range area <NUM>. The camera sends data to controller <NUM> concerning various characteristics of the food product <NUM>, including food product position, orientation, and alignment on the conveyor <NUM>. The controller <NUM> has instructions for analyzing the data.

When the controller executes instructions to determine a particular food product or stack of food products is not in a predefined preferred orientation, the controller <NUM> will send re-orientation instructions to the robot <NUM>. When misorientated food product <NUM> is within the working diameter <NUM>, the robot will move the food product to the preferred position and orientation according to the re-orientation instructions from the controller <NUM>.

As shown in <FIG>, food product 150a is misorientated within food product row 151a. The controller <NUM> receives position, orientation, and alignment data or information about food product 150a from the camera <NUM>. While or before the food product reaches the working diameter <NUM>, the controller executes analyzing instructions comparing location and orientation values received from the camera to predefined location and orientation values. If a particular food product is determined by the controller to be mis-positioned or mis-orientated, the controller sends instructions to the robot to move food product 150a into a predefined proper or preferred orientation and/or orientation. When food product 150a reaches the working diameter <NUM> of the robot <NUM>, the robot carries out the instruction and moves and re-orientates the food product so that is it in proper orientation and alignment as shown by food products 150b and 150c. Food products 150b and 150c represent food product 150a after it is reorientated by the robot and conveyed downstream at various points downstream.

Referring to <FIG>, the food products of row 151c are misaligned longitudinally and transversely with the conveying direction and they are also misorientated. The camera <NUM> will have obtained position data about each food product at or upstream of the working diameter <NUM> of the robot <NUM>. Assuming food product 150e fits the predefined proper position and orientation, the controller will instruct the robot <NUM> to move food product 150d along the y axis toward the edge of the conveyor <NUM>, rotating it slightly to be square with a plane defined by the conveyor edge. The controller will instruct the robot <NUM> to move food product 150f downstream in the X direction relative to the row 151c. The controller will instruct the robot <NUM> to re-orientate food product <NUM> to be square with the plane defined by the conveyor <NUM> edge. The robot will carry out these instructions making the appropriate movement of the food products while the food products are within the working diameter <NUM> so food product row 151c is aligned and orientated as shown by food product row <NUM> after the robot carries out the instructions from the controller <NUM>. The controller is able to instruct the robot <NUM>, and the robot is able to carry out any repositioning instructions while the conveyor <NUM> is in continuous motion. To determine what food products are to be within a particular row, the controller will analyze data from the sensor comprising a row width for food products positioned therein and defining the scope of food products to be considered as within a given row. The row width is a predefined area within which food products are to be aligned on a predefined row alignment within a predefined row.

The controller <NUM> may be programmed to provide orientation or alignment instructions for food products or food product rows according to any user defined or pre-defined orientation or alignment on the conveyor <NUM>.

In one embodiment, the camera <NUM> will detect when a stack of food products <NUM> is not properly stacked or aligned in the vertical direction along the Cartesian Z axis (<FIG>). The controller <NUM> will instruct the robot to correct the vertical mis-alignment, for example, by straightening the stack with the arms <NUM> (<FIG>) of the gripper <NUM>, when the robot has the gripper <NUM>, such as shown in <FIG>, attached to the movable plate <NUM>. The robot may also align by moving individual food product of a food product stack to bring the food product stack into the preferred vertical alignment.

In one embodiment, the camera <NUM> will detect and the controller will determine when a food product / food product stack is not correctable by the alignment robot <NUM>. An uncorrectable food product is when a food product <NUM> or a stack of food products is misaligned or misorientated to the extent that the robot <NUM> cannot bring the food product or the stack of food products into the predefined preferred alignment or predefined preferred orientation. When a food product is uncorrectable, the controller will not instruct the robot <NUM> to correct the food product. In one embodiment, the uncorrectable food product will travel to a downstream end <NUM> (<FIG>, <FIG>) of the main conveyor <NUM>. The controller will not instruct the shuttle robot <NUM> to pick up the uncorrectable food product or stack or will affirmatively instruct the robot not to pick up the uncorrectable food product. The uncorrectable food product or stack will fall onto the downstream end <NUM> of the off-weight conveyor <NUM>. Alternatively, in another embodiment, the controller may instruct the shuttle robot <NUM> to pick up the uncorrectable food product and place it on the downstream end <NUM> of the off-weight conveyor <NUM>.

The off-weight conveyor <NUM> will convey the robot-uncorrectable food product to the off-weight station <NUM> where it will be corrected by a human <NUM> or another robot, or it will be discarded or recycled. At the off-weight station <NUM>, the food product may be added or subtracted to bring the food product or food product stack to a predefined weight or a predefined weight range. The food product may also be restacked, aligned or orientated at the off-weight station <NUM>. The corrected food product is moved to the parking station <NUM>.

As shown in detail in <FIG>, in one embodiment, the output conveyor <NUM> includes a classifier conveyor system <NUM>, such as described in <CIT>.

A classifier conveyor <NUM> is selectively pivoted by an actuator <NUM>, by signal from the controller <NUM>, to deliver food products alternately to the off-weight conveyor <NUM> or the main conveyor <NUM>. The actuator <NUM> can be a pneumatic cylinder with an extendable/retractable rod <NUM> connected to the classifier conveyor <NUM>.

The weighing conveyor <NUM> is located upstream of the classifying conveyor <NUM>. The weighing conveyor <NUM> signals to the controller <NUM> the weight of each food product or food product stack that passes over the weighing conveyor <NUM>. When the controller <NUM> determines that a particular food product or food product stack is not within a pre-defined weight range or a specific pre-defined weight, the controller <NUM> signals to the classifying conveyor <NUM> to lower the classifying conveyor to a reject position 42b. In the reject position 42b, the classifying conveyor connects to the upstream end portion <NUM> of the off-weight conveyor <NUM>. The off-weight food product is then carried by the off-weight conveyor <NUM> to the weight correction station <NUM>. When the classifying conveyor <NUM> is in a raised accept position 42a, it connects with the main conveyor <NUM>.

The off-weight conveyor <NUM> will convey the off-weight food product to the off-weight station <NUM> where it will be corrected by a human <NUM> or another robot; it will be discarded or recycled. At the off-weight station <NUM>, food product slices may be added or subtracted to bring the food product or food product stack to a predefined weight or a predefined weight range. The food product may also be restacked, aligned or orientated at the off-weight station <NUM>. The corrected food product is then moved to the parking station <NUM>.

In one embodiment, the output conveyor <NUM> comprises an optical grading system <NUM>, such as disclosed in <CIT>.

<FIG> illustrates the optical grading system <NUM> which captures the image of the slice passing on the weighing conveyor <NUM>. When the weighing conveyor <NUM> senses the slice to be viewed on the scale, the controller <NUM> triggers the system <NUM> to capture the slice image. The system <NUM> will capture an image of the top of the slice on top of the stack <NUM> or, in the case of a single slice, the top of the slice. The optical grading camera <NUM> captures the slice image within an image field of vision <NUM> pixel-by-pixel. The shutter speed of the camera is fast enough to capture the image while the slice or stack is in motion. The image is then retrieved from the digital frame grabber printed circuit board into the memory of the system <NUM> or of the controller <NUM>.

Software can then perform various analyses on the digital image data. The software may be contained in the system <NUM>, or in the CPU <NUM>, or in the controller <NUM>. The slice perimeter or boundary dimensions are determined due to the brightness or color contrast between the slice and the weigh scale belting on which the slice is transferred. A grayscale analysis, pixel-by-pixel, can be undertaken by the software, wherein black is <NUM> and white is <NUM>. An experimentally determined grayscale cutoff point between fat pixels (light) and lean pixels (dark) can be used to characterize each pixel as being fat or lean. The ratio of light pixels (fat) to dark pixels (lean) within the slice boundary is then calculated, as representative of a fat-to-lean ratio. Additionally, local areas constituting "flaws" in the slice can be quantified in size, by calculating and summing adjacent non-lean pixels, and then compared to a flaw tolerance or limit. A flaw can be a fat deposit, a gland, muscle or bone piece, a void, or other undesirable bit.

Alternatively, the calculations and routines utilized to capture and evaluate slice image data can be as described in <CIT>; <CIT> and/or <CIT>.

The mathematical analysis of pixel data can be as described in <CIT>.

The data is calculated and compared to predetermined standards or customer programmable standards regarding overall fat content and flaw size and/or quantity limits.

A calculation is made to determine whether the slice is to be classified as a "pass", that is, being below stringent fat content or flaw limits, or "reject", that is being above acceptable fat content or flaw limits, or "grade-off", that is being below acceptable fat content or flaw limits but above stringent fat content or flaw limits.

Based on the calculated parameters and the comparison to the pre-selected tolerances, the slice is determined to be a grade reject if the fat-to-lean ratio is greater than the allowable tolerance, or if the slice includes a flaw, or a pre-selected number of flaws, greater in size, individually and/or in the aggregate, than an allowable tolerance. These tolerances can be adjustable and determined by the user, typically as a plant standard.

Advantageously, in the production of straight stacks or shingled stacks of sliced product, each slice need not the scanned, rather, the top of each stack can be scanned to determine a fat-to-lean ratio, and the presence of flaws, after the stack has been cut and stacked from the loaf. The condition of the top slice, being cut from the loaf in the close vicinity of the remaining slices in the stack, is an accurate representation of the condition of all the slices in the stack.

When grading stacks of slices, the top slice of one stack is almost an exact representation of the bottom slice of the following stack. It may be advantageous to remember this image of the top slice of a stack and "flag" it as also representing the bottom of the next stack to pass below the camera. Combined with the next following image, the actual top of the stack, it can be accurately estimated, by evaluating the bottom and top slices of the stack, whether the entire stack meets the quality criteria. According to this procedure, it is not necessary to image each and every slice in the stack or draft to accurately characterize the quality of the stack.

Thus, the stack can then be characterized as a grade reject, grade off or acceptable stack based on the characteristics of one slice of the stack or based on the characteristics of the top and bottom slices of the stack.

If the slice or stack of slices is determined to be a grade reject, the classifier conveyor <NUM> will be pivoted by the actuator <NUM>, by signal from the controller <NUM> to put the classifier conveyor in a reject position 42b. The reject position will direct the slice or stack of slices onto the off-weight conveyor <NUM>. All out-of-weight tolerance slices or groups of slices, regardless of their visual acceptance, can be placed on the off-weight conveyor <NUM>. Products placed on the off-weight conveyor are moved to the correction station <NUM>, where they may be corrected by weight, orientation, or position, or they may be removed from the station <NUM> for disposal or recycling. If the operator <NUM> or other machine of the correction station <NUM> corrects the food product then is it optionally moved to the parking station <NUM>.

In one embodiment, the system has a vacancy reduction device or system that includes the alignment robot <NUM> also serving as a vacancy filling robot. When the classifier conveyor <NUM> diverts a food product to the off-weight conveyor <NUM> a vacancy is created in the food product stream on the conveyor <NUM>. An example vacancy is shown in food product row 151c in <FIG> and <FIG>. The camera or vacancy detector <NUM> will signal to the controller <NUM> that a vacancy exists in a particular location on the conveyor. Such a vacancy is shown by the absence of at least one food product as shown in food product row 151c in <FIG> and food product row 151d in <FIG>. A parking station sensor or food product detector 214a will signal to the controller when a food product is parked at the parking station <NUM>. The vacancy detector 214a, as shown in <FIG>, may be located adjacent to the parking station <NUM> or underneath (not shown) the parking station surface. Alternatively, the vacancy detector may be a sensor or camera 214b (<FIG>), such as the type of camera <NUM> described above, mounted to focus the sensor range area 214c on the parking station. In one embodiment, the parking station sensor sends a signal to the controller <NUM> indicating the number of food products or food product stacks parked at the parking station <NUM>.

The controller will instruct the robot to take a food product from a position on the parking station to fill a vacancy, if there is a food product available at the parking station when the vacancy is in the working diameter <NUM> of the robot. If the product was removed from the parking station the parking station will advance another available food product to fill the vacancy created by removal of the food product that filled the vacancy on the main conveyor <NUM>. In one aspect of the embodiment, if the food product was parked in the first position <NUM> then a conveying surface of the parking station will advance the next food product to the first position in the parking station. If there are no products in the parking station, the parking station conveying surface may stop advancing while the entire parking station is empty.

The controller is able to fill any vacancy in the food product stream, regardless of how it was created as long as it was created before the vacancy area advances out of the sensor area range <NUM> of the conveyor <NUM>.

In one embodiment, as shown in <FIG>, and <FIG>, the shuttle sensor or camera <NUM> is at the end of the main conveyor. Regardless of where the camera <NUM> is located, the shuttle sensor <NUM> has at least one sensor range <NUM>, as shown in <FIG>. The sensor range <NUM> comprises an end portion of the main conveyor. The sensor range <NUM> may include the width of the main conveyor <NUM>. In another embodiment, the sensor <NUM> has a second sensor range <NUM> that comprises at least a portion <NUM> of the packing station <NUM>. The second sensor range <NUM> may encompass the shuttle working area <NUM>. The sensor <NUM> detects food products, such as those shown in food product row <NUM> in <FIG>. The camera <NUM> is mounted on a support structure (not shown) above or adjacent to the downstream end <NUM> of the main conveyor <NUM>.

The camera <NUM> and controller <NUM> comprises a second vision system. The vision system of the camera <NUM> and the controller <NUM> may comprise the second vision system. In one embodiment, the camera <NUM> is that described in <CIT>.

<FIG> and <FIG> illustrate the shuttle robot <NUM> of the system. The main or upstream conveyor <NUM> delivers food products <NUM> to the packing station <NUM>. The conveyor <NUM> may operate in a state of continuous motion. The food products <NUM> may be delivered in rows <NUM> where the number of food products <NUM> in the rows <NUM> correspond to the number of pockets or containers <NUM> in a row of containers <NUM>.

The shuttle robot <NUM> may be suspended above or located adjacent to the filling station <NUM> by a structure (not shown), so that the robot gripper <NUM> operates at least over the filling station and a downstream portion of the main conveyor <NUM>. The filling station <NUM> is adjacent to the main conveyor <NUM>. The shuttle robot has a range of motion covering Cartesian X, Y and Z directions such that the robot may move transversely and longitudinally with respect to the conveying direction and also vertically. In one embodiment, the shuttle robot operates in the shuttle working area <NUM>. The shuttle robot comprises a gripper <NUM> at a bottom of the shuttle robot <NUM>.

In one embodiment, the shuttle robot <NUM> is a six-axis robot having six degrees of freedom, such as disclosed in <CIT>.

A device of the basic six-axis robot concept is disclosed in <CIT>.

In another embodiment, the shuttle robot <NUM> may be a six-axis robot such as one of the Viper™ s650, s850, s1300, or s1700 robots manufactured by Adept Technologies Inc. having its corporate headquarters located in Livermore, California in <NUM>. In another embodiment, the shuttle robot may be another type of robot having a working range in the Cartesian X, Y and Z directions.

In one embodiment, the robot <NUM> has a maximum payload in the range of <NUM> to <NUM>, a reach in the range of <NUM> to <NUM>, and a repeatability rating in the range of plus or minus <NUM> to plus or minus <NUM>. In one embodiment, the robot has a joint range of motion for each joint as follows: joint <NUM> ± <NUM>°, joint <NUM> -<NUM>°, +<NUM>°, joint <NUM> +<NUM>°, +<NUM>°, joint <NUM> ± <NUM>°, joint <NUM> ± <NUM>°, joint <NUM> ± <NUM>°.

As shown in detail in <FIG>, <FIG>, and <FIG>, the gripper <NUM> has a plurality of first arms 161a-f, and a corresponding plurality of oppositely facing second arms 162a-f. The first arms are connected together along or formed into a horizontal arm connection shaft <NUM>. Similarly the second arms 162a-f are connected together along or formed into a horizontal arm connection shaft (not shown). The arms move between an open position 165b and a closed or holding position 165a. Each arm may have a lower support 169a-f, 167a-f for supporting a bottom of a food product. Each arm is connected at a pivot point <NUM> to a horizontal arm 168a. The pivot point may lie on the horizontal arm connection shaft. Each horizontal arm is connected to a position plate <NUM>. The position plate <NUM> moves vertically by a pin <NUM> between a raised position 166a and a lowered position 166b by a solenoid 160a operatively connected to the pin <NUM>. The vertical movement of the position plate <NUM> causes each arm <NUM> to pivot about the pivot point <NUM>. The arms <NUM> are in the closed position 165a when the position plate <NUM> is in the raised position 166a, and the arms <NUM> are in an open position 166b when the position plate is in a lowered position 166b.

In one embodiment, the gripper <NUM> is connected to a cross plate <NUM> by a plurality of bolts <NUM> (not shown in <FIG>). The cross plate <NUM> is capable of supporting more than one gripper, such as gripper <NUM>. Gripper <NUM> is constructed and operates in the same manner as gripper <NUM>. The cross plate connects to the shuttle robot <NUM> at a connection location <NUM> with a plurality of bolts <NUM>, <NUM>.

When the containers are pockets <NUM> formed from a web <NUM>, the packaging machine <NUM> has a dwell period. At the dwell period, the packaging machine <NUM> stops the motion of the lower web <NUM>. During the dwell period, the packaging machine <NUM> forms another group of empty pockets <NUM> upstream from the packing station <NUM> at a container-forming station <NUM>. The container forming station <NUM> is shown schematically in <FIG>. After the dwell time period is over, the lower web of film <NUM> is advanced and new food products are deposited into new containers <NUM> as or after the lower web <NUM> advances to a new dwell position.

The shuttle robot <NUM> has at least one pickup location <NUM> at an end of the main conveyor <NUM> and at least one deposit position located <NUM> above a container <NUM> in the filling station <NUM>. The shuttle robot <NUM> may have a plurality of deposit positions located above a plurality of containers 131a in the filling station <NUM>. The filling station <NUM> may hold any number of containers for filling. <FIG> shows a filling station having four containers <NUM> or four rows of containers.

During the dwell period, the robot <NUM> moves between the pickup position(s) and the deposit positions to move food products from the main conveyor <NUM> to the containers <NUM>, 131a.

The shuttle sensor <NUM> detects food products on a downstream end of the main conveyor within the sensor range <NUM> or second sensor range <NUM>. The shuttle sensor sends information to the controller regarding the location of food products within the senor range. The controller determines whether and at what point the food products within the sensor range should be picked up and moved to the packaging station or the off weight conveyor by the shuttle robot. The controller instructs the robot to pickup one or more food products from the main conveyor at a location based on the location information received from the shuttle sensor. In one embodiment, the sensor detects which containers <NUM> in the packaging station are filled with food product and which are not filled with food product and sends that packaging fill information to the controller. The controller may instruct the robot to move food products from the main conveyor to the empty or incompletely filled containers in the packaging station based on the packaging fill information from the sensor.

As shown in <FIG>, during each pass between a particular pickup location and a drop or deposit location, the gripper <NUM> of the shuttle robot <NUM> grips a food product or stack of food products at the pickup location <NUM> on the main conveyor <NUM>. The shuttle robot may approach the pickup location <NUM> in an open position as shown at <NUM>. The shuttle robot <NUM> surrounds the food product 150a with the gripper <NUM> at the pickup location and moves the arms <NUM> of the gripper to a closed position. The conveyor <NUM> may be in continuous movement during this time such that the pickup location <NUM> and the shuttle robot <NUM> are in continuous motion tracking the location of the food product 150a.

The shuttle robot then moves the food product continuously or intermittently through a plurality of intermediate locations <NUM> to a particular deposit location <NUM> located above a container <NUM>. The container <NUM> may be empty or may be incomplete. When the shuttle robot is in deposit location <NUM> with a gripped food product, the gripper <NUM> will move to an open position releasing the food product to fall into the container <NUM>.

In one embodiment, as shown in <FIG>, the main conveyor <NUM> is a strip or o-ring belt conveyor. Such a strip conveyor has a conveying surface having multiple belts or strips <NUM>, <NUM>, <NUM>, <NUM> with gaps <NUM>, <NUM>, <NUM> provided between the belts. The belts are driven to rotate by a drive shaft <NUM> and operate around an idler shaft (not shown) opposite the drive shaft. The gaps between the belts of the strip conveyor are such that the food products <NUM>, 151a being conveyed do not fall between the gaps. In one embodiment, the strip conveyor is in continuous movement as the gripper approaches one or more target food products on the strip conveyor. The gripper is in or is moved to an open position. The gripper tracks the movement of the food product(s) on the conveyor as the gripper lowers around the food product(s). The shuttle robot lowers the lower supports 169a-f, 167a-f of the arms 161a-f, 162a-f of the gripper <NUM> into the gaps of the strip conveyer below the conveying surface. The arms of the gripper are then closed bringing the lower supports 169a-f, 167a-f under the food products <NUM>, 151a. The shuttle robot <NUM> then lifts the food product off the strip conveyor by bringing the lower supports 169a-f, 167a-f above the conveying surface and moves the food product towards destination packaging.

In one embodiment, the shuttle robot may move food product to a container <NUM> while the container is moving into the packing station <NUM>. The shuttle robot may move and track the position of a container <NUM> and release a food product into the container while the container is moving into the packing station and before it is stationary during the dwell period. Loading food products into the containers <NUM> during the advance time period is a time efficient way to load the pockets.

After the containers <NUM> in the packing station have been loaded with food product, the group of containers in the packing station is advanced downstream to a sealing station <NUM>. Containers <NUM> in the sealing location are sealed closed by the application of an upper web of film. The controller <NUM> synchronizes movement of the shuttle robot with the movement of the containers <NUM> and the conveyor <NUM> when needed.

The shuttle robot may fill the containers in any order, including filling the container closest to the main conveyor <NUM> first and filling containers progressively toward the container located within the fill station and furthest from the main conveyor. Alternatively, the shuttle robot may fill the containers in reverse, wherein the first filled row of containers is the row furthest upstream in the direction D (<FIG>), and the shuttle robot advances to fill the second row, then advances again to fill the third row, etc. After the group of rows is filled during the dwell period, the containers <NUM> advance and an empty new group of containers <NUM> is moved into the fill station <NUM>.

In one embodiment, the gripper is configured to grip one food product or one stack of food products. In another embodiment, the shuttle robot has a gripper that is a row gripper capable of gripping more than one food product or an entire transverse row of food products and moving those food products to fill a transverse row of containers <NUM> in the fill station. In another embodiment, the row gripper has multiple corresponding pairs of gripping arms for gripping each food product of a row individually. This allows individual food products to be selectively gripped. The row gripper is capable of moving less than an entire transverse row of food products by selectively gripping the food products. This may be desirable if one or more of the food products of a food product row is uncorrectable or otherwise unsatisfactory for packing in one or more aspects, such as weight, form, or visual presentation.

In another embodiment, the row gripper is capable of gripping a longitudinal row or column of two or more food products to move and fill a longitudinal row of containers in the fill station. In another embodiment the row gripper has multiple corresponding pairs of gripping arms for gripping each food product of a longitudinal row individually. This allows individual food products to be selectively gripped. The row gripper is capable of moving less than a longitudinal row of food products by selectively gripping the food products. In another embodiment, the shuttle robot may comprise multiple shuttle robots for gripping and moving food products between the main conveyor and the packing station.

Claim 1:
Food handling system comprising:
a food positioning system comprising:
a main conveying surface (<NUM>) configured to move food products (<NUM>),
an electronic sensor (<NUM>) configured to capture position data about one or more food products (<NUM>) on the main conveying surface (<NUM>) within a sensor range of the sensor (<NUM>),
a robot (<NUM>), and
a controller (<NUM>) which is
signal-connected to the electronic sensor (<NUM>) and the robot (<NUM>), and configured to instruct the robot (<NUM>) to move a food product (<NUM>) from the main conveying surface (<NUM>) to a destination position,
characterized in that:
with respect to the food positioning system: the food products (<NUM>) on the main conveying surface (<NUM>) comprising a stack of food products (<NUM>), the electronic sensor (<NUM>) configured to detect when the stack of food products (<NUM>) is not properly stacked or aligned in a vertical direction on the main conveying surface (<NUM>), and the controller (<NUM>) configured to instruct the robot (<NUM>) to correct the vertical mis-alignment of the stack of food products (<NUM>).