Cutting/portioning using combined X-ray and optical scanning
A processing system ( 10 ) and corresponding method ( 158 ) are provided for processing workpieces (WP), including food items, to cut and remove undesirable components from the food items and/or portion the food items while being conveyed on a conveyor system ( 12 ). An X-ray scanning station ( 14 ) is located on an upstream conveyor section ( 20 ) to ascertain size and/or shape parameters of the food items as well as the location of any undesirable components of the food items, such as bones, fat or cartilage. Thereafter the food items are transferred to a downstream conveyor ( 20 ) at which is located an optical scanner ( 102 ) to ascertain the size and/or shape parameters of the food items. The results of the X-ray and optical scanning are transmitted to a processor ( 18 ) to confirm that the food item scanned by the optical scanner is the same as that previously scanned by the X-ray scanner. Once this identity is confirmed, if required, the data from the X-ray scanner is translated or transformed onto the data from the optical scanner. Such translation may include one or more of the shifting of the food items in the X and/or Y direction, rotation of the food item, scaling of the size of the food item, and sheer distortion of the food item. Next, the location of the undesirable material within the food item is mapped from the X-ray scanning data onto the optical scanning data. Thereafter, the undesirable material is removed by a cutter(s) ( 28 ). The food item may also (or alternatively) been portioned by the cutter(s) ( 28 ).
1. A system for processing food items to perform at least one operation selected from the group consisting of cutting and removing undesirable components from the food items and portioning the food items while the food items are being conveyed on a conveyor system, the system comprising:
a conveyor system comprising an upstream conveyor section for conveying the food items;
an X-ray scanner positioned at the upstream conveyor section for scanning the food items on the upstream conveyor section to ascertain physical parameters of the food items comprising size and shape parameters of the food items and the location(s) of the undesirable components to be removed from the food items, the ascertained physical parameters represented by a first data set corresponding to at least one of the size of the food items, shape of the food items and to the location(s) of the undesirable components of the food items;
the conveyor system comprising a downstream conveyor section positioned downstream of the upstream conveyor section for receiving the food items previously conveyed by the upstream conveyor section and for further conveying the food items;
an optical scanner at the downstream conveyor section for scanning the food items on the downstream conveyor section to ascertain physical parameters of the food items comprising the location of the food items on the downstream conveyor section and at least one of the size and shape parameters of the food items on the downstream conveyor section, at least some of the ascertained physical parameters represented by a second data set corresponding to at least one of the size and shape of the food items;
one or more cutters for cutting the food item to perform at least one operation selected from the group consisting of removing the undesirable food item components and portioning the food item;
a processor configured for:
receiving the first and second data sets;
comparing the second data set from the optical scanner with the first data set from the X-ray scanner; and
optionally performing translations of the first data set onto the second data set, such translations including one or more of:
directional translation of the food item;
rotational translation of the food item;
scaling the size of the food item;
shear distortion of the food item
performing at least one function selected from the group consisting of locating the undesirable components on the food item and determining how to portion the food item; and
controlling the one or more cutters to perform at least one operation selected from the group consisting of: cutting the food item to remove the undesirable components; and portioning the food item.
2. The system of claim 1 , wherein:
a physical parameter from the X-ray scanner comprises the outer perimeter configuration of the food item on the upstream conveyor section; and
a physical parameter ascertained by the optical scanner comprises the outer perimeter configuration of the food item on the downstream conveyor section.
3. The system according to claim 2 , wherein:
the first data set corresponding to locations along the outer perimeter of the food item on the upstream conveyor section; and
the second data set corresponds to locations along the outer perimeter of the food item on the downstream conveyor section.
4. The system according to claim 3 , wherein:
the first data set comprises coordinates corresponding to locations along the outer perimeter of the food item on the upstream conveyor section; and
the second data set comprises coordinates along the outer perimeter of the food item on the downstream conveyor section.
5. The system according to claim 1 , wherein the translation of the food item, the scaling of the food item and the shear distortion of the food item is in the X or Y direction.
6. The system according to claim 1 , wherein at least one of the size and shape parameters ascertained by at least one of the X-ray scanner and the optical scanner comprise the food item length, width, aspect ratio, thickness, thickness profile, contour, outer contour, outer perimeter, outer perimeter configuration, outer perimeter size, outer perimeter shape, volume or weight of the food items.
7. The system according to claim 1 , wherein the processor is configured to compare the first data set from the X-ray scanner with the second data set from the optical scanner using an analysis methodology selected from the group consisting of a Root Mean Square error analysis of the data of the first and second data sets, a standard deviation analysis of the data of the first and second data sets, and a least squares regression analysis of the data of the first and second data sets.
8. The system according to claim 1 , wherein the system does not monitor the location of the food item along the conveyor system from the X-ray scanner to the optical scanner.
9. The system according to claim 1 , wherein:
the location of travel of the food item along the upstream conveyor section is not monitored; and
the processor receives the first data set as the food item leaves the upstream conveyor section.
10. The system according to claim 1 , wherein:
the downstream conveyor section comprises a conveyor belt extending therealong; and
the processor is configured to, upon receiving the first data set, note the position of the conveyor belt relative to the downstream conveyor section.
11. The system according to claim 10 , wherein the downstream conveyor section comprises a belt and an encoder to monitor the position of the conveyor belt along the downstream conveyor section.
12. The system according to claim 11 , wherein the processor is configured to, upon receiving the first data set, note the position along the conveyor belt on the downstream conveyor section via an encoder reading.
13. The system according to claim 1 , wherein the processor is configured to, in comparing the first data set from the X-ray scanner with the second data set from the optical scanner, verifying that the food item scanned by the optical scanner corresponds to the same food item previously scanned by the X-ray scanner.
14. The system according to claim 1 , wherein the processor is configured to, in comparing the first data set from the X-ray scanner with the second data set from the optical scanner, match the second data set to the first data set and selects the first data set that corresponds to the second data set.
15. The system according to claim 1 :
wherein the processor is configured to, in comparing the first data set from the X-ray scanner with the second data set from the optical scanner, determine whether the food item scanned by the optical scanner is the same food item as the food item previously scanned by the X-ray scanner by comparing the first data set from the X-ray scanner with the second data set from the optical scanner; and
if it is determined that the food item scanned by the optical scanner is not the same food item as previously scanned by the X-ray scanner, then determining if a subsequent food item scanned by the X-ray scanner is the same food item as scanned by the optical scanner.
16. A system for processing food items to perform at least one operation selected from the group consisting of cutting and removing undesirable components from the food items and portioning the food items while the food items are being conveyed on a conveyor system, the system comprising:
a conveyor system comprising an upstream conveyor section for conveying the food items;
an X-ray scanner positioned at the upstream conveyor section for scanning the food items on the upstream conveyor section to ascertain physical parameters of the food items comprising the location(s) of the undesirable components to be removed from the food items, the ascertained physical parameters represented by a first data set corresponding to the food items and to the location(s) of the undesirable components of the food items;
the conveyor system comprising a downstream conveyor section positioned downstream of the upstream conveyor section for receiving the food items previously conveyed by the upstream conveyor section and for further conveying the food items;
a first optical scanner positioned at the downstream conveyor section for scanning the food items on the downstream conveyor section to ascertain physical parameters of the food items comprising the location of the food items on the downstream conveyor section and at least one of the size and shape parameters of the food items on the downstream conveyor section, at least some of the ascertained physical parameters represented by a second data set corresponding to at least one of the size and shape of the food items;
a second optical scanner positioned at the upstream conveyor section for scanning the food items on the upstream conveyor section to ascertain physical parameters of the food items comprising at least one of the size and shape parameters of the food items and optionally the location(s) of undesirable components to be removed from the food items, the ascertained physical parameters represented by a third data set corresponding to at least one of the size and shape of the food items and optionally to the location(s) of the undesirable components of the food items;
one or more cutters for performing at least one operation selected from the group consisting of cutting the food item to remove the undesirable food item components and portioning the food item;
a processor configured for:
receiving the first, second and third data sets;
comparing the second data set from the first optical scanner with the third data set from the second optical scanner; and
optionally performing translations of the third data set onto the second data set, such translations including one or more of;
directional translation of the food item;
rotational translation of the food item;
scaling the size of the food item;
shear distortion of the food item
performing at least one function selected from the group consisting of locating the undesirable components on the food item and determining how to portion the food item; and
controlling the one or more cutters to perform at least one operation selected from the group consisting of: cutting the food item to remove the undesirable components; and portioning the food item.