Determining the thickness profile of work products

CROSS-REFERENCE TO RELATED APPLICATION

0001This application claims the benefit of U.S. Provisional Application No. 62/855,700, filed May 31, 2019, the entire contents of which are incorporated herein by reference in their entirety.

BACKGROUND

0002Work products, including food products, are portioned or otherwise cut into smaller portions by processors in accordance with customer needs. Customers usually desire to portion and/or trim the work products into uniform sizes, for example, steaks to be served in restaurants, chicken fillets used in frozen dinners or in chicken burgers or bacon slabs cut from pork bellies. Much of the portioning/trimming of work products, in particular food products, is now carried out with the use of high-speed portioning machines. These machines rely on various scanning techniques to ascertain the size and shape of the food product as they are being advanced on a moving conveyor. This information is analyzed with the aid of a computer to determine how to most efficiently cut the food product into optimum sizes or portions. For example, a customer may desire bacon portioned into one-pound slabs or may desire chicken breast portions in two different weight sizes, but with no fat or with a limited amount of acceptable fat. The pork belly or chicken breast is scanned as it moves on an infeed conveyor belt and a determination is made through the use of a computer as how to best portion the pork belly or chicken breast to achieve the weight(s) desired by the customer, so as to use the pork belly or chicken breast most effectively.

0003Cutting and/or trimming of the work product can be carried out by various cutting devices, including high-speed liquid jet cutters, wherein the liquid may include, for example, water or liquid nitrogen. Alternatively, the cutting device may be composed of a rotary or reciprocating blade. Once the cutting/trimming has occurred, the resulting portions are off-loaded from the cutting conveyor and placed on a takeaway conveyor for further processing or perhaps to be placed in a storage bin.

0004Portioning machines of the foregoing type are known in the art. Such portioning machines, or portions thereof, are disclosed in prior patents, for example, U.S. Pat. Nos. 4,962,568 and 5,868,056, which are incorporated by reference herein. Typically, the work products are first carried by an infeed conveyor past the scanning station where at the work products are scanned to ascertain selected physical parameters, for example, the size and shape, including length, width and/or thickness profile. From this information, the weight of the work product, or portions thereof, can be determined by utilizing an assumed density for the work product.

0005The scanning of the work product can be carried out utilizing a variety of techniques, including X-ray scanning and optical scanning. In X-ray scanning, X-rays are passed through the work product, with the level of attenuation of the work product being related to mass of the work product. An optical scanning system may utilize a CCD camera or video camera to view a work product illuminated by one or more light sources. The optical camera is capable of determining the physical parameters of the overall exterior configuration of the work product, including its size and shape. These scanning techniques assume that the bottom of the work product lies flat on the conveyor on which the work product is being carried during scanning and subsequent trimming or cutting. However, the bottom side of the work product may not lie flat against the top surface of the conveyor belt, rather an undercut may exist beneath the work product. Also, an unseen void may exist within the interior of the work product. If these situations exist, then in typical scanning systems the undercut or void is not detected. Accordingly, the work product is analyzed as if the undercut or void did not exist. As such, erroneous information is utilized concerning the physical parameters of the work product. If the goal is to cut the work product into uniform portions by weight, then the presence of an undercut or void can cause the end portion to not be within the approved weight range for the portion(s) cut from the work product.

0006X-ray scanners can “see through” work products, including foods. However, X-ray scanners cannot detect undercuts or voids. Also, optical scanners are capable of ascertaining the physical aspects of the exterior of the work product, but are not able to ascertain the existence of a void within the work product or an undercut beneath the work product.

0007The present disclosure seeks to provide a method and system for locating voids, undercuts and similar anomalies in the work product and then analyzing the work product taking into consideration the existence of voids, undercuts or other anomalies so as to portion or otherwise process the work product knowing the existence, location, size and shape of any voids, undercuts or similar anomalies in the work product.

SUMMARY

0008This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This summary is not intended to identify key features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.

0009An embodiment of the present disclosure includes a method for determining the thickness profile of a work product, comprising (a) scanning a work product with an X-ray scanner, (b) analyzing the data from the X-ray scanner with a computer processor to develop a thickness profile of the work product, (c) scanning the work product with an optical scanner, (d) analyzing the data from the optical scanner with a computer processor to develop a thickness profile of the work product based on the optical scanning data, (e) comparing the thickness profiles from the X-ray scanning data and the optical scanning data and determining (quantifying) the differences between the thickness profiles from the X-ray scanning data and the optical scanning data, and (f) mapping the location(s) on the work product where a difference exists between the thickness profiles from the X-ray scanning data and the optical scanning data.

0010The method of any embodiment of the present disclosure, wherein the differences between the thickness profiles from the X-ray scanning data and the optical scanning data correspond to voids, undercuts and similar locations associated with the work product that is not occupied by the work product.

0011The method of any embodiment of the present disclosure, wherein the work product is a food product, and the differences between the thickness profile developed from the X-ray scanning data and the thickness profile developed from the optical scanning data correspond to a void in the work product, an undercut beneath the work product, or other location devoid of the work product.

0012The method of any embodiment of the present disclosure, wherein the food product comprises meat, and the difference between the thickness profile from the X-ray scanning relative to the thickness profile from the optical scanning comprises a void in the meat, an undercut in the lower surface of the mat, or other location that is devoid of the meat.

0013The method of any embodiment of the present disclosure, further comprising transporting the work product on a conveyance device past the X-ray scanner and the optical scanner.

0014The method of any embodiment of the present disclosure, further comprising positioning the X-ray scanner and the optical scanner relative to the conveyance device.

0015The method of any embodiment of the present disclosure, further comprising positioning the X-ray scanner and the optical scanner to simultaneously scan the same location on the work product.

0016The method of any embodiment of the present disclosure, further comprising processing the work product using the determined differences between the thickness profiles from the X-ray scanning data and the optical scanning data and the location(s) on the work product where a difference exists between the thickness profiles from the X-ray scanning data and the optical scanning data.

0017The method of any embodiment of the present disclosure, wherein the work product is processed by trimming, cutting or portioning.

0018The method of any embodiment of the present disclosure, further comprising transporting the work product in a direction of travel past the X-ray scanner and the optical scanner.

0019The method of any embodiment of the present disclosure, wherein the X-ray scanner scans the work product along a line extending transversely to the direction of travel of the work product.

0020The method of any embodiment of the present disclosure, wherein the optical scanner scans the work product along a line extending transversely to the direction of travel of the work product.

0021The method of any embodiment of the present disclosure, wherein the optical scanner scans the work product along the same line that the X-ray scanner scans the work product.

0022The method of any embodiment of the present disclosure, wherein the conveyance device comprises a first conveyor corresponding to the X-ray scanner and a second conveyor corresponding to the optical scanner.

0023The method of any embodiment of the present disclosure, further comprising (g) wherein the data from the X-ray scanning comprises a first data set corresponding to the two dimensional shape of the work product, (h) wherein the data set from the optical scanning comprises a second data set corresponding to the two dimensional shape of the work product, (i) comparing the first and second data sets from the X-ray scanning and the optical scanning corresponding to the two-dimensional shape of the work product, and (j) determining if a sufficient variation exists between the first and second data sets to require translation of the first data set into the second data set.

0024The method of any embodiment of the present disclosure, wherein translation of the first data set from the X-ray scanning onto the second data set from the optical scanning comprises one or more of: (i) directional translation of the work product; (ii) rotational translation of the work product; (iii) scaling the size of the work product; (iv) shear distortion of the work product.

0025The method of any embodiment of the present disclosure, wherein the conveyance device comprises a first conveyor corresponding to the locations of the X-ray scanner and the optical scanner; and further comprising a second optical scanner and a second conveyor corresponding to the location of the second optical scanner.

0026The method of any embodiment of the present disclosure, wherein the data set from the optical scanner comprises a second data set corresponding to the two-dimensional shape of the work product, wherein the data from the second optical scanner comprises a third data set corresponding to the two-dimensional shape of the work product, and further comprising comparing the second and third data sets from the optical scanner and from the second optical scanner corresponding to the two-dimensional shape of the work product, and determining that sufficient variation exists between the second and third data sets to require a translation of the second data set into the third data set.

0027The method of any embodiment of the present disclosure, wherein translation of the second data set into the third data set comprises one or more of: directional translation of the work product; rotational translation of the work product; scaling of the size of the work product; shear distortion of the work product.

0028The method of any embodiment of the present disclosure, wherein the conveyance device comprised a first conveyor corresponding to the X-ray scanner and the optical scanner and a second conveyor corresponding to a processing station whereat the work product is processed using the thickness profiles determined from the X-ray scanning data and the optical scanning data.

0029A further embodiment of the present disclosure including a system for determining the thickness profile of a work product, comprising: a conveyance device for conveying the work product; an X-ray scanner for scanning the work product being conveyed on the conveyance device and generating a first data set regarding the physical characteristics of the work product, including a thickness profile of the work product; an optical scanner for scanning the work product being conveyed on the conveyance device for generating a second data set regarding the physical characteristics of the work product, including the thickness profile of the work product; and a control system configured to: generating thickness profiles of the work product from the X-ray scanning data and the optical scanning data; quantifying the differences between the thickness profiles of the work product from the X-ray scanning data and the optical scanning data; and mapping the location(s) on the work product where differences exist between the thickness profiles from the X-ray scanning data and the optical scanning data.

0030The system of any embodiment of the present disclosure, wherein the difference between the thickness profiles of the work product from the X-ray scanning data and the optical scanning data corresponds to a void in the work product, an undercut beneath the work product, or other location with respect to the work product that is devoid of the work product.

0031The system of any embodiment of the present disclosure, wherein the work product comprises a food product and the differences between the thickness profile of the food product from the X-ray scanning data and the thickness profile of the food product from the optical scanning data corresponds to a void in the food product, an undercut beneath the food product, or location with respect to the food product that is devoid of the food product.

0032The system of any embodiment of the present disclosure, wherein the food product is meat, and the difference between the thickness profile of the meat from the X-ray scanning relative to the thickness profile of the meat from the optical scanning is due to the presence of a void within the meat, an undercut beneath the meat, or other location with respect to the meat that is devoid of meat.

0033The system of any embodiment of the present disclosure, wherein the X-ray scanner and the optical scanner are positioned relative to the conveyance device to simultaneously scan the same location on the work product.

0034The system of any embodiment of the present disclosure, wherein the X-ray scanner is configured to scan the work product along a line extending transversely to the direction of travel of the work product on the conveyance device.

0035The system of any embodiment of the present disclosure, wherein the optical scanner is configured to scan the work product along a line extending transversely to the direction of travel of the work product on the conveyance device.

0036The system of any embodiment of the present disclosure, wherein the optical scanner is configured to scan the work product along the same line that the X-ray scanner is configured to scan the work product.

0037The system of any embodiment of the present disclosure, wherein the optical scanner is configured to scan the work product along the same line and at the same time that the X-ray scanner is configured to scan the work product.

0038The system of any embodiment of the present disclosure, wherein the conveyance device comprises a first conveyor corresponding to the X-ray scanner and a second conveyor corresponding to the optical scanner.

0039The system of any embodiment of the present disclosure, wherein the control system compares a first data set from the X-ray scanning data corresponding to the two-dimensional shape of the work product with a second data set from the optical data scanning corresponding to the two-dimensional shape of the work product and comparing the first and second data sets from the X-ray scanning and the optical scanning to determine if a sufficient variation exists between the first and second data sets to require translation of the first data set into the second data set.

0040The system of any embodiment of the present disclosure, wherein the translation of the first data set from the X-ray scanning into the second data set from the optical scanning comprises one or more of: directional translation of the work product; rotational translation of the work product; scaling of the size of the work product; and shear distortion of the work product.

0041The system of any embodiment of the present disclosure, further comprising a processing station located downstream of the optical scanner for processing the work product using the quantified differences between the thickness profile of the work product from the X-ray scanning versus the thickness profile of the work product from the optical scanning.

0042The system of any embodiment of the present disclosure, wherein the processing station comprises a cutter for trimming, cutting, and/or portioning the work product.

DESCRIPTION OF THE DRAWINGS

0043The foregoing aspects and many of the attendant advantages of this invention will become more readily appreciated as the same become better understood by reference to the following detailed description, when taken in conjunction with the accompanying drawings, wherein:

0044<figref idref="DRAWINGS">FIG. 1</figref> is a schematic representation of a system and apparatus for processing work products according to a first embodiment of the present disclosure;

0045<figref idref="DRAWINGS">FIG. 2</figref> is a schematic view of an X-ray scanner which may be utilized in the system and method of the present disclosure;

0046<figref idref="DRAWINGS">FIG. 3</figref> is a schematic view of another X-ray scanner that may be utilized with the system and method of the present disclosure;

0047<figref idref="DRAWINGS">FIGS. 4A-4C</figref> are plots of thickness profiles of a work product generated by X-ray scanning and optical scanning showing the differences therebetween;

0048<figref idref="DRAWINGS">FIG. 5</figref> is a flow diagram of a work product processing method using the system and apparatus of <figref idref="DRAWINGS">FIG. 1</figref>;

0049<figref idref="DRAWINGS">FIG. 6</figref> is a schematic view of another embodiment of a system and apparatus for processing work products in accordance with the present disclosure;

0050<figref idref="DRAWINGS">FIGS. 7A-7F</figref> schematically illustrate the manner in which work products may move or distort when transferred from a first conveyor belt to a second conveyor belt;

0051<figref idref="DRAWINGS">FIG. 8</figref> is a flow diagram illustrating one method of utilizing the system and apparatus of <figref idref="DRAWINGS">FIG. 6</figref>;

0052<figref idref="DRAWINGS">FIG. 9</figref> is a schematic view of another embodiment of a system and apparatus for processing work products in accordance with the present disclosure; and

0053<figref idref="DRAWINGS">FIG. 10</figref> is a flow diagram schematically illustrating a method of utilizing the system and apparatus of <figref idref="DRAWINGS">FIG. 9</figref>.

DETAILED DESCRIPTION

0054The description set forth below in connection with the appended drawings, where like numerals reference like elements, is intended as a description of various embodiments of the disclosed subject matter and is not intended to represent the only embodiments. Each embodiment described in this disclosure is provided merely as an example or illustration and should not be construed as preferred or advantageous over other embodiments. The illustrative examples provided herein are not intended to be exhaustive or to limit the disclosure to the precise forms disclosed. Similarly, any steps described herein may be interchangeable with other steps, or combinations of steps, in order to achieve the same or substantially similar result.

0055In the following description, numerous specific details are set forth in order to provide a thorough understanding of exemplary embodiments of the present disclosure. It will be apparent to one skilled in the art, however, that many embodiments of the present disclosure may be practiced without some or all of the specific details. In some instances, well-known process steps have not been described in detail in order not to unnecessarily obscure various aspects of the present disclosure. Further, it will be appreciated that embodiments of the present disclosure may employ any combination of features described herein.

0056The present application may include references to “directions,” such as “forward,” “rearward,” “front,” “back,” “ahead,” “behind,” “upward,” “downward,” “above,” “below,” “top,” “bottom,” “right hand,” “left hand,” “in,” “out,” “extended,” “advanced,” “retracted,” “proximal,” and “distal.” These references and other similar references in the present application are only to assist in helping describe and understand the present disclosure and are not intended to limit the present invention to these directions.

0057The present application may include modifiers such as the words “generally,” “approximately,” “about”, or “substantially.” These terms are meant to serve as modifiers to indicate that the “dimension,” “shape,” “temperature,” “time,” “quantity,” “percentage,” or other physical parameter in question need not be exact, but may vary as long as the function that is required to be performed can be carried out. For example, in the phrase “generally circular in shape,” the shape need not be exactly circular as long as the required function of the structure in question can be carried out.

0058In the following description, various embodiments of the present disclosure are described. In the following description and in the accompanying drawings, the corresponding systems assemblies, apparatus and units may be identified by the same part number, but with an alpha suffix or a prime or double prime designation. The descriptions of the parts/components of such systems assemblies, apparatus, and units that are the same or similar are not repeated so as to avoid redundancy in the present application.

0059In the present application, references to “food,” “food products,” “food pieces,” and “food items,” are used interchangeably.

System Summary

0060An embodiment of the processing system <b>10</b> of the present disclosure is illustrated in <figref idref="DRAWINGS">FIG. 1</figref> as including, in basic form, the conveyance device <b>12</b> in a form of a conveyor <b>28</b> having an endless belt <b>30</b> for carrying work products or workpiece WP, such as food products, for example, pork bellies, poultry breasts and other types of food products, past an X-ray scanner <b>14</b> to ascertain physical parameters of the work product. Such physical parameters may include the size and/or shape of the work product including, for example, the length, the width, aspect ratio, thickness, thickness profile, contour, outer contour, outer perimeter, outer perimeter shape, volume and/or weight of the work product. With respect to the thickness profile of the work product, such profile can be ascertained along the length of the work product, across the width of the work product as well as both across the width and along the length of the work product. The data from the X-ray scanner <b>14</b> is transmitted to control system <b>18</b>. Such data is coordinated with corresponding data from an encoder <b>20</b> associated with the conveyance device <b>12</b> so as to match the X-ray scanning data with positions along the conveyance device corresponding to locations along the work product being scanned.

0061The system <b>10</b> also includes an optical scanner <b>22</b> which is positioned relative to the conveyance device <b>12</b> to simultaneously scan the work produce with the X-ray scanning being conducted. The optical scanner also ascertains physical parameters of the work product, including, for example, physical parameters pertaining to the size and/or shape of the work product as discussed above with respect to the X-ray scanner <b>14</b>. The data from the optical scanning is also transmitted to the control system <b>18</b> and can be used to develop a thickness profile of the work product.

0062The thickness profile of the work product determined from the X-ray scanner is based on the mass of the work product. Thus, if there is a void within the work product or an undercut at the bottom of the work product, this can be ascertained by the X-ray scanner due to the reduction in mass resulting from the void or undercut. However, the optical scanner ascertains the height and contours of the top exterior of the work product and does not take into consideration whether there is a void within the work product or an undercut beneath the work product. As such, the two thickness profiles generated by the X-ray scanning and the optical scanning can be compared. If a void exists within the work product or an undercut exists beneath the work product, the thickness of the work product as determined by the optical scanning will be larger than the thickness of the work product as determined from the X-ray scanning With this information, it is possible for the control system <b>18</b> to not only ascertain the existence of a void or undercut, but also more specifically the shape, size, and location of the void or undercut. This information can be used by the control system <b>18</b> in determining how to trim, cut and/or portion the work product into desired final pieces, for example, final pieces of a desired weight or weight range.

0063The need for mapping of the thickness data ascertained from the X-ray scanning with the thickness data ascertained from optical scanning can be reduced or perhaps eliminated if the X-ray scanner and optical scanner are configured to simultaneously scan the same location(s) of the work product.

0064Even if there still be a need for mapping thickness data from the X-ray and optical scanning operations, if the scanning occurs simultaneously, the matching or mapping of the data will likely be more accurate. Also, the matching/matting may possibly be done with simple timestamps, and not with any need for monitoring of the position of the work pieces on the belt with encoder “counts” or other monitoring techniques.

0065The work product can be trimmed or cut at a cutting station <b>26</b> using one or more cutters controlled by control systems <b>18</b>. Thereafter, the trimmed or cut work product may be transferred on for other or further processing. Other types of processing in addition to or in lieu of the cutting or trimming of the work product can occur using the information regarding the thickness profile of the work product ascertained using the data from the X-ray scanner <b>14</b> and the optical scanner <b>22</b>.

Conveyor

0066Next, describing the foregoing aspects of the processing system <b>10</b> in more detail, referring to <figref idref="DRAWINGS">FIG. 1</figref>, conveyance device <b>12</b> is in the form of a belt conveyor <b>28</b> having an endless belt <b>30</b> trained over end rollers <b>32</b> and <b>34</b>. The encoder <b>20</b> is associated with the end roller <b>34</b>. The roller <b>34</b> is powered so as to drive the conveyor belt in the downstream direction as shown by arrow <b>36</b> past the X-ray scanner <b>14</b>, optical scanner <b>22</b>, and cutting station <b>26</b>. As noted above, the encoder <b>20</b> monitors the location or position of the belt <b>30</b> along the length of the conveyor <b>28</b>.

0067The belt <b>30</b> is illustrated as being of open form or grid construction so that the water jet(s) at the cutting station <b>26</b> is (are) free to pass downwardly through the belt to a collection tank or other receptacle, not shown, positioned beneath the conveyance device. Various constructs of conveyor belts corresponding to belt <b>30</b> are described in U.S. Pat. No. 6,854,590, incorporated by reference herein.

X-Ray Scanning

0068X-ray scanner <b>14</b> is used to inspect the work product WP to determine physical parameters of the work product, including as described above, the shape and size of the work product and further including, for example, the thickness and thickness profile of the work product. The X-ray scanner can also determine if undesirable material, such as bones, fat, metal, plastic, glass, is located within the work product.

0069Generally, X-rays are attenuated as they pass through an object in proportion to the total mass of the material to which the X-rays pass. The intensity of the X-rays received by an X-ray detector, after they have passed through the object such as work product WP, is inversely proportional to the total mass of the object. For example, X-rays passing through a work product that has a void or an undercut will be less attenuated as X-rays that pass through the work product without an undercut or void. Thus, the portion of a work product at which a void or undercut is located will be analyzed as being of lesser thickness than adjacent the sections of the work product without an undercut or void.

0070Further, using a given value for the density of the work product being analyzed, whether beef, poultry or fish, the dimensional thickness of the work product can be calculated. This information can be determined for the entire volume of the work product. A general description of the nature and use of X-rays in processing food products can be found in U.S. Pat. No. 5,585,603, incorporated herein by reference.

0071As noted above, system <b>10</b> includes a position sensor in the form of encoder <b>20</b> that generates a signal indicative of the position of the belt <b>30</b>, and thus the work product WP, along the length of the conveyor <b>28</b>. As the work products move along the conveyor <b>28</b>, with respect to X-ray scanner <b>14</b> the position of the work product along the length and width of the conveyor belt <b>30</b> can be ascertained by the X-ray system. As noted above, the X-ray scanner can also provide other information with respect to the physical parameters of the work product in addition to the thickness or the thickness profile of the work product described above. Such physical parameters include, for example, the length, width, aspect ratio, contour, outer contour configuration, perimeter, outer perimeter configuration, outer perimeter size and/or shape, volume and/or weight of the work product. With respect to the outer perimeter configuration of the work product, the X-ray scanner can be used to determine locations along the outer perimeter of the work product, including based on an X-Y coordinate system or other coordinate system.

0072The X-ray scanner <b>14</b> includes an X-ray source or generator <b>40</b> for emitting X-rays <b>42</b> downwardly toward the work product. An X-ray detector <b>44</b> is located beneath the upper run of the conveyor belt <b>30</b> for receiving the X-rays <b>42</b> that have passed through the work product. The X-ray detector <b>44</b> includes a linear array of detector units extending across the underside of the conveyor belt <b>30</b> to generate a signal corresponding to the intensity of the X-rays impinging thereon. The signals generated by the X-ray detector <b>44</b> are transmitted to an image processor <b>46</b>, which forms part of the overall control system <b>18</b>. The control system processes the data signals from the X-ray detector <b>44</b> to determine physical parameters of the work product, including the thickness profile of the work product, across the width of the work product as well as along the length of the work product. As noted above, the physical parameters ascertainable from the X-ray scanning also includes the shape and size of the work product as well as the location of the work product on the conveyor belt <b>20</b>.

0073Referring to <figref idref="DRAWINGS">FIG. 2</figref>, an X-ray detector <b>14</b> is illustrated as including a layer or strip of scintillator material <b>48</b> located above a plurality of photodiodes <b>50</b><i>a</i>-<b>50</b><i>n</i>. The X-ray source or generator <b>40</b> is located a sufficient distance above the conveyor belt <b>30</b> so that the X-rays <b>42</b> emitted from the generator <b>40</b> completely encompass the length of the X-ray detector <b>44</b> that extends across the conveyor belt <b>30</b>. The X-rays <b>42</b> pass through the work product WP, through the upper run of the conveyor belt <b>30</b>, and then impinge upon the layer or strip of scintillator material <b>48</b>. Since the photodiodes <b>50</b><i>a</i>-<b>50</b><i>n </i>respond only to visible light, the scintillator material <b>48</b> is used to convert the X-ray energy impinging thereon into visible light flashes that are proportional to the strength of the received X-rays. The photodiodes <b>50</b><i>a</i>-<b>50</b><i>n </i>generate electrical signals that have an amplitude proportional to the intensity of the light received from the scintillator material <b>48</b>. These electrical signals are relayed to the image processor <b>46</b>.

0074As shown in <figref idref="DRAWINGS">FIG. 1</figref>, the photodiodes <b>50</b><i>a</i>-<b>50</b><i>n </i>are arranged in a line across the width of the conveyor belt <b>30</b> for detecting X-rays passing through a line or “slice” of the work product WP. Alternative photodiode layouts are possible, for example, the photodiodes can be positioned in several rows to form a rectangular grid thereby to increase the scanning area of the X-ray detector <b>44</b>, if desired.

0075Other embodiments of an X-ray scanner can be utilized, which are also capable of detecting the intensity (or attenuation) of the X-rays that have passed through the work product WP to determine a thickness profile of the work product. For example, referring to <figref idref="DRAWINGS">FIG. 3</figref>, an alternative embodiment of an X-ray detector <b>14</b>′ includes a fluoroscope screen <b>54</b>. The screen is activated to produce light flashes in proportion to the attenuation of the impinging X-rays <b>42</b>. Light flashes are then recorded by a video camera <b>56</b>, or other device capable of capturing the “picture” produced by the fluoroscope screen <b>54</b>. The images captured by the video camera <b>56</b> are transmitted to image processor <b>46</b> and converted into digital values related to the intensity of the light generated by the fluoroscope screen <b>54</b>.

0076Further alternatively, direct flat panel X-ray imaging technology or direct radiography may be used. For example, an array of amorphous selenium detectors may be used as an X-ray detector to directly detect the intensity of the impinging X-rays, and to transmit data in this regard to the image processor <b>46</b>.

0077Other X-ray options include the use of a dual-energy X-ray source or the photon-counting, multi-bin X-ray system.

0078Further, other types of scanners may be employed, for example, infrared scanning, sonar/ultrasound scanning, CT scanning or MRI scanning

Optical Scanning

0079Referring to <figref idref="DRAWINGS">FIG. 1</figref>, optical scanner <b>22</b> is positioned along conveyance system <b>12</b>. Optical scanning can be carried out using a variety of techniques, including with a scanner such as scanner <b>22</b>, to view a work product WP illuminated by one or more light sources <b>60</b>. The light from the light source(s) <b>60</b> is extended across the moving conveyor belt <b>30</b> to define a sharp shadow or light stripe <b>61</b>, with the area forward of the transverse beam being dark. When no work product is being carried by the conveyor belt <b>30</b>, the shadow line/light stripe <b>61</b> forms a straight line across the belt <b>30</b>. However, when a work product WP passes across the shadow line/light stripe, the upper irregular surface of the work product produces an irregular shadow line/light stripe as viewed by video cameras <b>62</b> directed downwardly on the work product and the shadow line/light stripe <b>61</b>. The video cameras detect the displacement of the shadow line/light stripe <b>61</b> (i.e., in the Z-axis direction) from the position it would occupy if no work product is present on the conveyor belt <b>30</b>. This upward displacement of the light stripe <b>61</b> represents the “thickness” of the work product along the shadow line/light stripe as viewed by the optical scanner.

0080The length of the work product is determined by the length of time that the shadow lines <b>61</b> are created by the work product. In this regard, encoder <b>20</b> generates pulses at fixed time intervals corresponding to the forward movement of the conveyor belt <b>30</b>. During such movement of the conveyor belt, the thickness profile of the entire work product in both the “X” and the “Y” direction relative to the conveyor belt is generated.

0081As shown in <figref idref="DRAWINGS">FIG. 1</figref>, the light source <b>60</b> and video cameras <b>62</b> are positioned relative to the X-ray scanner <b>14</b> so that the light stripe <b>61</b> coincides with and is aligned with the X-ray detector <b>44</b> positioned across the conveyor belt <b>30</b>. As such, the X-ray scanner and the optical scanner simultaneously scan the same transverse location (slice) across the work product. This alignment of the light stripe <b>61</b> with the X-ray detector <b>44</b> may eliminate the need for transformation of the data from the X-ray scanner <b>14</b> with the data from the optical scanner <b>22</b> due to the work pieces moving or shifting. Though mapping of the data from the X-ray scanner to the data from the optical scanner may be required due to the somewhat different viewpoints for the X-ray detector and the optical cameras or during calibration or set up of the processing system <b>10</b>.

0082Although a single light source <b>60</b> is shown in FIGURES, multiple light sources can be utilized. For example, a second light source may be positioned on the opposite side of X-ray generator <b>40</b> from the light source <b>60</b>.

0083Also, although two cameras <b>62</b> are shown as in use in <figref idref="DRAWINGS">FIG. 1</figref>, a single camera can be used. However, “shadowing” can occur if a single camera is used. In this regard, the light stripe may be momentarily blocked from view of the single camera by a section of the workpiece that extends upward above the surrounding portions of the work piece. This may not be a problem or source of inaccuracy. But if shadowing results in missing height data, the X-ray image data would be used to fill in the missing data.

0084Further, as noted above, the processing system <b>10</b> is designed to ascertain whether or not there is a void in the work product WP or whether an undercut in the underside of the work product exists or whether or not the work product is lying flat on the conveyor belt <b>20</b>. In this regard, as discussed above, the upward displacement of the light stripe <b>61</b> from the optical scanner provides the thickness of the work product, across the width of the work product at the location of the light stripe. However, optical scanning will not ascertain whether or not a void, undercut, etc., exists. Rather, the optical scanning instead provides the height profile of the upper surface of the work product WP relative to the top surface of the conveyor belt <b>30</b>.

0085On the other hand, the X-ray scanning provides the actual thickness of the work product across the work product corresponding to the location of the X-ray detector. If a void, undercut or similar anomaly exists in the work product, the work product will be determined to be thinner at such location since the intensity of the X-rays passing therethrough will be greater than if no void, undercut or other anomaly exists. Thus, if the “thickness” of the work product from the optical scanning is compared with the thickness of the work product from the X-ray scanning, any different therein will indicate the presence of a void, undercut or similar anomaly causing reduced attenuation of the X-rays reaching the X-ray detector.

0086The foregoing analysis is schematically illustrated in <figref idref="DRAWINGS">FIGS. 4A-4C</figref>. In <figref idref="DRAWINGS">FIG. 4A</figref>, the profile line <b>70</b> depicts the thickness profile above the datum “D” across a “slice” of the work product as generated by optical scanner <b>22</b>. The profile line <b>72</b> depicts the thickness profile above the datum “D” along the same slice of the work product as ascertained by the X-ray scanning Profile line <b>74</b> represents the height of the bottom surface work product when the X-ray height is subtracted from the optical height. For the most part, the profile line <b>74</b> is at a zero height above the datum because the height of the work product as determined by the optical scanning is the same as determined from the X-ray scanning. However, as shown in <figref idref="DRAWINGS">FIG. 4C</figref>, a section <b>76</b> of the profile line <b>74</b> is about the datum “D”. Section <b>76</b> of the profile line <b>74</b> represents the shape, size and location of a void or undercut in the work product. Except at the location of the profile <b>74</b>, the resulting height is zero relative to the datum “D”. The above analysis enables the more accurate processing of the work product, for example, trimming or cutting the work product into desired portion weights.

0087It will be appreciated that in certain types of food products, a relatively large undercut or void can occur, especially if the food product has curled or otherwise assumed a configuration that causes a work product to not lie flat on the conveyor belt <b>30</b>. For example, it is not uncommon for the edges of a smoked pork belly to turn or curl under thereby causing significant portions of the underside of the pork belly to not lie flat on the conveyor belt on which the pork belly is being supported during cutting of the pork belly into fixed weight portions. This commonly occurs along the edges of the pork belly.

0088Chicken breasts, especially when very fresh, can have undercutting from the edge in, or at the very front towards the back. Also, in chicken breasts when a muscle (the “tender”) is removed, a hollow may occur, which is known as the “tender tunnel”. This can cause inaccuracies when cutting or portioning the chicken breasts.

0089As discussed above, an assumed density value for the work product is used to translate the mass related data from the X-ray scanning to the height or thickness of the work product. In many situations, it will be assumed that the density value applies to the entire work product, for example, a chicken breast or fish fillet. In these situations, fat, which has less density than meat per se, is typically located around the edges of the meat. Further, the fat often is not of significant quantity, so errors caused by applying a generalized density value is typically relatively small. Further, if the fat present is on the surface of the food product is visible to the optical scanner, then the control system <b>18</b> can apply a different density value to the fat.

0090There are other types of food products, for example, pork bellies, that may consist of up to 50% fat, and such fat is interspersed throughout the muscle meat. In this situation, a generalized density value can be used that takes into consideration the likely level of fat in the food product.

0091Further, in meat food products, as indicated below, the density of fat is less than the density of the whole muscle meat. In this regard, the density of the food product being scanned can be calculated by dividing the mass measured from the X-ray scanning by the volume determined from the optical scanning. If the calculated density is less than the density of even the fat, then the conclusion is that there must be a void or undercut at the location of the food product being analyzed.

0092As a further matter, if it is known that the food product FP is lying flat on the conveyor belt <b>30</b>, for example, if the food product has been pressed prior to scanning, then the above method for calculating density by dividing the mass determined from the X-ray scanning by the volume determination from the optical scanning can be used to determine the fat/protein muscle ratio in the food product.

0093For example, if the density of pork is 1.1 g/cm³and the density of fat in pork is 0.9 g/cm³, if the density is calculated using the processes above as being 1.0, then pork belly being analyzed has a fat content of approximately 50%.

0094Referring to <figref idref="DRAWINGS">FIG. 1</figref>, as noted above, the X-ray scanner <b>14</b> and the optical scanner <b>22</b> are positioned relative to each other so that the same “slice” across the work product is being analyzed simultaneously by the X-ray scanning and the optical scanning Although this configuration of the portioning system <b>10</b> can simplify the analysis of the X-ray scanning and the optical scanning by not requiring translation of the data from the X-ray scanning into the data of the optical scanning or vice versa, it will be appreciated that the X-ray scanner may be positioned at a different location along the conveyance device <b>12</b> than the location of the optical scanner <b>22</b>, as discussed below regarding <figref idref="DRAWINGS">FIG. 6</figref>. In that case, it will be necessary to translate the data from the X-ray scanning into the data from the optical scanning. However, this process should be fairly straightforward in that both the X-ray scanning and optical scanning view the work product in slices across the width of the work product. The encoder data can be used to match the X-ray scanning data to the optical scanning data for the same slice location across the work product.

0095As noted above, the X-ray detector <b>44</b> is configured as a line array detector so as to receive X-rays along the same slice or line across the conveyor belt as the location of the light stripe <b>61</b> from the optical scanner <b>22</b>. As also noted above, the X-ray detector instead can be configured as having a width along the length of the conveyor belt <b>20</b>. In that situation, the data from the X-ray detector may need to be “associated” with the data from the optical scanner. In such case, the X-ray data may need to be transformed into the data from the optical scanner using existing transformation techniques.

Control System

0096<figref idref="DRAWINGS">FIG. 1</figref> schematically illustrates control system <b>18</b> which controls the operation of processing system <b>10</b>. The control system includes a computer <b>80</b> to which is operably connected the image processor <b>46</b> which receives the data from X-ray detector <b>44</b> as well as from the optical cameras <b>62</b> and processes such data for use by the computer. The control system also includes an interface <b>81</b> for receiving signals and information from encoder <b>20</b> as well as from other data sources of system <b>10</b>, as described herein. A memory unit <b>82</b> is provided for storing information for use by the control system, including the computer <b>80</b>. A keyboard or other input device <b>84</b> is provided to enable an operator to communicate with the control system <b>18</b>. Also, a display or other output device <b>86</b> is provided to convey information from the control system, including from computer <b>80</b> to the operator. As noted below, the control system <b>18</b> controls the operation of the portioning system <b>10</b>, including conveyance device <b>12</b>, X-ray scanner <b>14</b>, optical scanner <b>22</b>, and cutting station <b>26</b>. The control system <b>18</b> can be connected to a network <b>88</b>. Also, rather than employing a local computer <b>80</b>, a network computing system can be used for this purpose.

Cutting Devices

0097Once the work product has passed by the X-ray and optical scanners <b>14</b> and <b>22</b>, the work product WP moves on to cutting station <b>26</b>. As described above, information from the X-ray scanner and optical scanner can be combined so that locations of voids, undercuts and similar anomalies are known. With that information, the control system <b>18</b> determines how the work product can be trimmed or cut, for example, into portions of desired weights or other sizes and parameters.

0098Various types of cutting devices can be utilized at the cutting station <b>26</b> to cut or trim the work product as desired. One type of cutter <b>90</b> that may be used employs high-pressure water jets, as disclosed in U.S. Pat. Nos. 4,875,254, 5,365,186 and 5,868,056, incorporated herein by reference.

0099As schematically shown in <figref idref="DRAWINGS">FIG. 1</figref>, the water jet cutter <b>90</b> includes a nozzle <b>92</b> that may be moved relative to conveyor belt <b>30</b> longitudinally of the belt and laterally of the belt, as well as vertically relative to the upper surface of the belt. This enables the water jet cutter <b>90</b> to cut and/or trim the work product so as to achieve one or more desired configurations, sizes, portions, etc.

0100Although <figref idref="DRAWINGS">FIG. 1</figref> only shows one water jet cutter <b>90</b>, it is to be understood that at least several water jet cutters can be utilized in conjunction with the system <b>10</b> so as to achieve a desired production level. For example, four, eight or even more water jet cutters can be utilized in a coordinated fashion to cut and/or trim work products at cutting station <b>26</b>.

Method

0101<figref idref="DRAWINGS">FIG. 5</figref> illustrates a method of utilizing the processing system <b>10</b> of the present disclosure shown in <figref idref="DRAWINGS">FIGS. 1-4</figref>. The process begins at step <b>200</b> wherein work products WP are loaded onto conveyor <b>28</b> at step <b>202</b>. Thereafter, the work products are scanned at step <b>204</b> using X-ray scanner <b>22</b>. Next, at step <b>206</b>, the data from the X-ray scanning of the work product is transmitted to image processor <b>46</b>.

0102Thereafter, at step <b>208</b>, simultaneously with the X-ray scanning of the work product, the work product is also optically scanned by scanner <b>22</b>. At step <b>210</b>, the data from the optical scanner is sent to the image processor <b>46</b>.

0103Next, at step <b>214</b>, the data from the X-ray scanner and optical scanner is processed with the results of such processing made available to the computer <b>80</b> so that thickness profiles from the X-ray scanning and optical scanning can be generated, at step <b>216</b>. The two thickness profiles are analyzed so that the locations of voids, undercuts and similar anomalies can be mapped at step <b>218</b>.

0104Thereafter, at step <b>220</b> the cutting path for the water jet or other type of cutter <b>90</b> is generated by computer <b>80</b>. Next, at step <b>222</b>, the work product is cut, trimmed or otherwise divided into portions of desired physical parameters, such as weight. Then next, at step <b>224</b>, the work product can be subjected to one or more further processing operations.

Further Embodiment

0105<figref idref="DRAWINGS">FIG. 6</figref> illustrates a further embodiment of the present disclosure wherein the parts or components that operate the same as in <figref idref="DRAWINGS">FIG. 1</figref> and represented by the same part number, and the components or parts that are similar to these in <figref idref="DRAWINGS">FIG. 1</figref> are represented by a prime (′) designation. In <figref idref="DRAWINGS">FIG. 6</figref>, processing system <b>10</b>′ includes a conveyance system <b>12</b>′ consisting of a first conveyor <b>100</b> associated with X-ray scanner <b>14</b> and a second conveyor <b>102</b> associated with optical scanner <b>22</b>. Although located apart from each other, X-ray scanner <b>14</b> and optical scanner <b>22</b> function in the manner described above with respect to portioning system <b>10</b>.

0106The first conveyor <b>100</b> is operationally and structurally compatible with the X-ray scanner <b>14</b>. In this regard, the first conveyor <b>100</b> includes an X-ray permeable, flat endless belt <b>104</b> that is trained over an end roller <b>106</b>. The endless belt <b>104</b> can be powered in a conventional manner. An encoder <b>108</b> is associated with the end roller <b>106</b> in a manner similar to encoder <b>20</b> associated with the roller <b>34</b> of conveyor <b>102</b>. The encoder <b>108</b> monitors the location or position of the belt <b>104</b> and thus the work product WP, along the length of the conveyor <b>100</b>.

0107As mentioned above, the conveyor belt <b>104</b> is made from material that is permeable to X-rays, such as rubber, plastic, or a combination of both. Because of this construction, the X-rays easily pass through the conveyor belt to impinge upon the detector <b>44</b> located beneath the upper run of the belt <b>104</b>.

0108It is to be understood that conveyance devices <b>12</b> and <b>12</b>′, as well as other conveyance devices described herein, are not limited to belt conveyors for moving work products either continuously or intermittently. For example, the conveyance devices described herein can be replaced with moving platforms for conveying work products or other conveyance mechanisms.

0109The X-ray scanner <b>14</b>, in addition to developing a thickness profile in the manner described above with respect to <figref idref="DRAWINGS">FIG. 1</figref>, also is used to determine other physical parameters of the work product, including the overall shape and size of the work product, the outer perimeter configuration of the work product, as well as the location of the work product on the conveyor belt <b>104</b>. Such physical parameters are determined by the control system from the data generated by the scanner <b>14</b>.

0110After being scanned by X-ray scanner <b>14</b> on conveyor <b>10</b>, the work product is transferred onto a second, downstream conveyor <b>102</b>. Conveyor <b>102</b> is constructed in the manner of conveyor <b>28</b> shown in <figref idref="DRAWINGS">FIG. 1</figref>, as described above. As shown in <figref idref="DRAWINGS">FIG. 6</figref>, optical scanner <b>22</b> and cutter station <b>26</b> are positioned over the downstream conveyor <b>102</b>. The work product, after being scanned on upstream conveyor <b>100</b>, is transferred to the downstream conveyor <b>102</b> for optical scanning and for processing.

0111As discussed above, the exterior configuration of the work product is discernible by the optical scanner <b>22</b>, which ascertains parameters relative to the size and/or shape of the work product, for example, length, width, aspect ratio, thickness, thickness profile, contour (both two-dimensionally and three-dimensionally), outer contour configuration, perimeter, outer perimeter configuration, outer perimeter size and/or shape, volume and/or weight. Thus, the scanner <b>22</b> shown in <figref idref="DRAWINGS">FIG. 6</figref> operates in the same manner as scanner <b>22</b> shown in <figref idref="DRAWINGS">FIG. 1</figref>. The data from scanners <b>14</b> and <b>22</b> shown in <figref idref="DRAWINGS">FIG. 6</figref> is analyzed in the same manner as described above with respect to <figref idref="DRAWINGS">FIG. 1</figref> so as to be able to ascertain the existence of and location of voids, undercuts or other anomalies of the work product. Also, as described above, the data from scanners <b>14</b> and <b>22</b>, under certain conditions, can be combined to determine the extent or percentage of fat in meat work products.

0112Further, as also mentioned above, since the X-ray scanner <b>14</b> and optical scanner <b>22</b> are located apart from each other, they no longer simultaneously scan the same slice across the work product at the same time. Rather, X-ray scanning of the work product occurs first on the conveyor <b>100</b> then optical scanning of the work product occurs on conveyor <b>102</b>. As also described above, the information from the two scanners must be integrated together or otherwise transformed so that the data from the X-ray scanning corresponds to the same slice taken across the work product as when scanned by the optical scanner <b>22</b>.

0113For the foregoing analysis, it is important to verify that the data from the X-ray scanning device corresponds to the same work product as the subsequently obtained data from the optical scanning. In this regard, the control system <b>18</b> can identify coordinates along the outer perimeter of the work product as determined by the X-ray scanner and then by the optical scanner, and such data can be compared. If these data sets match within a fixed threshold level, then confirmation is provided that the work product scanned at the optical scanner is the same as the work product previously scanned at the X-ray scanner.

0114However, if for example, a work product was removed from conveyor <b>100</b>, or from conveyor <b>102</b> before the work product reaches the optical scanner <b>22</b>, then the next work product scanned at optical scanner <b>22</b> will not match the scanning data from the X-ray scanner <b>14</b>, since the X-ray scanning data will correspond to the work product that has been removed. Thus, the control system <b>18</b> will determine that there is no match between the perimeter coordinate data sets of the work products from the X-ray and optical scanners <b>14</b> and <b>22</b>. As such, the optical scanner <b>22</b> will scan the next work product which passes by to determine whether such next work product matches the scanning data of the work product scanned at the X-ray scanner <b>14</b> and transmitted to the control system <b>18</b>. The processor will determine whether the work product scanned at the optical scanner <b>22</b> corresponds to the work product that was scanned at the X-ray scanner <b>14</b> right after the X-ray scanning of the removed work product occurred. The control system <b>18</b> will match the correct scanning data from the X-ray scanner <b>14</b> with the scanning data from the same work product from the optical scanner <b>22</b>. Of course, this is essential so that the thickness profile information of the work product determined by the optical scanner <b>14</b> coincides with the work product scanned by the optical scanner <b>22</b>.

0115The control system <b>18</b> will go through the “matching” process a finite number of times. One example of determining the number of data sets from the X-ray scanner that must be checked can be determined as follows. Divide the distance between scanners by the sum of the length of product+the product gap+a dimensional factor of safety. For example, if there is a disclosure of 9 feet between the X-ray and optical scanners, and the work products are approximately 450 mm long product, then the maximum number of data sets in the queue that will be checked is calculated by: 9*12/(17.7+2+2)=4.9, so five matching attempts are made. The data set from the optical scanner will be compared to five data sets from the X-ray scanner stored in memory unit <b>82</b>. For longer length products the number of data sets in the memory queue is smaller than for shorter work products. Also, if the distance between the scanners is short enough, only one matching comparison is carried out. Also, it will be appreciated that differences or changes in belt speed can change the number of comparisons that are possible. With faster belt speed, there may need to be a larger gap between products and/or a larger safety margin and there will be less time to make the necessary calculations.

0116If no match occurs, a “no match found” error message is generated. The system proceeds to the next work product arriving in the optical scanner, and searching for the new work product is initiated.

0117If for example one work product is removed from the conveyor <b>100</b> after the X-ray scanning but before the optical scanning, only two matching attempts should be required before a match occurs. However, in the unlikely event that a work product WP is so distorted in the transfer from belt <b>104</b> to belt <b>30</b> that the control system <b>18</b> fails to recognize the X-ray image of the work product, then after the predetermined matching attempts the work product will proceed down the belt <b>30</b> without being cut and/or trimmed/portioned. The above noted error message is generated, and the uncut work product can be identified or marked by the control system <b>18</b> and can be removed to a specific location for re-working or other disposition.

0118It will be appreciated that there is no attempt to continuously track the location of the work product WP from X-ray scanner <b>14</b> to optical scanner <b>22</b>. Rather, the foregoing described methodologies are used to match the work product scanned at X-ray scanner <b>14</b> with the same work product scanned at optical scanner <b>22</b>. Also, although the foregoing description does indicate that the system of the present disclosure can be used to locate the work product on the first and/or second conveyor at one or more specific points in time, the specific location of the work product is not continuously tracked. Moreover, in the present system <b>10</b>′, it is not necessary to locate the work product at any specific time along the conveyance device <b>12</b>′.

0119The scanning data from the scanners <b>14</b> and <b>22</b> can be used to determine whether or not the work product has transferred accurately from conveyor belt <b>104</b> to conveyor belt <b>30</b> and determine what level of physical distortion or movement of the work product has occurred during the transfer process. Such distortion or movement may include shifting of the work product side-to-side with respect to the center line or other datum line of the conveyors. The work product may also have shifted longitudinally along the length of the conveyor relative to the position of the work product on the conveyor <b>100</b>.

0120If shifting of the work product occurs in the X and/or Y direction(s), then control system <b>18</b> functions to translate or manipulate the X-ray image of the work product and the underlying data from the X-ray imaging to the optically scanned image of the work product so as to improve the match of the shapes or outlines of the work products. This translation is schematically illustrated in <figref idref="DRAWINGS">FIG. 7A</figref>, wherein the work product as scanned at X-ray scanner <b>14</b> is shown in broken line and the work product as scanned at optical scanner <b>22</b> is shown in solid line. The control system <b>18</b> translates the broken line image onto the optical image shown in solid line in <figref idref="DRAWINGS">FIG. 7A</figref>.

0121Transfer of the work product from conveyor belt <b>104</b> to conveyor belt <b>30</b> may also result in rotation of the work product as shown in <figref idref="DRAWINGS">FIG. 7B</figref>, wherein the work product as scanned by X-ray scanner <b>14</b> is shown in broken line, whereas the work product as scanned by the optical scanner <b>22</b> is shown in solid line. So that the cutter(s) at the cutter station <b>26</b> can trim or cut the work product WP, the outline or shape data from the X-ray scanner <b>14</b> is transformed onto the image data from the optical scanner <b>22</b>.

0122A further type of distortion that may occur during transfer of the work product from belt <b>104</b> to belt <b>30</b> is that the work product may increase or decrease in scale (length) in the Y direction (across belt <b>30</b>) and/or in the X direction (along belt <b>30</b>). <figref idref="DRAWINGS">FIG. 7C</figref> shows that the work product has increased in scale in the Y direction, whereas <figref idref="DRAWINGS">FIG. 7D</figref> shows that the work product has increased in scale in the X direction. Of course, the work products may also decrease in scale in the X direction, especially if the scale is increased in the Y direction, and vice versa the work product may decrease in scale in the Y direction especially if increased in scale in the X direction. Nonetheless, the scanning data from the X-ray scanner <b>14</b> is transformed in terms of X and Y scale to the work product as scanned by the optical scanner <b>126</b>.

0123Another form of distortion that may occur during the transfer of the work product from conveyor belt <b>104</b> to conveyor belt <b>30</b> is a distortion in shear in the X direction, as shown in <figref idref="DRAWINGS">FIG. 7E</figref>. In shear distortion, the work product may progressively distort or shift in the X direction across the width of the work product as shown in <figref idref="DRAWINGS">FIG. 7E</figref>. Of course, the shear distortion may occur as a mirror image as that shown in <figref idref="DRAWINGS">FIG. 7E</figref>. Also, the shear distortion is shown as occurring progressively linearly across the work product, but the shear distortion also may be non-linear across the work product. As with other types of distortion, shear distortion may be due to various causes, such as a difference in the speeds of the conveyors or imperfect alignment of the two conveyors. As a result, in the direction across the conveyor belt, the work product may have progressively shifted rearwardly or forwardly relative to the direction of travel of the conveyor belt.

0124<figref idref="DRAWINGS">FIG. 7E</figref> shows a forward (in the right-hand direction) shifting of the work product on the second conveyor belt <b>30</b> due to shear distortion. As noted above, of course the shear distortion could have occurred in the opposite direction (in the left-hand direction) so that the work product extends rearwardly relative to the nominal position of the work product going across the conveyor belt.

0125<figref idref="DRAWINGS">FIG. 7F</figref> illustrates that shear distortion can occur in the Y direction, wherein the work product shifts laterally relative to the belt along the length of the work product. <figref idref="DRAWINGS">FIG. 7F</figref> shows shear distortion of the work product in the Y direction (upward along the page). It will be appreciated that the shear distortion may occur in the opposite direction than as shown in <figref idref="DRAWINGS">FIG. 7F</figref>.

0126Regardless of the direction of the shear distortion, the data from the X-ray scanner is transformed onto the work product as scanned at the optical scanner. Once the needed transformations have occurred to correct for movement and/or distortion of the work products, the shape, size, and outline of the work product from the optical scanner has been better matched to the position, orientation, and/or shape of the work product as scanned by the optical scanner.

0127It will be appreciated that without the foregoing transformation step or steps to correct or adjust for the distortion and/or shifting that may have occurred to the work product during transfer from conveyor <b>100</b> to conveyor <b>102</b>, the determination of the thickness and thickness profile of the work product may be erroneous. As such attempts to determine the location of voids, undercuts and other anomalies in the work product may prove unsuccessful.

0128As with the “matching” analysis described above to verify that the work product optically scanned at optical scanner <b>22</b> is the same work product that was previously scanned at X-ray scanner <b>14</b>, the data sets analyzed by the control system <b>18</b> to perform the above transformations may consist of coordinate locations along the outer perimeter of the work product. In this regard, the control system <b>18</b> may compare the data consisting of coordinate locations along the outer perimeter of the work product as determined at the X-ray scanner <b>14</b> with the corresponding coordinates of the same locations along the outer perimeter of the work product as determined at the optical scanner <b>22</b>. Such comparison of the data sets can be used to determine whether or not the work product upon transfer to the conveyor belt <b>20</b> has distorted or shifted, for example, in X-Y translation, rotation about the Z axis. Mismatch of the data sets will indicate what type(s) of distortion occurred and the extent of such distortion so that an appropriate correcting transformation of the X-Y scanning data can be applied to the work product as scanned by the optical scanner <b>22</b>.

0129Once the work product has passed the optical scanner <b>22</b>, it moves on to the cutting station <b>26</b>. As described above, the information from the X-ray scanner and the optical scanner are combined so that the location of voids, undercuts and other anomalies can be determined.

Method

0130A method of utilizing the processing system <b>10</b>′ of the present disclosure is schematically illustrated in <figref idref="DRAWINGS">FIG. 8</figref>. The process begins at step <b>300</b> wherein work products are loaded onto flat belt conveyor <b>100</b> at step <b>302</b>. Thereafter, the work products are scanned using X-ray scanner <b>14</b> at step <b>304</b>. Next, at step <b>306</b>, the data from the scanning of the work product is transmitted to image processor <b>46</b>.

0131Next, at step <b>308</b>, the work product is transferred from the X-ray scanning conveyor <b>100</b> to the portioning conveyor <b>102</b>. Thereafter, at step <b>310</b>, the work product is optically scanned by scanner <b>22</b>. Thereafter at step <b>312</b>, the data generated by the optical scanner <b>22</b> is transmitted to the image processor <b>46</b>, see step <b>312</b>.

0132Next, at step <b>316</b>, computer <b>80</b> compares the output from the image processor <b>46</b> to determine whether or not the work product being optically scanned is the same as that which was previously scanned by the X-ray scanner. As discussed above, the data being compared can consist of coordinate locations along the outer perimeter of the work product.

0133Various methods and techniques can be used to compare the first data set from the X-ray scanner <b>14</b> with the second data set from the optical scanner <b>22</b> to verify that the work product scanned by the optical scanner corresponds to the same work product previously scanned by the X-ray scanner. For example, the Root Mean Square (RMS) error between the two data sets can be calculated and such error value compared with the maximum RMS previously established for verifying that the food item scanned by the X-ray scanner is the same as the food item scanned by the optical scanner. In this regard, an RMS error is calculated for each corresponding coordinate locations along the outer perimeter of the work product. In essence, the difference in position of each of the coordinates is calculated as the root square of the sum of the squares of the difference in X and Y coordinate values. Thereafter, the square values of these distances are summed up, and the sum is divided by the number of corresponding coordinate pairs. Finally, the square root of the quotient is taken as an RMS error. The calculated RMS error is compared with the pre-established maximum RMS error allowable and still concluding that the same work product was scanned by the optical scanner and the X-ray scanner.

0134Another analysis methodology that may be utilized is by determining the difference in the X and Y coordinate values of each location along the work product and selecting a standard deviation that defines an acceptable variation or difference in the X-Y coordinate values. In this technique, a confidence level may be defined in terms of the standard deviation at each of the various coordinate locations along the perimeter of the work product. An acceptable confidence level or level of allowable standard deviation between the X-Y coordinate is established ahead of time.

0135Other regression analysis techniques may also be utilized, for example the least squares regression analysis.

0136If it is determined that the work product from the optical scan matches that of the previous X-ray scan, then at step <b>320</b>, the control system <b>18</b> proceeds to determine if there is a need to transform physical parameter data from the X-ray scanning results to the optical scanning results due to movement or distortion of the work product when transferred to the portioning conveyor <b>102</b>. As discussed above, such distortion may include X and/or Y translation of the work product, rotation of the work product about the Z axis, change in scale of the work product in the X and/or Y directions, and shear distortion in the X and/or Y directions. If sufficient shifting or distortion in the work product WP has occurred, then the requisite transformations are carried out by the processor <b>18</b>. As a result, a close match is achieved between the configuration, including, for example, outer perimeter and size and shape of the work product as scanned by the X-ray scanner <b>14</b> and optically scanned by the optical scanner <b>22</b>.

0137If, on the other hand, it is determined that the work product WP from the optical scan does not match that of the previous X-ray scan, then the processor at step <b>318</b> compares the optically scanned data with the next data set received from the X-ray scanning to determine whether the next work product on the conveyor belt is the same as the work product from the optical scan. In this situation, if a single work product was removed from either first conveyor <b>100</b> or second conveyor <b>102</b> at a location upstream from the optical scanner <b>14</b>, then the next work product traveling along the conveyors will correspond to the work product which was optically scanned. However, if more than one work product WP was removed from the conveyors upstream from optical scanner <b>22</b>, then the computer <b>80</b> continues with the comparison analysis until a match occurs between the work product, which has been optically scanned, and the corresponding work product which has been scanned at X-ray scanner. Once a match has been achieved in the data sets from the X-ray scanning and the optical scanning, then the process moves to step <b>320</b> to determine if there is a need to carry out any transformations as discussed above.

0138Next, at step <b>322</b>, the thickness profiles of the work product are generated from the X-ray and optical scanning data. Thereafter, at step <b>324</b> the thickness profiles from the X-ray scanning data and the optical scanning data are analyzed for the presence of undercuts, voids and other anomalies in the work product, and if undercuts, voids or anomalies exist, then the location, size and shape of such are mapped at step <b>324</b>.

0139Thereafter, the cutting path or paths for cutter <b>90</b> is generated at step <b>326</b> bearing in mind the result of the analysis at prior step <b>324</b>. Next, at step <b>328</b>, the work product is trimmed, cut, or otherwise portioned in the manner determined at step <b>326</b>. Next, at step <b>330</b>, the work product can be subjected to one or more further processing operations.

Further Embodiment

0140<figref idref="DRAWINGS">FIGS. 9 and 10</figref> illustrate a further processing system <b>10</b>″ and method in accordance with the present disclosure. The components and parts of system <b>10</b>″ shown in <figref idref="DRAWINGS">FIG. 9</figref> that are the same as in <figref idref="DRAWINGS">FIGS. 1-4 and 6</figref> are identified with the same reference numbers, and their descriptions will not be repeated here. Rather, the following description will focus on the changes or differences in the system <b>10</b>″ and the method as shown in <figref idref="DRAWINGS">FIGS. 9 and 10</figref> relative to that illustrated in <figref idref="DRAWINGS">FIGS. 1-8</figref>. Nonetheless, it is to be understood that applicable components and parts of system <b>10</b>″ do apply to the embodiment of <figref idref="DRAWINGS">FIG. 1</figref>. The same pertains to the steps of <figref idref="DRAWINGS">FIG. 5</figref>.

0141Referring to <figref idref="DRAWINGS">FIG. 9</figref>, the portioning system <b>10</b>″ includes X-ray scanner <b>14</b> and optical scanner <b>22</b> in the same manner as shown in <figref idref="DRAWINGS">FIG. 1</figref> except located over a smooth X-ray pervious belt <b>100</b>′ rather than over the open weave belt <b>30</b> shown in <figref idref="DRAWINGS">FIG. 1</figref>. Further, the system <b>10</b>″ shown in <figref idref="DRAWINGS">FIG. 9</figref> includes a second optical scanner <b>120</b> located over the belt <b>30</b> of second conveyor <b>102</b>″. Although the optical scanner <b>120</b> is illustrated as being of substantially the same construction as scanner <b>22</b>, other types of optical scanners could be used for both optical scanner <b>22</b>″ and <b>120</b>. For example, these optical scanners can utilize charged coupled devices (CCD) or infrared cameras.

0142One difference in system <b>10</b>″ versus system <b>10</b>′ is that the X-ray scanner <b>14</b> need not be used to determine the outer contours of the work product and then such data translated into the data from optical scanner <b>120</b> located above conveyor <b>102</b>′. Rather, the data pertaining to the outer contour of the work product can be obtained from the optical scanner <b>22</b> located above the first conveyor <b>100</b>′ and such data pertaining to the outer contour of the work product can be compared with corresponding data obtained from downstream optical scanner <b>120</b>. Thus, the type of data being generated with respect to determining the outer contour of the work product is of the same nature thereby reducing the complexity of comparing the two data sets from the two optical scanners <b>22</b> and <b>120</b>.

0143Other than as just described, the processing apparatus <b>10</b>″ shown in <figref idref="DRAWINGS">FIG. 9</figref> is the same as the processing system <b>10</b>′ shown in <figref idref="DRAWINGS">FIG. 6</figref>. Moreover, since the imaging process of the two optical scanners <b>120</b> and <b>22</b> are the same, a better match between the data from the two optical scanners may occur than when using data from X-ray scanner <b>14</b> and optical scanner <b>22</b> in seeking to confirm that the same work product is being scanned by the optical scanner <b>22</b> as previously scanned by the X-ray scanner <b>14</b> as well as when seeking to determine whether the work product has moved to such an extent during transfer from the upstream smooth belt conveyor to the downstream portioning conveyor that the data pertaining to the physical parameters of the work product from the upstream scanner must be transformed with respect to the data obtained from the downstream scanning

Method

0144The method of utilizing the processing system <b>10</b>″ of the present disclosure is schematically illustrated in <figref idref="DRAWINGS">FIG. 10</figref>. To a large extent, the method shown in <figref idref="DRAWINGS">FIG. 10</figref> is the same as shown in <figref idref="DRAWINGS">FIG. 8</figref>, with the differences primarily due to the use in a system <b>10</b>″ of a second optical scanner <b>120</b> positioned over the portioning conveyor <b>102</b>. Accordingly, the steps in <figref idref="DRAWINGS">FIG. 10</figref> that are the same as in <figref idref="DRAWINGS">FIG. 8</figref> are indicated with the same part numbers, and the steps that are similar to the steps of <figref idref="DRAWINGS">FIG. 8</figref> are indicated by use of a double prime (″) after the number of the step. As such, the following description will focus on the differences between a method in <figref idref="DRAWINGS">FIG. 10</figref> versus the method in <figref idref="DRAWINGS">FIG. 8</figref>.

0145With respect to the method of <figref idref="DRAWINGS">FIG. 10</figref>, in step <b>307</b><i>a </i>the work product is optically scanned simultaneously with the X-ray scanning, and at the same location across the work product, for example, as shown above in <figref idref="DRAWINGS">FIG. 1</figref> and discussed in the method illustrated in <figref idref="DRAWINGS">FIG. 5</figref>. In step <b>307</b><i>b</i>, the first optical scanner data is sent to image processor <b>46</b>.

0146At step <b>314</b>″, the data from the X-ray scanning and both optical scanners is processed by the image processor <b>46</b>. Then at step <b>316</b>″, the optical scanner data from the scanner <b>112</b> is compared with the data from the scanner <b>14</b> to verify that the work product is the same. If not, then the process moves to step <b>318</b>″ in the same manner as described above, but in the present situation using data from the two optical scanners rather than data from an X-ray scanner and an optical scanner. Further, at step <b>320</b> a determination is made if transformation of the data from the first optical scanner <b>14</b> needs to be integrated into the data from the second optical scanner <b>120</b> due to movement or distortion of the work product when transferred from conveyor <b>100</b> to conveyor <b>102</b>. Other than these steps, the process shown in <figref idref="DRAWINGS">FIG. 10</figref> coincides to the process shown in <figref idref="DRAWINGS">FIG. 8</figref>.

0147While illustrative embodiments have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention. For example, the foregoing describes X-ray scanning occurring prior to optical scanning or that X-ray and optical scanning occur at the same time. It is to be understood that the present disclosure also envisions optical scanning occurring ahead of X-ray scanning and then the data from both optical and X-ray scanning being analyzed to determine the presence of voids, undercuts and similar anomalies due to the differences in the thickness profile of the work product as determined by analysis of the data from the optical scanning and X-ray scanning.

0148As another embodiment of the present disclosure, it is contemplated that in some situations similar to that of <figref idref="DRAWINGS">FIG. 9</figref>, the transfer of the work product from conveyor <b>100</b> to conveyor <b>102</b> may occur accurately enough that a second optical scanner, such as scanner <b>120</b>, is not needed. In this situation, small diameter end rollers at each end of the conveyor may be use at the interface of conveyors <b>100</b> and <b>102</b>. Or a transfer conveyor having small diameter end rollers may be used to bridge between conveyors <b>100</b> and <b>102</b>. As such, the processing of the work product can occur on conveyor <b>102</b> without the need for the second scanner <b>120</b>. See, for example, US Publication No. 2018/0029246, which is incorporated by reference herein. This could simplify the processing system and method and also enable faster throughput of the work products.

0149While illustrative embodiments have been illustrated and described, it will be appreciated that various changes can be made therein without departing from the spirit and scope of the invention.