BACKGROUND

[0001] This application claims priority to U.S. Provisional Application No. 63/338,687 filed 05 May 2022, entitled "System and Method of Quality Checking Contents of a Shipping Order", and hereby incorporates herein by reference the entirety of the aforementioned provisional application.

FIELD

[0002] The present disclosure relates to a method of quality checking contents of a shipping order. More specifically, the present disclosure relates to a method for quality check of contents in a shipping order based on X-Ray imaging, weight checking, and RFID detection, where each of these process checking subsystems are modular.

BACKGROUND

[0003] Packing and shipping different product orders of electronic components is time consuming. Once a shipping box is packed, manually performing a quality control process requires an inspector to open the box, check the contents of the box, match it against a Bill of Materials (BOM) for the order, and verify the serial number of the electronic components to confirm the materials are in the box. The results of the above process can be logged into a system or not, depending on what is required and the individual performing the inspection. This process relies on the individual performing the BOM check, hence adding a certain amount of subjectivity and inherent human error.

[0004] Optionally, a semi-automated system can be used that involves an X-ray detector. A software application including a graphic user interface (GUI) such as that shown in Fig. 7 can be used to display a BOM necessary to fulfill a shipping order and an X-ray image of contents of a box. A trained inspector is required to check/uncheck boxes on the GUI to verify the contents of a box so that the information can be sent to a programmable logic controller. As the box passes through the X-Ray imaging system and an X-ray image is obtained, the image is displayed on the right picture box, and the list of required materials is displayed on the left. The inspector then visually compares the BOM to the image of the box contents and checks/unchecks boxes on the GUI. The WAIT button converts to a PASS button. If the inspector unchecks any item from the list, the button turns to FAIL.

[0005] Speeding up the process and verifying the accuracy of a box packed based on a particular order is desirable to decrease costs associated with fulfilling the orders and to increase customer satisfaction. Thus, there is a need for process automation to increase reliability and repeatability of a shipping quality control process before a shipment is sent out. In addition, it is desirable to generate a data log of each individual order processed and shipped so that this data can be collected and used for process control, inventory management, verification of order status, reconciliation of a product return, or other analytical management. [0006] To overcome the problems described above, preferred embodiments of the present disclosure automate the entire process to remove the objectivity described above and also log each and every result into a digital format.

[0007] According to an embodiment of the present disclosure, a system to verify contents of a box includes a barcode label on the box that corresponds to order information; a conveying system to physically move the box through an inspection station; a barcode scanner along the conveying system to scan the barcode label; the inspection station including an X-ray imaging system that creates an X-ray image of contents in the box and forwards the X-ray image to a computer; the computer that runs an object detection algorithm to detect a contents of the box based on the X-ray image; and a programmable logic controller that receives the contents of the box from the computer and forwards the contents of the box and the order information to a database that compares the contents of the box and the order information.

[0008] According to another embodiment of the present disclosure a method of verifying contents of a box includes conveying the box through an inspection station; scanning a barcode label on the box, the barcode label corresponding to order information; capturing a X-ray image of contents of the box as the inspection station and forwarding the X-ray image to a computer; determining a contents of the box by the computer running an object detection algorithm based on the X-ray image; transmitting the order information and the contents of the box to a database; comparing by the database the contents of the box and the order information. [0009] The above and other features, elements, characteristics, steps, and advantages of the present invention will become more apparent from the following detailed description of preferred embodiments of the present invention with reference to the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] Fig. 1 is a layout of an automated system to quality check packed boxes according to an embodiment of the disclosure.

[0011] Fig. 2 is a block diagram of a communication and control system.

[0012] Fig. 3 is an image of Zones 300-800.

[0013] Fig. 4 is an image of Zones 800-1200.

[0014] Fig. 5 is an image of Zone 1300.

[0015] Fig. 6 is an image of boxes including labels.

[0016] Fig. 7 shows a graphic user interface of a manual check software.

[0017] Fig. 8 is a CAD drawing of the system to quality check packed boxes.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

[0018] Fig. 1 is a layout of an automated routing and inspection system to quality check packed boxes prior to shipment according to an embodiment of the disclosure. Fig. 8 is a CAD drawing of the system. The system is a conveying system that moves, inspects, and sorts boxes. As shown, the system can include four designated sections, Sections 1-4, where each section can include at least one zone. The purpose of these zones is to create spacing such that one box is on one zone at one time so that multiple boxes do not bottle neck or go into the inspection stations at the same time. The motion of the boxes in these zones is controlled by motor driven rollers (MDRs) and MDR controllers connected to a Programmable Logic Controller (PLC). There are proximity sensors or PhotoEyes (PEs), indicated as triangles in Fig. 1, in each zone that detect boxes and feedback to the PLC. The PLC logic determines if the box can move forward or should stay in the zone.

[0019] Each box has a label with the barcode of the order number which can be scanned to look up the contents, weight, and/or RFID tags relating to that order. Scanners, indicated as numbered squares shown in Fig. 1, scan the barcode on the box and save the condition after the respective section with reference to the order number. Examples of boxes with a barcode label with the barcode representing the order number are shown as the smaller label in Fig. 6. [0020] Section 1 is at the input of the system and includes infeed Zones 100 and 200. The boxes containing the packed orders are fed to the system through these zones and metered via Scanner 1. A Motionlinx controller communicates with the PLC to start and stop the MDRs in each zone. As the boxes move through the zones, the PEs detect the box, send a signal to the PLC indicating a box has passed through the zone. The PLC then sends a command to the Motionlinx controller to stop the MDR of the zone where the box has already passed, and start the MDRs of the zone where the box is entering. Upon leaving Section 1, the boxes enter Section 2.

[0021] Section 2 includes zones 300 and 400. Zone 300 is the X-Ray imaging system. As the box passes through the X-Ray imaging system, an image created is sent to a computer that runs an Object Detection Algorithm to detect the contents of the box. For example, the Object Detection Algorithm can be based on the YOLOv4 model or another suitable tool. YOLOv4 is a machine learning object detection model that involves teaching a computer to recognize objects in an image. After the computer determines the contents of the box, the information of contents of the box is then transferred to the PLC. Once that information is received, the box is moved onto Zone 400 in which the box is justified toward one edge of the conveying system so that every box is located at the same relative position as it moves through the system, as will be discussed in more detail below. Upon leaving Section 2, the boxes enter Section 3.

[0022] Section 3 includes Zones 500 and 600 and 700. Physically, Zones 500 and 600 reside in the same location. Zone 600 is a movable fixture that covers the conveying line over the top of Zone 500, as shown in Fig. 3. Zone 500 is a Weight Checker that weighs the box. As the box passes through Zone 500, the weight of the box is measured and sent to the PLC. Zone 600 is a RFID reading system which is triggered to start reading RFID tags as soon as the box enters Zone 500/600. For example, the shipping order can include electronic equipment with a unique identifier such as a serial number or a MAC address. When the order is prepared, this electronic equipment is applied with an RFID tag that is encoded with that unique identifier. As the box leaves Zone 600, a stop read trigger is sent to the RFID read system. The data of any RFID tags read are sent to the PLC.

[0023] Scanner 2 scans the order number on a label on the box, and ties the results of Section 3 with the results of Section 2. For example, when the box passed through Section 2, data is stored in the PLC with the order number and contents of the box. As the box passes through the Section 3, the RFID tags and weight of the box are recorded. Scanner 2 reads the order number and adds information from the RFID tags and weight to the data associated with the contents of the box. At the end of Section 3, the data will contain contents of the box, information from the RFID tags, and weight.

[0024] When the box reaches Zone 700, the PLC has all the required information to perform a quality control check of the order. As such, the contents of the box have been received from the computer after detection in Zone 300, the weight from Zone 500, and RFID tag information of the electronic equipment in the box in Zone 600. In the quality control check, the PLC sends a request to a database with this information to compare with the order information (i.e, BOM, weight, and serial number/MAC identifier). The database can be any database which is configured to accept the above request. The PLC receives a confirmation from the database whether or not the information provided from the PLC matches the order information. Upon leaving Section 3, the boxes enter Section 4.

[0025] Section 4 includes Zones 800-1300 and Zone 1500. The physical location of the Zone 1300, a print and apply (P&A) system, is the same as Zone 800, as shown in Fig. 5. If a positive match is confirmed at Zone 700, Zone 1300 is instructed to print a shipping label associated with the order. If a match is not confirmed at Zone 700, Zone 1300 is instructed to print a FAIL label. As the box moves through the Zone 800/1300, the movement triggers a proximity sensor on the P&A system and the correct label is applied to a side of the box. Fig. 6 shows bigger shipping labels next to the smaller barcode labels. The reason to justify the boxes towards the side of the conveying system is so that every box is at the same distance from the P&A system and the labels can be properly located repeatedly. As the box moves through Zone 800, Scanner 3 reads the barcode label and the second label (i.e., shipping label or FAIL label). The result of this read is sent to the PLC. There are three possible combinations of this read: (i) Shipping order number + shipping label for Ground Shipping, (ii) Shipping order number + shipping label for Express shipping, or (iii) Shipping order number + FAIL label. The PLC controls the movement or sorting of the box based on the result of the Scanner 3 read.

[0026] As shown in Fig. 1, Zone 1000 is next to Zone 900 and not on a straight-through path. Zones 900 and 1100 have the capability to move boxes either straight-through or horizontally. If the read combination is (i) (Shipping order number + shipping label for Ground Shipping), the PLC moves the box from Zone 800 to Zone 900 to Zone 1100. If the read combination is (ii) (Shipping order number + shipping label for Express shipping), the PLC moves the box from Zone 800 to Zone 900 to Zone 1000 to Zone 1200. If the read combination is (iii) (Shipping order number + FAIL label), the PLC moves the box from Zone 800 to Zone 900 to Zone 1000 to Zone 1500 (Gravity Conveyor).

[0027] Zone 1100 (Ground) and Zone 1200 (Express) lead the box directly to shipping trucks where the boxes are loaded to be shipped. Zone 1500 (Gravity Conveyor) moves the box to a location where a manual check can be performed to determine what items are missing from the box or discrepancy failed to cause a match so that corrective action can be taken.

[0028] Each of the Zones or subsystem explained above are modular in design. Each of the zones has wheels at the bottom and can be moved to a new location, different order, and/or removed from the system. For example, if a quality check of only the box weight is required, the Zones 200 (X-Ray Imaging system) and 500 (RFID read system) can be removed from the line. This makes deployment of system very flexible. All of the inspection data collected for every box is stored in an inspection database for review and analysis.

[0029] Fig. 2 is a block diagram of the communication and control system used to interface with and operate the system described with respect to Fig. 1. The communication and control system shown in Fig. 2 includes the following components.

[0030] A programmable logic controller (PLC) is included. This is where all the control logic resides, and all the outputs are decided based on inputs and states of different portions of the system. The PLC uses two communication protocols, EtherCAT and EthernetIP, both of which are industry standards. [0031] The EtherCAT switch connects the PLC to all the devices which are EtherCAT compatible. In Fig. 2, these devices are MotionLinx MDR controllers and the RFID reader.

[0032] A power over Ethernet (PoE) switch is a regular Ethernet industrial protocol (IP) switch with Power over Ethernet capabilities which connects the PLC to all the Ethernet IP devices. In Fig. 2, these devices are the Cognex barcode readers (scanners), and the Scale (Weightchecker).

[0033] The MotionLinx MDR Controllers control the motor driven roller, and hence control the physical flow of boxes. The inputs to these controllers are the PhotoEyes that detect whether a box is present in a particular zone. This input is relayed to the PLC which makes the decision to turn the zone ON (move the box forward) or OFF (keep the box in the current zone). [0034] The RFID reader reads the RFID tags as the boxes move through the given zone.

[0035] The Cognex Barcode reader (scanners) read the 2D barcode presented in front of them and relay the information to the PLC for decision making based on the logic required.

[0036] The Scale (Weightchecker) measures the weight of the box and relays the information to the PLC for decision making based on the logic required.

[0037] A network switch connects the PLC to the internet and other computers and systems which are required to be online. In Fig. 2, these devices are a PC for user interface for X-Ray image display and storage (Dell PC), the print and apply (P&A) system, and an internet drop.

[0038] The Dell PC is a computer that communicates with the X-ray imaging system and displays the image of the box on the screen, saves a copy of the image locally, and also communicates with the PLC regarding the contents of the box.

[0039] The print and apply (P&A) system prints a label and applies it to a box based on the decisions the PLC makes whether to PASS or FAIL the box.

The X-Ray imaging system takes images of the boxes passing through it, and transfers the image to the Dell PC for further evaluation purposes.

[0040] It should be understood that the foregoing description is only illustrative of the present invention. Various alternatives and modifications can be devised by those skilled in the art without departing from the present invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications, and variances that fall within the scope of the appended claims.