The present disclosure relates generally to the field of mail and parcel processing, and in particular, to a system and a method for correcting parcel singulation yield.
Parcel distribution centers typically receive large quantities of parcels or packages, often widely varying in size, that are unloaded en masse from trucks or other transportation media. The packages merge into a central area in a random order and orientation where they are oriented and aligned in a single file by singulators for further processing. The further processing may include, for example, scanning of destination-identifying bar codes and sortation to destination areas for subsequent loading onto trucks or other transportation media.
State of the art techniques in parcel singulation exhibit varying degrees of accuracy. When more than one parcel is presented as a single parcel, this represents an error in singulation, commonly called a “double feed”, even though more than two parcels can be involved in each instance. When a singulation error occurs, multiple parcels tend to be processed as one, which typically results in the mis-sorting of at least one parcel. This, in turn, can result in delayed or even incorrect delivery of goods.
Briefly, aspects of the present disclosure are directed to a improved technique for detecting and correcting parcel singulation errors.
A first aspect of the present disclosure is directed to a parcel processing system. The parcel processing system comprises a conveyor segment configured to transport a stream of singulated items received from a parcel singulator. The parcel processing system further comprises an imaging device configured to discretely capture an image of each singulated item of the stream of singulated items transported on the conveyor segment. The parcel processing system further comprises an automatic recognition system configured to process the captured images and utilize a binary classification model to generate a classier output designating each image as a positive, representing a singulation error, or as a negative, representing a correct singulation. The parcel processing system further comprises an operator station configured to selectively receive a sequence of images from the automatic recognition system to enable an operator to validate the classifier output for the received images, for identifying false positives and/or false negatives therefrom. The parcel processing system is configured to process items associated with images that are identified as false positives at the operator station as correctly singulated items and/or to process items associated with images that are identified as false negatives at the operator station as incorrectly singulated items.
A second aspect of the present disclosure is directed to a method for processing parcels. The method comprises transporting, on a conveyor segment, a stream of singulated items received from a parcel singulator. The method further comprises capturing an image of each singulated item of the stream of singulated items transported on the conveyor segment. The method further comprises feeding the captured images to an automatic recognition system, whereupon the automatic recognition system processes the captured images and utilizes a binary classification model to generate a classier output designating each image as a positive, representing a singulation error, or as a negative, representing a correct singulation. The method further comprises selectively receiving a sequence of images at an operator station for validating, by an operator, the classifier output for the received images, to identify false positives and/or false negatives therefrom. The method further comprises processing items associated with images that are identified as false positives at the operator station as correctly singulated items and/or processing items with images that are identified as false negatives at the operator station as incorrectly singulated items.
Additional technical features and benefits may be realized through the techniques of the present disclosure. Embodiments and aspects of the disclosure are described in detail herein and are considered a part of the claimed subject matter. For a better understanding, refer to the detailed description and to the drawings.
The foregoing and other aspects of the present disclosure are best understood from the following detailed description when read in connection with the accompanying drawings. To easily identify the discussion of any element or act, the most significant digit or digits in a reference number refer to the figure number in which the element or act is first introduced.
Various technologies that pertain to systems and methods will now be described with reference to the drawings, where like reference numerals represent like elements throughout. The drawings discussed below, and the various embodiments used to describe the principles of the present disclosure in this patent document are by way of illustration only and should not be construed in any way to limit the scope of the disclosure. Those skilled in the art will understand that the principles of the present disclosure may be implemented in any suitably arranged apparatus. It is to be understood that functionality that is described as being carried out by certain system elements may be performed by multiple elements. Similarly, for instance, an element may be configured to perform functionality that is described as being carried out by multiple elements. The numerous innovative teachings of the present disclosure will be described with reference to exemplary non-limiting embodiments.
To prevent delayed or incorrect delivery of goods, it is desirable that errors in singulation are corrected on site. For this, the output of a parcel singulator may be continuously monitored to identify and remove incorrectly singulated items from a stream of singulated items. The monitoring may be done, for example, by positioning one or more operators downstream of the parcel singulator. The operators have the job of visually observing the stream of singulated items coming out of the parcel singulator, typically at a high rate, to identify incorrectly singulated items. Once identified, the incorrectly singulated items may be removed either manually or automatically (for example, via an automatic divert system). Another possibility of monitoring singulation output is to leverage machine vision to recognize incorrectly singulated items so that they can be automatically removed from the stream of singulated items.
The present inventors have devised an improved technique for detecting and correcting errors in parcel singulation. The technique utilizes an automatic recognition system based on captured images of the singulated items received from the parcel singulator. The automatic recognition system utilizes a binary classification model which produces an output designating each image as a positive, representing a singulation error, or as a negative, representing a correct singulation. The classification model may be tuned for a high detection rate at the cost of a high false positive rate. Rather than act on the results of the automatic recognition system alone, the images along with their classifier output from the automatic recognition are presented to a human operator for validation, identify false positives and/or false negatives. Subsequent processing of the items is carried out based on the correction of the false positives and/or false negatives. The present technique provides an improvement over the above-described approaches and is particularly suited to applications that require a lower operator duty cycle and/or a lower rate of failure (either a false positive or false negative).
Turning now to the drawings,
In the shown configuration, the parcel singulator 106 comprises a merge conveyor 108 that converges a two-dimensional stream of items (or parcels) 104 with spacing in X and Y directions into a single file with spacing only in X direction, followed by an alignment conveyor 110 that aligns the converged stream of items 104 against a wall 112 to align the items. Though not shown, the parcel singulator 106 may additionally comprise an upstream singulation device that converts a bulk flow of items into a two-dimensional stream of items with metered spacing in the transport direction (X direction). The merge conveyor 108 and the alignment conveyor 110 may comprise, for example, angled rollers. The shown configuration of the parcel singulator is exemplary, it being understood that several other types of singulator configurations may be used.
The output of the parcel singulator 106 is typically a one-dimensional stream of singulated items 104, which is received and transported on the conveyor segment 102 for subsequent processing. The term “singulated item” refers to a discretized output from the parcel singulator, which may either be a correctly singulated item, consisting of a single item, or an incorrectly singulated item (also referred to as singulation error or “double feed”), where more than one item is presented as a singulated item. Incorrectly singulated items 104 are identified with the notation (E) in
An exception handling system 114 may be located downstream of the conveyor segment 102. In the shown example, the exception handling system 114 includes a main conveyor 116 and an extraction conveyor 118 oriented at an angle to the main conveyor 116. The extraction conveyor 118 may be used for extracting incorrectly singulated items 104(E) that are identified using the present technique, as well as for extracting other exceptional items, such as non-conveyable items, among others. The regular or correctly singulated items 104 may be transported along the main conveyor 116 toward a sorting location. The main conveyor 116 may comprise rollers 120, where each roller 120 is configured to rotate about a rotation axis, for transporting the items, and is pivoted about a pivot axis. The pivot angle of the rollers 120 may be controllable for diverting items that are identified as exceptional toward the extraction conveyor 118. The extraction conveyor 118 may comprise a belt conveyor, or a roller conveyor, or combinations thereof, or any other transport mechanism. In one embodiment, a gapping system may be provided downstream of the exception handling system 114, to correct inconsistencies in spacing between the items, for example, resulting from the extraction of exceptional items from the stream, prior to being sent to a sorter. In an alternate embodiment, the sorter itself may be provided with exception handling capability, for example including diverting mechanism such as cross-belts, tilt trays, shoes movable on slats (shoe sorter), among others, for separating exceptional items from regular items.
As shown in
The captured images 134 are communicated to an automatic recognition system 126, typically as digital data comprising pixel information. The automatic recognition system 126 may comprise one or more computers or computing devices including a combination of hardware and/or software specifically configured to process and classify the captured images 134 to detect singulation errors. For example, the automatic recognition system 126 may be provided with image processing hardware, such as a central processing unit (CPU), a graphics processing unit (GPU), a field programmable gate array (FPGA), among others, or any combinations thereof. The automatic recognition system 126 may be configured to perform one or more machine vision based image processing steps on the captured image data, for example but not limited to, filtering, thresholding, segmentation, edge detection, pattern recognition, etc. The automatic recognition system 126 may then use a binary classification model (or “classifier”) to generate a classier output designating each image as a positive, representing a singulation error, or as a negative, representing a correct singulation. In some embodiments, the automatic recognition system 126 may be configured to select one or more classification models among several available classification models that represent the system.
A binary classification model represents a mapping of instances (images) into two classes. In this case, the two classes include a positive class (representing singulation error) and a negative class (representing correct singulation). For a given classification model, the variable distance in feature space between the mapped instances correlates to an ambiguity of the model. As an illustration, a two-dimensional feature space 200 is shown in
Referring to
The automatic recognition system 126 may be configured to leverage one or more classification models tuned to a discrimination threshold setting that aggressively provides a high detection rate at the cost of a high false positive rate. In one embodiment, this may be achieved by using the one or more classification models at a discrimination threshold setting that is above a knee-point in the ROC curve associated with the respective model. A knee-point in the ROC curve is a point beyond which the curve vector begins to flatten or change in slope toward being asymptotic with the x-axis. Above the knee-point, the false positive rate increases significantly with an increase in detection rate. For example, in the case of the model M2 in
The high detection rate resulting from the above-described setting of the discrimination threshold ensures that singulation errors are captured to a maximum extent. The resulting increase in failure rate (false positives) may be continuously corrected by selectively presenting only the “positive” results from the automatic recognition system 126 to an operator for validation. Thus, the overall failure rate due to both false positives and false negatives is significantly reduced. Furthermore, by having an operator validate only “positive” results from the automatic recognition system 126, the operator duty cycle is also significantly reduced.
Referring back to
The sequence of images 136 received at the operator station 128 may comprise both designated positive images and designated negative images. In the described embodiments, the sequence of images 136 received at the operator station 128 selectively consists only of designated positive images. For each classifier output, the automatic recognition system 126 may use the respective classification model to determine a confidence level of the output. For example, the confidence level of a “positive” classifier output for an instance (image) may be quantitively determined as a function of a distance in feature space of that instance from the center of the “positive” cluster, among other factors. For illustration, referring to
In the validation process, an operator makes a visual validation that the images actually reflect singulation errors. When the operator identifies a false positive, i.e., determines than an image does not indicate a singulation error, the item associated with that image is processed as a correctly singulated item 104 and is allowed to proceed to subsequent processing, such as sorting. When the operator identifies a false negative, i.e., determines than an image does indicate a singulation error, the item associated with that image is processed as an incorrectly singulated item 104(E). Items 104(E) associated with images that are validated by the operator as truly indicating a singulation error (true positive or false negative) may be extracted from the stream of singulated items 104 by the exception handling system 114 as described above.
As shown in
The described architecture of the parcel processing system 100 makes it possible for multiple human operators to serve the validation workflow of a single parcel singulator. Furthermore, by reducing the operator duty cycle using the described techniques, it is possible for a single operator station 128 or even a single operator to serve the validation workflow of multiple parcel singulators of the parcel processing system 100. In one embodiment, the operator station 128 may located remotely (for example, in a different building or geographic location) from the parcel singulator(s). In some embodiments, the operator station 128 may be co-located with the automatic recognition system 126.
In a further development, the parcel processing system 100 may comprise a feedback module 132 comprising one or more computers with memory configured to store and provide analyses of classifier outputs that are identified as false positives and/or false negatives at the operator station 128. The results 138 from validation would thus present a basis for continued refinement of the automatic recognition system 126 through engineering development and tuning. As the singulation system operates, the validation results 138 pertaining to images associated with false positives and/or false negatives may be stored. Over time, analysis may be applied to the data regarding false positive and/or false negative events. In one embodiment, this may comprise a manual data mining process, through which common characteristics or features are identified and associated with the false positive and/or false negative events, but not true positive or negative events. Once these features are identified, improvements 140 can be introduced to the automatic recognition system 126 to reduce the proportion of false positives and/or false negatives. In another embodiment, the feedback module 132 may utilize a machine learning model to automatically analyze the stored data. The machine learning model may include, for example, one or more neural networks. The stored validation results 138 may be used as training data to continuously or periodically re-train the neural network(s) to improve the accuracy of the automatic recognition system 126. The feedback module 132 thus enables using “ground truth” from the process to adapt the classifier of the automatic recognition system 126. Although identified separately in
Block 402 involves transporting a stream of singulated items received from a parcel singulator on a conveyor segment. The singulated items on the conveyor segment may include both correctly and incorrectly singulated items received from the parcel singulator. In one embodiment, the conveyor segment has a length that accommodates a latency between the execution of block 404 and block 412 of the method 400.
Block 404 involves discretely capturing one or more images of each singulated item being transported on the conveyor segment. For each item, an image of at least one side and up to all six sides of the item may be captured.
Block 406 involves feeding the captured images, typically as digital image data comprising pixel information, to an automatic recognition system.
At block 408, the automatic recognition system performs image processing and uses one or more binary classification models to generate a classier output for each image, designating each image as a positive, representing a singulation error, or as a negative, representing a correct singulation. The one or more classification models may be tuned to a discrimination threshold setting that results in a high detection rate at the expense of a high false positive rate. In one embodiment, the one or more classification models may be used at a discrimination threshold setting that is above a knee-point in the ROC curve associated with the respective classification model.
Block 410 involves selectively receiving a sequence of designated positive images at an operator station. In one embodiment, a confidence level is determined by the automatic recognition system for each “positive” classifier output, wherein the sequence of designated positive images received at the operator station consists of images for which the classifier output is positive with a confidence level below a threshold confidence level. In another embodiment, the sequence of designated positive images received at the operator station consists of all images for which the classifier output is positive.
Block 412 involves visual validation of the images received at the operator station by a human operator, to identify false positives and/or false negatives therefrom.
Block 414 involves subsequent processing of the singulated items based on the correction of false positives and/or false negative. Items associated with images that are identified as false positives at the operator station are processed as correctly singulated items and may be allowed to proceed to subsequent processing, such as sorting. Items associated with images for which the classifier output is validated as true positive and/or false negative at the operator station may be extracted from the stream of singulated items by an exception handling system located downstream of the conveyor segment.
A further operational block 416 may comprise storing and providing analyses of classifier outputs that are identified as false positives and/or false negatives at the operator station, for development and/or tuning of the automatic recognition system. In one embodiment, a machine learning model may be used for providing said analyses.
The system and processes of the figures are not exclusive. Other systems and processes may be derived in accordance with the principles of the disclosure to accomplish the same objectives. Although this disclosure has been described with reference to particular embodiments, it is to be understood that the embodiments and variations shown and described herein are for illustration purposes only. Modifications to the current design may be implemented by those skilled in the art, without departing from the scope of the claims.
Filing Document | Filing Date | Country | Kind |
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PCT/US2020/044386 | 7/31/2020 | WO |