Technical Field
[0001] The present invention relates to image processing and more particularly relates to
over-the-belt optical character recognition (OCR) systems. Specifically, the invention
relates to an indicia reader system that includes a projected optical guide to assist
the-positioning of parcels on a conveyor.
Background of the Invention
[0002] For years, machines have been used to scan parcels as they travel along a conveyor.
Over-the-belt optical character recognition (OCR) systems have been recently developed
that can read indicia, such as a typed or hand-written destination address on parcels
to be shipped. Parcel delivery companies, such as United Parcel Service, ship millions
of parcels every day. These parcel delivery companies make extensive use of OCR systems
to read the destination address labels on parcels to facilitate sorting and routing
the parcels to their proper destinations.
[0003] The fundamental physical components of an OCR system are a scanner and a character
recognition system including a central processing unit (CPU), a computer memory, and
a sophisticated character recognition program module. The scanner is typically an
optical camera, such as a charge-coupled device (CCD) array, that captures an image
of the destination address on the parcels as they travel past the scanner on the conveyor.
Generally, a continuous video image of the conveyor carrying the parcels is captured
by the scanner, which video image is converted into digital format and transmitted
to the character recognition system. But only a small part of the video image, such
as the portions including the destination addresses of the parcels, needs to be processed
by the character recognition system. The OCR system, therefore, must have some way
to identify the portions of the video image that need to be processed by the character
recognition system.
[0004] One approach is to store the entire video image created by the scanner, and later
parse out the portions of the video image that need to be processed by the character
recognition system. But a continuously running scanner generates an enormous amount
of video data. This data is formatted as a continuous bit map of the conveyor as the
conveyor carries parcels past the scanner. This bit map inherently conveys information
about the spatial relationship of the pixels of the image. Storing this continuous
bit map requires an enormous amount of computer memory. It is therefore advantageous
to reduce the memory storage requirement.
[0005] Data compression is one technique for reducing the memory storage requirement. The
video data may be compressed for storage using any of a variety of well known data
compression methods, such as run length encoding. These data compression techniques,
however, alter the bit-map format of the data. This is undesirable because it is advantageous
for the character recognition program module to operate on bit maps that allow easy
access to information regarding neighborhoods around individual pixels. The compressed
data must therefore be uncompressed, typically into a frame buffer, for processing
by the character recognition program module. Compressing the video data for storage,
and then uncompressing the video data for processing, burdens the CPU and slows the
character recognition process.
[0006] Real-time extraction of the desired portions of the video data is another technique
for reducing the memory storage requirement. Indeed, real-time data extraction is
a very effective technique because most of the video data created by the continuously
running scanner is a useless image of the conveyor and the non-indicia bearing areas
of the parcels moving along the conveyor; only a small percentage of the data includes
the destination addresses of the parcels to be shipped. Therefore, extracting only
small portions of the video data, such as relatively small areas covering the destination
addresses, greatly reduces the memory storage requirement and speeds up the character
recognition process.
[0007] Systems have been developed for triggering a video camera system so as to store only
desired video images. For example,
Tonkin, U.S. Patent No. 4,742,555, describes a mechanical limit switch, optical sensor, or
magnetic sensor that triggers a video system to capture and store an image of a parcel
as the parcel reaches a predetermined location along a conveyor. But the system described
by
Tonkin would have a significant drawback if applied to a parcel shipping system. This is
because the system described by
Tonkin captures an image of the entire parcel; is not operative for capturing only a specific
portion of the image, such as the destination address. In a parcel shipping system,
the destination address must be captured for sorting and routing purposes, but other
indicia on the parcel, such as the return address, is not needed to route the parcel
to its proper destination. It is therefore advantageous to identify the destination
address prior to storing the image of the parcel, so that only the portion of the
image containing the destination address may be stored in the computer memory.
[0008] Several difficulties are encountered, however, in attempting to identify the destination
addresses on various parcels traveling on a conveyor. First, the destination addresses
may vary in size, and may be in different locations on different parcels. Second,
the parcels themselves may vary in size, shape, and position on the conveyor. Thus,
the exact position of a destination address on a parcel cannot be determined by simply
detecting the edge of the parcel using a limit switch or sensor, as described by
Tonkin.
[0009] Systems have been developed for storing video images of selected portions of parcels
traveling of a conveyor. For example,
Kizu et al., U.S. Patent No. 4,516,265, describes a two-camera system that reads the postal (zip)
codes on envelopes traveling on an envelope transport system. The system includes
a low resolution prescanner that coarsely scans the surface of the envelope. The position
of the destination address block is determined from the coarse scan, and the coordinates
of the destination address block with respect to the leading edge of the envelope
are then passed to a second, high-resolution camera system. The second camera system
stores an image of the destination address block by first detecting the leading edge
of the envelope. The second camera system begins storing an image of the destination
address block when the block reaches the second camera, and stops storing the image
when the block moves past the second camera. A postal code reader subsequently processes
the high-resolution scan to read the postal code.
[0010] Another example is disclosed in
Morton et al., U.S. Patent No. 5,642,442. This patent describes a two-camera system that reads
the destination addresses on parcels traveling on a conveyor. A fluorescent ink fiduciary
mark is superimposed relative to the destination address on a parcel.. A first camera
captures an image of the fiduciary mark, the position and orientation of which is
ascertained. The position and orientation of the fiduciary mark is then used to extract
an image of the destination address from a video data signal created by a second camera,
which is positioned downstream from the first camera. The image of the destination
address is stored in a computer memory for subsequent processing by a character recognition
system.
[0011] The two-camera systems described above are very effective at minimizing the amount
of video data that must be stored in an OCR system. They are, however, rather expensive
systems that are best suited for very high-speed parcel handling systems. The cost
associated with these systems may not be justified for many lower-speed parcel handling
systems. The IBM Technical Disclosure Bulletin, Vol. 15 Nr. 4, Pg. 1170-1171 describes
a moving-light parcel positioning scanning and sorting system that captures images
of addresses on parcels. But this system does not describe further techniques for
obtaining sharp image of the addresses, nor does it describe a non-moving-light parcel
positioning system. In addition, the IBM disclosure document does not describe a multi-conveyor
parcel positioning system.
[0012] There is, therefore, a need for a less expensive and more effective system for minimizing
the amount of video data that must be stored in an OCR system. In particular, there
is a need for an inexpensive yet effective indicia reader system that is suited to
low- to medium-speed parcel handling systems.
Summary of the Invention
[0013] The invention seeks to provide a low-cost system for minimizing the amount of video
data that must be stored in an OCR system. In particular, the invention seeks to provide
an inexpensive indicia reader system suited to low- to medium-speed parcel handling
systems.
[0014] According to the invention there is provided an optically guided indicia reader system
comprising a conveyor, for transporting a parcel from an upstream location of the
conveyor to a downstream location of the conveyor, and a moving-light indicia reader
system comprising an illumination source for defining a spot that moves at the same
speed 5 as the conveyor to assist in positioning the parcel on the conveyor, a scanner
located downstream of the illumination source and positioned to capture an image of
the parcel, and a computer memory for storing the images; wherein
means are provided for operating the computer memory and the scanner so as to store
an image of a region of a parcel defined with respect to the spot defined by the illumination
source.
[0015] The invention also provides a method of obtaining an image of parcel indicia using
this system.
[0016] In use an operator positions a parcel on the conveyor so that indicia to be imaged,
such as the destination address on the parcel, coincides with a moving spot light
defined by an illumination source. A scanner located downstream of the illumination
source captures an image of a region that is defined with respect to the spot defined
by the illumination source. For example, the optical guide may include a moving light,
such as a narrow-beam spot light, that is projected onto the conveyor, and that travels
at the same speed as the conveyor. Positioning a parcel on the conveyor so that the
spot light is located in the center of the city and state address lines of the destination
address allows a scanner to efficiently capture an image of the destination address
for processing by a character recognition reader.
[0017] The moving-light indicia reader system includes a conveyor for transporting a parcel
from an upstream location of the conveyor to a downstream location of the conveyor.
A moving-light system, which is preferably positioned above the conveyor, includes
an illumination source for defining a spot that moves at the same speed as the conveyor
to assist in positioning the parcel on the conveyor. A scanner, which is located downstream
from the moving-light illumination source, and a processing module are operated so
as to store an image of a region of the parcel defined with respect to the spot defined
by the moving-light illumination source. For example, the illumination source may
define a spot that is substantially smaller than the region to be imaged by the scanner
of the indicia reader system. An operator may then position a parcel so that the spot
defined by the moving-light illumination source is located approximately in the center
of the city and state lines of the destination address on the parcel.
[0018] A moving-light indicia reader system may also include a reflectivity sensor located
upstream of the scanner and positioned to determine reflectivity data associated with
the parcel. Reflectivity data from the reflectivity sensor is obtained for the spot
defined by the moving-light illumination source so that reflectivity data is collected
regarding the parcel at the region to be captured and stored for subsequent processing
by a character recognition system. A communication link transmits this reflectivity
data from the reflectivity sensor to the scanner, and the gain of the scanner is adjusted
in response to the reflectivity data. In addition, a moving-light indicia reader system
may include a height sensor located above and upstream of the scanner and positioned
to determine height data associated with the parcel at the location of the destination
address. Height data from the height sensor is obtained for the spot defined by the
moving-light illumination source so-.that height data is collected regarding the parcel
at the region to be captured and stored for subsequent processing by the character
recognition system. A communication link transmits this height data from the height
sensor to the scanner, and the scanner is focused in response to the height data.
[0019] According to another aspect of the invention, a multi-conveyor indicia reader system
includes a plurality of moving-light indicia reader systems, wherein each moving-light
indicia reader system includes an illumination source for defining a spot that moves
at the same speed as its respective conveyor to assist in positioning parcels on the
conveyor. The processing module and the scanner of each moving-light indicia reader
system are operated so as to store an image of a region of the parcel defined with
respect to the spot defined by the illumination source. In addition, the illumination
sources are operated so as to time-division multiplex the storage of the images generated
by the several moving-light indicia reader systems.
[0020] The invention also provides a method of obtaining an image of parcel indicia using
such a multi-conveyor system.
[0021] That the present invention improves over the drawbacks of the prior art and accomplishes
the objects of the invention will become apparent from the following detailed description
of the preferred embodiment and the appended drawings and claims.
Brief Description of the Drawings
[0022]
FIG. 1 including FIGS.1A-1E illustrates a moving-light indicia reader system.
FIG. 2 illustrates a parcel with the spot defined by the moving-light system located
approximately in the center of the city and state address lines of the destination
address.
FIG.3 illustrates a multi-conveyor indicia reader system.
Detailed Description
[0023] FIGS.1A-1E illustrate an embodiment of the invention, a single-conveyor moving-light
indicia reader system in which a moving-light illumination source defines a spot that
moves at the same speed as a conveyor to assist the positioning of a parcel on the
conveyor. FIG.2 illustrates a parcel in this moving-light indicia reader system with
the spot defined by the moving-light illumination source located approximately in
the center of the region to be captured. More specifically, the parcel is preferably
positioned on the conveyor so that the center of the spot defined by the moving-light
illumination source is approximately in the center of the city and state lines of
the destination address. FIG. 3 illustrates a multi-conveyor indicia reader system,
in which the illumination sources of a plurality of moving-light indicia reader systems
are operated so as to time-division multiplex the storage of the images generated
by the several moving-light indicia reader systems. These embodiments of the invention
are described below.
[0024] FIGS. 1A-E illustrate a moving-light indicia reader system
200 including a conveyer
212 carrying a parcel
214 from an upstream location
216 to a downstream location
218 of the conveyor
212. The parcel
214 includes indicia to be read by the moving-light indicia reader system
200, such as a destination address
220. The parcel
214 may include other indicia, such as the return address, that the moving-light indicia
reader system
200 preferably avoids reading.
[0025] The moving-light indicia reader system
200 includes a moving-light illumination source
224 that includes a plurality of discrete illumination sources
226a through
226n, such as light-emitting diodes (LEDs), that project columnar beams of light represented
by the beam
228. The illumination source
224 is positioned a sufficient distance above the conveyor
212 so that the parcel
214 may be positioned on the conveyor
212 to pass beneath the moving-light illumination source
224. An operator may therefore view the spot
230, which is defined by light projected by the moving-light illumination source
224, directly on the parcel
214 as the operator positions the parcel
214 on the conveyor
212. The spot
230 thus provides an optical guide to assist the operator in positioning the parcel
214 on the conveyor
212.
[0026] A sensor assembly
232, including a height sensor and reflectivity sensor, is located toward the downstream
end of the illumination source
224. A communication link
234 functionally connects the sensor assembly
232 to a scanner
236 that is located downstream from the sensor assembly
232. The scanner
236 includes internal components
233 well known to those skilled in the art to automatically focus the scanner
236 in response to height data from the height sensor, and to automatically adjust the
gain of the scanner
236 in response to reflectivity data from the reflectivity sensor, so that the scanner
236 generates a clear image of the top of the parcel
214 at the region to be captured and stored for subsequent processing by a character
recognition system
240 as the parcel
244 passes beneath the scanner
236. The scanner
236 is aligned with the spot
230 so that the scanner may be operated to capture an image of the destination address
220 on the parcel
214.
[0027] A belt encoder
238 measures the displacement of the conveyor
212. A communication link
240 functionally connects the belt encoder
238 to the scanner
236 and to a character recognition system
240 that includes a processing module
241 and a computer memory
242. A second communication link
244 functionally connects the character recognition system
240 to the scanner
236, and a third communication link
246 functionally connects the character recognition system
240 to the moving-light illumination source
224. The signal from the belt encoder
238 is used to determine the speed of the conveyor
212, which is used to synchronize the operation of the moving-light illumination source
224, the scanner
236, and the character recognition system
240 so that an image of a region
250 defined with respect to the spot
230 is stored in the computer memory
242. The height data from the sensor assembly
232 indicates the presence of a parcel
214 in association with a spot
230 so that an image of a region
250 is only stored in the computer memory
242 when a parcel
214 is present in association with a spot
230 defined by the moving-light illumination source
224.
[0028] To use the moving-light indicia reader system
200, an operator positions the parcel
214 on the conveyor
212 so that the spot
230 defined by the moving-light illumination source
224 is centered with respect to the destination address
220 on the parcel
214. For example, FIG. 1A illustrates the parcel
214 positioned so that the spot
230 defined by the first discrete illumination source
226a is centered with respect to the destination address
220. From this position, the parcel
214 travels on the conveyor
212, and the spot
230 travels at the same speed as the parcel
214, so that the spot
230 remains stationary relative to the parcel
214. Thus, as illustrated in FIG.1B, the parcel
214 is later positioned so that the spot
230' defined by the third discrete illumination source
226c is centered with respect to the destination address
220. Later still, as illustrated in FIG. 1C, the parcel
214 is positioned so that the spot
230" defined by the last discrete illumination source
226n is centered with respect to the destination address
220.
[0029] FIGS.1D and 1E illustrate the scanning of the parcel
214 by the scanner
236, which includes a CCD array that repeatedly generates an image of a scan line
252 to generate a video signal. The operation of the scanner
236 and the processing module
241 of the character recognition system
240 are synchronized with the movement of the spot
230 so as to store in the computer memory
242 an image of the region
250, which is defined with respect to the spot
230. When the region
250 reaches the scan line
252, which happens shortly after the parcel
214 is in the position shown in FIG.1D, the processing module
241 causes the computer memory
242 of the character recognition system
240 to begin storing the video data generated by the scanner
236. The video data generated by the scanner
236 continues to be stored until the region
250 passes the scan line
252, which happens shortly before the parcel
214 is in the position shown in FIG. 1E.
[0030] It will be understood that, when the parcel
214 is positioned as shown in FIGS.1D-E, the spot
230 is not visible to an operator because the parcel
214 is not under the moving-light illumination source
224. Nevertheless, the character recognition system
240 uses the signal from the belt encoder
238 to keep track of the spot
230 after the parcel
214 travels past the moving-light illumination source
224. Thus, an image of the region
250, which is defined with respect to the spot
230, is stored in the computer memory
242 of the character recognition system
240.
[0031] FIG. 2 illustrates a parcel
214 with the spot
230 defined by the moving-light illumination source
224. The spot
230 is typically a round or oval area that is somewhat smaller that than the region
250 to be imaged by the scanner
236. For example, the area associated with the spot
230 may be approximately one 1 inch (2.5 cm) across, whereas the region
250 may be approximately 4 inches (10 cm) by 4 inches (10 cm). The parcel
214 is preferably positioned so that the center of the spot
230 is approximately in the center of the city and state address lines of the destination
address
220. This allows the scanner
236 to capture an image of the destination address
220 by imaging the region
250.
[0032] It will be appreciated, however, that the spot
230 may have virtually any size or configuration, and that multiple spots may be used
to identify indicia on the parcel, such as four spots defining the corners of a rectangular
region to be imaged. For example, the spot
230 may be defined by an illuminated area, or by an illuminated border, or by two illuminated
spaced-apart parallel lines, etc. In addition, the spot
230 could be configured to correspond to the width of the region
250 to be stored in the computer memory
224. This would assist an operator in orienting a parcel
214 so that the destination address
220 can be effectively scanned by the indicia reader system
200 as configured. Alternatively, the operator may determine that the parcel
214 cannot be oriented so that the destination address
220 can be effectively scanned by the indicia reader system
200 as configured. This may happen if the destination address
220 is larger than the region
250 to be stored in the computer memory
242. In this case, the operator can divert the parcel
214 for hand sorting or imaging using a differently configured indicia reader system.
[0033] To capture the image of the region
250, the character recognition system
240 is operative to selectively trigger the storage of an image in the computer memory
242. Triggering the storage of the image of the region
250 in the computer memory
242 may be accomplished in several different ways. For example, the scanner
236 may be toggled on and off by the processing module
241 in response to the signal from the belt encoder
238. Or the scanner
236 may run continuously, and the processing module
241 may respond to the signal from the belt encoder
238 by latching a control line to an input buffer of the character recognition system
240. Alternatively, the signal from the belt encoder
238 may be used as an input to a software-based algorithm running on the processing module
241, which triggers the storage of video data from the scanner
236 in the computer memory
242. Many other means known to those skilled in the art may equivalently be employed
to operate the character recognition system
240 and the scanner
236 so as to store an image of the region
250 in the computer memory
242.
[0034] Acceptable performance is experienced when moving-light indicia reader system
200 is configured as follows. The belt encoder
238 is a standard belt-driven, opto-mechanical encoder that provides a signal indicating
the linear displacement of the conveyor
212. The CCD array of the scanner
236 is cycled in response to the signal from the belt encoder
238 to generate a series of analog images of the scan line
252 that are transmitted to an analog-to-digital converter within the scanner
236. The analog-to-digital converter of the scanner
236 uses a standard thresholding or similar process to convert the analog signal produced
by the CCD array of the scanner
236 into an eight-bit digital video signal that is transmitted via the communication
link
246 to the character recognition system
240, which is operable for storing the video data in the computer memory
242 for subsequent processing.
[0035] The scanner
236 is preferably a monochrome, 4,096 pixel line-scan type CCD array such as one using
a Thompson TH7833A CCD chip. As the field of view of the scanner
236 is approximately 16 inches (41 cm) at the conveyor
212, the resolution of the image created by the scanner
232 is approximately
256 pixels or "dots" per inch (DPI) (101 dots per cm) across the field of view of the
scanner
236. The belt encoder
238 preferably triggers the CCD array of the scanner
236 at a rate of approximately
256 cycles per inch (2.54 cm) so that the resolution of the image created by the scanner
232 is approximately
256 pixels or "dots" per inch (DPI) (101 dots per cm) in the direction of conveyor travel.
It will therefore be appreciated that a digital image with a correct aspect ratio
(i.e., the ratio of the length of the image to the width) may be generated by the
scanner
236 and stored in the computer memory
242 of the character recognition system
240 by synchronizing the cycling rate of the scanner
236 with the linear speed of the conveyor
212.
[0036] The conveyor
212 may be approximately 24 inches (61 cm) wide and travel at linear speeds up to 20
inches per second or 100 feet per minute (51 cm per second or 30 meters per minute)
or more. The moving-light illumination source
224 is preferably positioned approximately 18 inches (46 cm) above conveyor
212 and defines a spot
230 that is approximately 1 inch (2.5 cm) wide and 1 inch (2.5 cm) long at the conveyor
212. The moving-light illumination source
224 may be operated so that successive moving spots
230 are spaced virtually any distance apart. For example, acceptable performance is experienced
when the moving-light indicia reader system
200 is operated with the conveyor
212 traveling at 50 feet per minute (25 cm per second or 15 meters per minute), and with
the moving spots
230 spaced 22 inches (56 cm) apart, which allows the moving-light indicia reader system
200 to handle approximately 1,636 parcels per hour if the operator places a parcel under
each moving spot.
[0037] The scanner
236 is preferably mounted to have an optical path of approximately
120 inches (305 cm) to the conveyor
212, with a 16 inch (41 cm) field of view at the conveyor
212. To save space, the scanner
236 is positioned approximately 30 inches (76 cm) above the center of conveyer
212 and is pointed towards a complex of mirrors (not shown) that increases the optical
path from the scanner
236 to the conveyor
212 to approximately
120 inches (305 cm). These parameters may be varied somewhat without unduly affecting
the performance of the disclosed embodiment of the present invention.
[0038] It should also be understood that the scan line
234 may be longer than the width of the region stored in the computer memory
242. For example, the scanner
232 may be positioned to have a field of view (i.e., the scan line
234) equal to approximately 16 inches (41 cm) at the conveyor
212. The region stored in the computer memory
242, however, may only be approximately 4 inches (10 cm) wide. This may be accomplished
by only storing the output of a portion of the cells of the scanner
232 (e.g., the center 1,024 pixels of a 4,096 pixel scanner) in the computer memory
242.
[0039] It will be appreciated that the moving-light illumination source
224 should be long enough to allow an operator to position the parcel
214 on the conveyor
212 while the spot
230 travels from the upstream end to the downstream end of the moving-light illumination
source
224. For example, a moving-light illumination source
224 having a length of 36 inches (91 cm) and 72 LEDs spaced 1/2 inch (1.3 cm) apart is
appropriate for the conveyor
212 traveling at 10 inches per second or 50 feet per minute (25 cm per second or 15 meters
per minute), as described above. The LEDs
226a-n of the moving-light illumination source
224 may be any of a variety of commercially available LEDs, such as a model AND190W0P
manufactured by AND. The sensor assembly
232 may include any of a variety of commercially available height sensors, such as a
model NR-40 manufactured by Innova Labs, Inc.
[0040] FIG. 3 is a diagram of a multi-conveyor indicia reader system
400 that includes a plurality of moving-light indicia reader systems
210a through
210n, which are virtually identical to those described above with respect to FIGS. 1A-.E.
Each of the moving-light indicia reader systems
210a through
210n are synchronized by, and provide their video data to, a single character recognition
system
240. The character recognition system
240 synchronizes the moving spots
230a through
230n of the moving-light indicia reader systems
210a through
210n so as to time-division multiplex the storage of the regions
250a through
250n from the several scanners
236a through
236n. In other words, the spots
230a through
230n are spaced relative to each other so that only one of the regions
250a through
250n captured by the scanners
236a through
236n needs to be stored in the computer memory
242 of the character recognition system
240 at any time. This allows the single character recognition system
240 to store the images generated by several moving-light indicia reader systems
210a through
210n, as shown in FIG. 3.
[0041] In view of the forgoing, it will be appreciated that the moving-light indicia reader
system
400 allows the video data stored in the computer memory
242 of the character recognition system
240 to be reduced to a standard-sized region that is only large enough to capture the
text of the destination addresses
220a-220n on the various parcels carried on the conveyors
212a-212n. The use of projected illumination allows the operator to view the spot
230a-230n defined by each moving-light illumination source
224a-224n directly on the top of the parcels
214a-214n. Thus, there is no displacement between each spot
230a-230n and the top of each parcel
214a-214n that could cause parallax-related alignment errors with tall parcels. In addition,
the moving-light indicia reader system
400 allows the angle of the field of view of the scanners
236a-236n to be relatively narrow so that the scanners generates sharp images of the top of
the parcels
214a-214n.
[0042] It should be understood that the foregoing relates only to specific embodiments of
the present invention, and that numerous changes may be made therein without departing
from the scope of the invention as defined by the following claims.