One-Dimensional Optical Sensor for Conveyor Jam Detection
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Solution Overview
Problem
Conveyor belt systems face challenges in detecting the motion of continuous or uniform objects, such as long rolls of paper, which can be difficult to distinguish from jammed states, often requiring direct human intervention or camera-based systems, and existing methods are inefficient and prone to false detections.
Innovation Solution
A non-contact motion detection system using a one-dimensional optical sensor that captures and compares pixel images over time, generating a frame differential image value to determine if objects are moving or jammed, with a processor-driven algorithm to analyze pixel signal strength and distance measurements, reducing hardware requirements and false alarms.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a camera-based system is used to monitor object flow on the conveyor belt, then the ability to detect motion is improved, but the device complexity and cost increase
Solution Approach 1:
The patent extracts only the essential function needed for motion detection from a full camera system. Instead of using a two-dimensional camera array, it employs a one-dimensional optical sensor that captures only the necessary cross-sectional view of the conveyor belt, eliminating unnecessary hardware while maintaining detection capability
Solution Approach 2:
The system creates a simplified optical copy of the conveyor belt surface using a single-line array sensor. This one-dimensional representation captures sufficient motion information without requiring a complete three-dimensional visual copy that a camera would provide, reducing hardware complexity while preserving detection functionality
2Device complexity
If direct human observation is used to determine object flow, then the system complexity is reduced, but the productivity and reliability decrease due to manual intervention requirements
Solution Approach 1:
The optical sensor system performs automated self-monitoring of the conveyor belt. The sensor continuously captures images and the processor automatically analyzes them to detect motion or jam conditions without requiring human intervention, enabling the system to monitor itself and report its own operational state
Solution Approach 2:
The patent replaces the mechanical system of human observation with an optical sensing system. The one-dimensional optical sensor and image processing algorithm substitute for human eyes and brain analysis, providing automated detection while maintaining simplicity
3Device complexity
If a one-dimensional optical sensor is used instead of a camera system, then the hardware cost and complexity are reduced, but the ability to detect uniform objects may be compromised
Solution Approach 1:
The system performs preliminary image processing by comparing each captured image with a reference image of the conveyor belt. This preliminary comparison establishes a baseline and enables the detection of even subtle changes in the uniform pattern, allowing accurate detection of uniform objects with simplified hardware
Solution Approach 2:
The sensor continuously captures images at regular intervals and performs periodic comparison with the reference image. This periodic sampling and comparison approach allows the system to detect motion in uniform objects by identifying changes over time, compensating for the limited spatial resolution of the one-dimensional sensor
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system effectively detects motion and jam states with minimal hardware, reducing false detections and easily identifying movement of uniform, light-colored, dark-colored, or multi-colored objects, providing a cost-competitive and economical solution for conveyor belt monitoring.
Implementation Method 1
A single optical imaging source, such as a one-dimensional sensor, may launch a linear optical beam that illuminates a target object being transported by a conveyor system and generate a detection signal as a function of a reflection of the linear optical beam off the target object
Implementation Method 2
A single optical imaging source, such as a one-dimensional sensor, may launch a linear optical beam that illuminates a target object and generate a detection signal as a function of a reflection of the linear optical beam off the target object
Data Source
AI summary
Apparatus and associated methods relate to a method of non-contact motion detection. A one-dimensional optical sensor detects motion of a target or objects on a conveyor belt through a continuous measurement of targets or objects and a real-time comparison of the pixel images captured by the one-dimensional optical sensor. In an illustrative embodiment, a one-dimensional sensor may be configured to determine motion of objects based on changes to the captured intensities of pixel images over time. The sensor may continually capture photoelectric pixel images and compare a current pixel image with a previous pixel image to determine a frame differential image value. The frame differential image value is evaluated against a predetermined threshold over a predetermined time period. Based on the evaluation, a signal is output indicating whether the objects on the conveyor belt are moving or jammed.