3D Camera Fault Detection for Transport Alignment
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Solution Overview
Problem
In beverage production, containers falling over during transport cause faults in production plants, and existing methods lack effective detection and remediation solutions for identifying and correcting misaligned or missing containers in bulk supplies.
Innovation Solution
A method and apparatus using image capturing devices, including 3D cameras, to detect misaligned or missing containers by analyzing alignment and depth information, with a fault elimination device, such as a robot, to correct issues by removing or reorienting containers and filling gaps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional transport devices are used without advanced detection systems, then device complexity is reduced, but fault detection capability deteriorates
Solution Approach 1:
The patent replaces complex mechanical detection systems with optical imaging devices (cameras) and computational image evaluation methods. Instead of using mechanical sensors or complex mechanical structures to detect container alignment, the system uses image capturing devices to photograph containers and algorithms to analyze the images, thereby achieving accurate fault detection with reduced mechanical complexity
Solution Approach 2:
The patent introduces image capturing devices and image evaluation algorithms as intermediary elements between the transport device and the control system. These intermediaries convert physical container states into visual data that can be processed and analyzed, enabling indirect but accurate detection of container alignment faults without requiring direct mechanical contact or complex sensing
2Productivity
If no real-time detection system is implemented, then device complexity is reduced, but productivity is worsened due to undetected faults
Solution Approach 1:
The patent implements a feedback mechanism where image capturing devices continuously monitor container alignment during transport, the image evaluation algorithm analyzes the captured images in real-time, and the control system receives feedback about detected faults to initiate corrective actions. This closed-loop feedback system enables immediate detection and response to alignment issues, maintaining high productivity by preventing fault propagation
Solution Approach 2:
The system enables self-service detection and correction by using automated image capture, evaluation, and control mechanisms that operate without human intervention. The image evaluation algorithm automatically identifies misaligned containers, and the control system automatically triggers corrective actions, allowing the transport system to self-diagnose and self-correct faults, thereby maintaining productivity
3Measurement precision
If simple 2D image capture is used, then device complexity is reduced, but measurement precision deteriorates due to inability to detect depth information
Solution Approach 1:
The patent transitions from two-dimensional image capture to three-dimensional measurement by introducing depth information acquisition capabilities. The system uses either stereo camera pairs (multiple cameras from different positions) or time-of-flight cameras that can measure distance to each pixel, thereby adding the depth dimension to the image data. This enables accurate determination of container alignment status by analyzing spatial relationships in 3D space
Solution Approach 2:
The patent merges multiple imaging functions into a unified detection system. By combining depth measurement capabilities with standard image capture in a single integrated system (either through stereo camera pairs working together or through time-of-flight camera technology), the system achieves both accurate 3D measurement and comprehensive visual inspection without requiring separate complex detection systems
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
Enables precise detection and correction of misaligned or missing containers, preventing production faults by ensuring continuous, upright transport of containers, thereby improving production efficiency and reducing downtime.
Implementation Method 1
by means of at least one first image capturing device (4a, 4b, 4c) a first region (R1) in which a plurality of transported objects (10) is located is captured
Implementation Method 2
an image capturing device not only outputs the usual two-dimensional information, but furthermore also information concerning the distance of the captured object from the image capturing device
Data Source
AI summary
Provided is a method for detecting faults in the context of transport of objects, wherein by a transport device, a plurality of objects are transported in a predetermined alignment of these objects along a predetermined transport path, wherein the objects are transported while at least partially in contact with each other, and wherein the objects are located on a movable surface of the transport device, wherein, by at least one image capturing device, at least one first region is captured in which a plurality of these containers is located and at least one sub-region of this region is identified in which no object is located in the predetermined orientation, wherein furthermore a distinction is then made as to whether an object with an alignment deviating from the predetermined alignment or an empty space is located in this region.