Bulk Object Counting via Segmented Feeding and Precision Detection
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Solution Overview
Problem
Conventional devices for counting bulk goods can only approximate the exact number of objects due to weight fluctuations, failing to provide precise counting, especially when exact numbers are required.
Innovation Solution
A device with a first feed device for pre-counting a subset of objects and a second feed device that adjusts to ensure the exact target number is met by counting objects individually, using vibrating conveyor sections and contactless counting modules for high precision, allowing the first and second subsets to be counted in an interleaved or parallel process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If weight-controlled dosing is used to count objects, then the dosing process is simple and fast, but the exact number of objects cannot be determined due to mass fluctuations
Solution Approach 1:
The dosing process is divided into two distinct phases: a first dosing phase where objects are fed at high speed without individual counting, and a second dosing phase where the remaining objects are fed one by one with individual counting. This segmentation allows the system to achieve both high productivity in the main dosing phase and high measurement precision in the final counting phase, resolving the contradiction between speed and accuracy.
Solution Approach 2:
The first dosing phase performs preliminary action by feeding the majority of objects (first subset) quickly before the final counting phase. This preliminary high-speed dosing reduces the total number of objects that need to be individually counted, thereby maintaining high productivity while enabling precise counting of the remaining objects to achieve the exact target number.
2Measurement precision
If individual counting of all objects is performed, then the exact number of objects is achieved, but the counting process becomes time-consuming
Solution Approach 1:
Instead of performing complete individual counting on all objects, the system applies partial action by only individually counting the second subset of objects (the difference between target number and first subset). This partial counting approach achieves the required measurement precision for exact object numbering while significantly reducing the time loss compared to counting every single object individually.
3Measurement precision
If the second subset of objects is fed slowly for accurate counting, then the exact target number is maintained, but the overall counting speed decreases
Solution Approach 1:
The feeding process is segmented into two phases with different speeds: the first dosing phase operates at high speed for the first subset, and the second dosing phase operates at low speed for individual counting of the second subset. This segmentation allows the system to maintain high overall productivity while ensuring the second subset is fed slowly enough to achieve the required measurement precision for the exact target number.
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 and efficient counting of objects, ensuring the specified target number is maintained with minimal excess, allowing for quick and accurate determination of the total number of objects.
Implementation Method 1
The bulk material can be conveyed in a controlled manner via this vibrating chute, with the quantity and speed of the conveyed bulk material being able to be adjusted by means of the control device via the strength of the vibration.
Implementation Method 2
The counting modules are able to record the number of objects with the utmost precision using appropriate sensors, even if an object is completely or partially covered by another object. The counting module used in the device according to the invention can make use of different measuring methods; it should be designed for optical and/or electromagnetic and/or capacitive detection of the objects.
Data Source
Figure 1~2
Figure 3
AI summary
The invention relates to a device for counting objects fed as bulk material, comprising a first feeding unit for pre-counting a first fixed subset of a target quantity of objects and a second feeding unit for preferably separately feeding a second subset of the target quantity of objects, wherein the device (1, 7, 10) is designed such that the quantity of objects of the first subset is transmitted to a control apparatus (5), which controls the second feeding unit such that the second subset of objects is fed enough objects that the second subset of objects corresponds to the difference between the first subset and the target quantity of objects, and the first subset of objects is poured into the second subset of objects.