Camera-Guided Loading Spout Alignment for Bulk Vehicle Hatches
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Solution Overview
Problem
Conventional methods for aligning loading spouts with vehicle hatches are time-consuming and imprecise, leading to increased downtime and costs due to limited spout motion range and manual vehicle maneuvering.
Innovation Solution
An automated camera-based guidance system that includes a movable spout support, loading spout assembly, camera, and programmable logic controller (PLC) to accurately align the spout with the hatch opening by capturing and analyzing real-time images, providing precise positioning and lighting adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual vehicle maneuvering and spout alignment methods are used, then the system is simpler and easier to operate, but the alignment precision and loading speed are insufficient
Solution Approach 1:
The patent replaces manual mechanical alignment operations with an automated optical measurement system. Cameras capture images of the vehicle hatch, and image processing algorithms automatically calculate the hatch center position and guide the spout alignment, eliminating the need for manual visual estimation and mechanical adjustments.
Solution Approach 2:
The patent uses optical copying by capturing images of the actual vehicle hatch and creating a digital representation through image processing. The system processes these images to extract geometric features and calculate the hatch center, effectively working with a copied visual model rather than the physical hatch directly.
2Productivity
If multiple passes and adjustments are made to align the spout with the hatch opening, then the alignment can be achieved, but the loading time increases and productivity decreases
Solution Approach 1:
The patent performs preliminary alignment by capturing images of the vehicle hatch before the loading operation begins and calculating the hatch center position in advance. This allows the spout to be pre-positioned accurately, eliminating the need for multiple adjustments during the loading process and reducing overall alignment time.
Solution Approach 2:
The system uses real-time image capture and processing to provide feedback on the spout's position relative to the hatch opening. The processed images display alignment information that guides operators or automated systems to make precise adjustments, ensuring rapid and accurate alignment without multiple trial passes.
3Adaptability or versatility
If the spout range of motion is limited, then the mechanical system is simpler, but the ability to reach and align with various hatch positions is reduced
Solution Approach 1:
The patent employs a movable spout support mechanism that can dynamically adjust its position in multiple directions. This dynamic positioning capability allows the spout to reach various hatch locations on different vehicles while maintaining a relatively simple mechanical structure through coordinated motion control based on image-guided positioning.
Data Source
AI summary
A bulk loading system for delivering bulk material to a storage compartment of a bulk transport vehicle through a hatch opening includes a movable positioner supporting an extendable loading spout assembly, a camera coupled to the positioner and a programmable logic controller communicatively coupled to the positioner, loading spout assembly and camera for automatically positioning the loading spout assembly over the hatch opening and filling the storage compartment of the vehicle with bulk material. The system provides accurate position information to a driver of the vehicle so that the vehicle and its storage compartments can be quickly positioned within a reach zone of the loading spout.