Camera-Based Load Control for Overload Detection in Handling
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Solution Overview
Problem
Existing technologies fail to effectively utilize data captured by cameras for load handling devices, leading to inefficiencies and potential overloading or improper handling of objects such as logs, tubes, or bags.
Innovation Solution
A load control device that uses cameras to capture data on objects, compares it with predefined reference data, and generates alerts or controls operations based on predefined thresholds, using a computer system that can be onboard, remote, or cloud-based, to ensure accurate loading and prevent overloading.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If camera data is captured and processed to monitor load parameters, then measurement precision and operational control are improved, but device complexity increases
Solution Approach 1:
The camera system is designed to perform multiple functions: capturing images of load objects, measuring dimensional parameters, counting objects, and comparing data against reference values. This multi-functionality improves measurement precision while avoiding the need for separate specialized devices for each function, thereby limiting the increase in overall system complexity.
Solution Approach 2:
A control unit serves as an intermediary between the camera and the load handling device. The control unit receives image data, processes it to extract load parameters, compares these parameters against reference data, and generates control signals accordingly. This intermediary approach simplifies the system architecture by centralizing processing logic and separating the sensing function from the control function.
2Reliability
If real-time camera monitoring and data comparison is implemented, then operational safety and overload prevention are improved, but productivity decreases due to additional processing time
Solution Approach 1:
Reference data for load parameters are pre-stored in the system before the actual loading operation begins. This allows the control unit to immediately compare captured camera data against known reference values without requiring real-time calculation or external consultation, thereby maintaining fast processing speeds while ensuring safe operational limits are not exceeded.
Solution Approach 2:
The system uses efficient image processing techniques that skip unnecessary analysis steps. The control unit is configured to extract only the critical load parameters needed for safety assessment from the camera images, rather than performing comprehensive analysis of all image features. This selective processing maintains productivity by rushing through only the essential measurement and comparison steps required for safety.
Data Source
AI summary
A load control device 28 has a camera 48 to capture information of objects of load 30 handled by a load handling device 26 to forward such information to a computer 52, which compares load data derived therefrom with reference data in a data source 54 and emits a signal to an output device 50 in the case of a certain conflict between the data.