Camera-Based Workpiece Counting for Flexible Clothing Orders
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Solution Overview
Problem
Custom manufacturing processes, such as custom clothing manufacturing, face challenges in efficiently counting finished products due to frequent order changes, machine and labor downtime, and the need for manual data collection, which hampers productivity and live reporting requirements.
Innovation Solution
A smart counting system with a camera-based platform divided into input, workspace, and output areas, using fiducial tags and a processing unit to detect and process real-time images, automatically incrementing counts based on tag visibility and motion detection, enabling accurate and live tracking of product completion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual counting methods are used with workers pressing buttons for each finished piece, then live data collection is achieved, but labor time and productivity are reduced
Solution Approach 1:
The patent replaces manual mechanical counting (workers pressing buttons) with an automated computer vision system using cameras and image processing algorithms. The system automatically detects finished products, identifies them through pattern recognition, and updates counts without human intervention, thereby maintaining counting accuracy while eliminating the labor time and productivity loss associated with manual counting operations.
Solution Approach 2:
The counting system performs self-service by automatically detecting and counting finished products without requiring worker intervention. The computer vision system continuously monitors the workspace, autonomously identifies completed items, and updates the count database, freeing workers to focus solely on manufacturing tasks and thereby improving overall productivity.
2Adaptability or versatility
If frequent order changes are implemented to meet personalized design needs, then customer satisfaction is improved, but machine and labor downtime increases
Solution Approach 1:
The patent implements a dynamic configuration system where the computer vision algorithm can be rapidly reprogrammed or reconfigured to recognize new product patterns and designs. When order changes occur, the system adapts by loading new reference images and updating recognition parameters, allowing frequent order changes without requiring physical reconfiguration of manufacturing equipment or extensive labor retraining, thus minimizing downtime.
Solution Approach 2:
The counting system serves multiple functions: it counts finished products, identifies product types through pattern recognition, tracks different designs, and provides real-time data reporting. This multi-functional capability allows the same system to handle diverse order types and design variations without requiring separate counting systems for each product type, thereby maintaining adaptability while reducing the time lost to reconfiguration.
3Productivity
If automated camera-based counting is implemented, then productivity is enhanced, but system complexity increases
Solution Approach 1:
The patent uses optical copying through camera imaging to create digital representations of physical finished products. Instead of requiring complex physical interaction with each product, the system captures images and processes them through pattern recognition algorithms. This approach simplifies the overall system by replacing complex mechanical counting devices with relatively simple camera-based optical sensing and software-based image processing.
4Measurement precision
If real-time monitoring of tag visibility and motion detection are performed, then counting accuracy is improved, but processing time increases
Solution Approach 1:
The patent implements periodic sampling of the workspace by the camera system rather than continuous analysis of every pixel change. The system captures images at regular intervals and processes them to detect tag visibility changes and motion. This periodic approach maintains counting accuracy by sufficiently sampling product appearances and movements while significantly reducing processing time and computational load compared to continuous real-time analysis.
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 enhances productivity by automating the counting process, reducing downtime, and providing real-time accurate reports, improving factory efficiency and customer satisfaction in custom manufacturing scenarios.
Implementation Method 1
A camera is mounted above the platform (e.g., to the ceiling) and points down towards the platform
Implementation Method 2
The processing unit repeats the previous step until it detects the second tag in the output area
Data Source
AI summary
The present invention discloses a smart counting method and system in manufacturing, specifically in custom clothing or fabric manufacturing. The smart counting method and system uses a camera to feed real-time image data of a working platform where a worker takes a unfinished clothing or fabric, processes the clothing or fabric, and puts the finished clothing or fabric in a finished pile to a processing unit. The processing unit automatically starts a new work order and counts the number of finished products in this work order by using computer vision techniques.