Camera-Based Container Occupancy Tracking for Conveyor Jam Prevention
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Solution Overview
Problem
Current jam switches in conveyor systems cannot provide feedback on filling behavior, predict when a jam will occur, or identify the position of containers, leading to inefficient operation and potential machine standstill.
Innovation Solution
A method using cameras to detect and analyze the occupancy situation of containers, employing image recognition algorithms and Kalman filters to track container positions and regulate the system's transport speed and feed/discharge rates, allowing for real-time monitoring and prediction of container positions and system adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If pressure relief switches are used to detect container buildup, then the system can detect when the conveyor is full, but the system cannot provide feedback on filling status, predict jams, or identify container positions
Solution Approach 1:
The patent replaces mechanical pressure relief switches with an optical detection system using cameras and image processing algorithms. This substitution enables comprehensive visual monitoring of container positions, filling status, and conveyor occupancy, transforming limited mechanical detection into rich optical information that provides real-time feedback, prediction capabilities, and detailed position data.
Solution Approach 2:
The patent introduces image processing algorithms and optical flow calculation as intermediaries between the camera system and the control system. These intermediaries process raw image data to extract meaningful information about container positions, filling status, and conveyor occupancy, enabling the control system to make informed decisions based on comprehensive visual feedback.
2Reliability
If jam switches are used to stop the conveyor when full, then the conveyor can be protected from overload, but the machine comes to a standstill and productivity is reduced
Solution Approach 1:
The patent implements continuous visual feedback from cameras through the conveyor system, enabling real-time monitoring of container positions and filling status. This feedback loop allows the control system to optimize conveyor speed, coordinate feed and discharge rates, and prevent jams before they occur, maintaining continuous operation while protecting against overload.
Solution Approach 2:
The patent uses optical flow analysis and image processing to predict potential jam conditions before they occur. By analyzing container positions, speeds, and spacing in real-time, the system can take preliminary actions such as adjusting conveyor speed or alerting operators, preventing complete stoppages and maintaining productivity.
3Loss of information
If multiple cameras are used to record occupancy situation, then real-time monitoring and prediction capabilities are improved, but data transfer requirements and system complexity increase
Solution Approach 1:
The patent divides the conveyor system into multiple evaluation areas, each monitored by specific cameras. This segmentation allows the system to process and analyze occupancy information in discrete zones, reducing the complexity of analyzing the entire conveyor at once and enabling targeted data collection where most relevant.
Solution Approach 2:
The patent creates digital representations (images and optical flow data) of the physical conveyor system state. These visual copies capture container positions, speeds, and spacing, providing comprehensive information about occupancy situations without requiring direct physical measurement of every parameter, simplifying the monitoring system.
Data Source
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AI summary
The invention relates to a method for determining the occupancy status of containers (11, 13-18, 37-50, 58-71) in a system, the method comprising: using at least one camera (1, 25, 26) to detect the occupancy status of the containers (11, 13-18, 37-50, 58-71) in the system and obtaining a detected occupancy status, analyzing the detected occupancy status and obtaining an analyzed occupancy status, and controlling the system based on the analyzed occupancy status. The invention further comprises a device including at least one camera (1, 25, 26) and a control device with instructions stored thereon, which, when executed by a processor, cause the control device to execute the method.