Camera-Based Container Occupancy Tracking for Conveyor Jam Prediction
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Solution Overview
Problem
Current jam switches in conveyor systems cannot provide feedback on filling behavior, predict jamming events, or determine container positions, leading to inefficiencies and potential machine standstill when containers are full.
Innovation Solution
A method using cameras to capture and analyze the occupancy situation of containers, employing image recognition algorithms and Kalman filters to track container positions and control conveyor speed, enabling real-time monitoring and prediction of full or empty states.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If jam switches are used to detect container occupancy, then container full state can be detected, but no feedback on filling behavior, position information, or prediction capability is provided
Solution Approach 1:
The patent replaces mechanical jam switches with an optical measurement system using cameras and image processing algorithms. This substitution enables comprehensive occupancy analysis including container positions, filling behavior detection, and jam prediction capabilities that mechanical switches cannot provide
Solution Approach 2:
The system implements continuous feedback by analyzing image sequences to provide real-time information on filling behavior, container positions, and occupancy patterns. This feedback loop enables prediction of jam situations and allows for adaptive control of the conveying system
2Reliability
If image sequences are recorded and optical flow is calculated to analyze dynamic state, then deviation from normal operation can be detected, but real-time container position and occupancy detail information is not provided
Solution Approach 1:
The patent segments the image analysis into distinct processing stages: individual container detection, tracking across frames, occupancy classification, and jam prediction. This segmentation allows simultaneous achievement of reliable operational monitoring and precise container position information
Solution Approach 2:
The system performs preliminary analysis of image sequences to establish baseline occupancy patterns and container positions before actual conveying operations. This preliminary action enables real-time detection of deviations and provides detailed position information without disrupting normal operations
Data Source
AI summary
The disclosure relates to a method for determining an occupancy situation of containers in an installation, the method comprising: using at least one camera for capturing the occupancy situation of the containers in the installation and obtaining a captured occupancy situation, analyzing the captured occupancy situation and obtaining an analyzed occupancy situation, and controlling the installation based on the analyzed occupancy situation. Furthermore, the disclosure comprises a device comprising at least one camera and a control device with instructions that are stored thereon and that, when executed by a processor, cause the control device to execute the method.