Conveyance Obstacle Imaging for Curved Path Collision Avoidance
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Solution Overview
Problem
Existing article conveyance apparatuses face issues with short lifespan, high cost, and low reliability due to mechanical wear and complex control requirements in obstacle detection mechanisms using optical reflection sensors, which struggle with detecting small obstacles and suffer from interference and limited detection angles.
Innovation Solution
The implementation of a camera-based obstacle detection system with front, left-side, and right-side imaging devices that capture images and calculate distances, eliminating the need for mechanical angle switching, reducing component count, and minimizing interference, allowing for stable and reliable detection of obstacles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If an optical reflection sensor with a driving mechanism is used to emit a fan-shaped light beam for obstacle detection, then the detection coverage is improved, but the device complexity and cost increase due to the mechanical switching mechanism
Solution Approach 1:
The patent replaces the mechanical driving mechanism with a solid-state light emitting diode array that can emit light in multiple directions simultaneously without moving parts. This substitution eliminates the mechanical switching mechanism while maintaining fan-shaped detection coverage, resolving the contradiction between detection coverage and device complexity
Solution Approach 2:
The patent divides the light source into multiple LED elements arranged in an array, where each LED emits light in a specific direction. This segmentation allows the system to achieve comprehensive angular coverage without requiring mechanical movement, as each segment (LED) contributes to a specific portion of the fan-shaped detection pattern
2Adaptability or versatility
If a motor-driven mechanism is used to switch the radiation angle of the light source, then the detection range is improved, but the reliability decreases due to mechanical wear from friction
Solution Approach 1:
The patent replaces the motor-driven mechanical switching mechanism with a solid-state LED array that provides detection range through spatial arrangement of multiple light-emitting elements. This eliminates moving parts and mechanical wear, significantly improving reliability while maintaining adaptable detection coverage
Solution Approach 2:
The patent achieves dynamic detection capability through electronic control of multiple LED elements rather than mechanical movement. The system can dynamically adjust which LEDs are activated based on detection needs, providing adaptability without relying on mechanical motion that would cause wear
3Adaptability or versatility
If multiple operations including light emission, reception, and angle switching are performed sequentially, then the detection functionality is improved, but the productivity decreases due to the large number of components and complicated control
Solution Approach 1:
The patent merges multiple detection functions into a single integrated LED array system. Multiple LEDs can emit light in different directions simultaneously, and multiple photodetectors can receive reflected light from different angles at the same time, eliminating the need for sequential operations and improving productivity
Solution Approach 2:
The LED array system serves multiple functions simultaneously: different LEDs provide different radiation angles, the array as a whole provides fan-shaped coverage, and the system can detect obstacles at various positions without requiring separate mechanisms for each function, thereby improving operational efficiency
4Device complexity
If an ordinary optical reflection sensor with fixed projection pitch is used, then the device simplicity is improved, but the measurement precision decreases due to inability to detect small obstacles in the middle of the projection pitch
Solution Approach 1:
The patent segments the detection field into multiple overlapping fields of view provided by different LED-detector pairs. This segmentation with overlap ensures that small obstacles anywhere within the fan-shaped region fall within the detection range of at least one LED-detector pair, improving measurement precision while maintaining relative simplicity
Solution Approach 2:
The patent uses more LED elements and photodetectors than the minimum required, creating overlapping detection zones. This excessive action ensures that no small obstacle falls between detection beams, improving precision without significantly increasing overall system complexity
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
This solution provides a long-lasting, cost-effective obstacle detection mechanism with high reliability, capable of detecting small obstacles and maintaining stability even with vibrations, by using imaging devices mounted at fixed angles to determine the presence and distance of obstacles along linear and curved sections of a transportation path.
Implementation Method 1
The optical reflection sensor radiates a predetermined radiation region with a light beam and detects an obstacle ahead in the radiation region based on the reflected light
Data Source
AI summary
An article conveyance apparatus including a front imaging device, a left-side imaging device, and a right-side imaging device. The front imaging device determines the presence or absence of an obstacle ahead of the imaging device and calculates a distance from the obstacle based on a comparison between images captured by a plurality of cameras. In a transition region from a linear section to a curved section, the left-side imaging device and the right-side imaging device capture images ahead of the left or the right side and determine the presence or absence of an obstacle ahead of the left or the right side. If a distance from a front obstacle is at most a predetermined threshold value and if it is determined that an obstacle is present ahead of the left or the right side, a controller avoids a collision between the article conveyance apparatus and the obstacle.