Conveyor Belt Degradation Detection via Image Processing
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Solution Overview
Problem
In paper sheet processing apparatuses, conveyor belts and rollers degrade over time, leading to unstable conveyance and inaccurate inspections, as existing systems lack effective methods to determine the optimal replacement time for these components, resulting in either incorrect inspections or unnecessary replacements.
Innovation Solution
A paper sheet processing apparatus equipped with an image detection device that captures images of both the paper sheet and conveyor belt, processes these images to assess the belt's degradation level, and a controller that alerts for timely replacement based on detected degradation, ensuring stable conveyance and accurate inspections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the conveyor belt is replaced periodically, then the stable conveyance is maintained, but unnecessary replacements occur when the belt is still usable
Solution Approach 1:
The patent replaces mechanical periodic replacement with an optical detection system. An image reading device captures images of the conveyor belt, and image processing automatically determines degradation levels, substituting mechanical judgment with optical-mechanical systems to achieve more precise and timely replacement decisions.
Solution Approach 2:
The system implements feedback by continuously monitoring the conveyor belt's degradation state through image capture and processing. The degradation level information feeds back to the control unit, which then determines optimal replacement timing, creating a closed-loop system that adjusts maintenance schedules based on actual belt conditions rather than fixed intervals.
2Loss of time
If the conveyor belt is used beyond degradation, then replacement frequency is reduced, but conveyance stability and inspection accuracy deteriorate
Solution Approach 1:
The patent employs an optical detection system with image reading devices and automated image processing to monitor conveyor belt degradation. This substitution of mechanical periodic inspection with optical-mechanical automated detection enables precise determination of the optimal replacement moment, ensuring inspection accuracy is maintained while minimizing unnecessary replacements.
Solution Approach 2:
The system performs preliminary detection of conveyor belt degradation before actual conveyance issues occur. By continuously monitoring belt condition through image capture and processing, the system identifies degradation trends early and determines optimal replacement timing in advance, preventing conveyance instability and inspection errors before they affect operations.
3Ease of operation
If manual inspection of conveyor belt condition is performed, then replacement decisions can be made, but detection accuracy and timeliness are insufficient
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical detection system. Image reading devices capture detailed images of the conveyor belt, and computer-based image processing automatically analyzes degradation patterns, substituting human judgment with precise optical-mechanical measurement systems that provide both ease of operation and high detection accuracy.
Solution Approach 2:
The system creates optical copies (images) of the conveyor belt's surface condition through image reading devices. These digital copies are then processed by image processing algorithms to accurately assess degradation levels, allowing precise measurement of belt condition without direct manual contact or subjective visual evaluation.
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 allows for accurate detection of conveyor belt degradation, preventing unstable conveyance and ensuring timely replacements, thus maintaining inspection accuracy and reducing unnecessary replacements, thereby enhancing the reliability and efficiency of the paper sheet processing apparatus.
Implementation Method 1
an image reading device that obtains an image of the paper sheet and an image of the conveyor belt
Data Source
Figure 1
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Figure 4
AI summary
According to one embodiment, a paper sheet processing apparatus (10) includes a conveyance device with a conveyor belt (BL1), and an inspection device configured to inspect a paper sheet (P) conveyed by the conveyor belt. The inspection device includes an image detection device (46) configured to capture an image of the paper sheet and the conveyor belt and obtain an image of the paper sheet and the conveyor belt, an image processing device (16) configured to detect a degradation level of the conveyor belt based on an belt image of the conveyor belt, and a controller (15) configured to transmit information encouraging replacement of the conveyor belt to a monitor (68).