Conveyor Controller Using Optical Imaging for Fitting Accuracy
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for checking the fitting accuracy of conveyor devices in production plants, particularly in automobile factories, are inefficient due to manual placement and operation of test gauges, leading to potential errors and disruptions in the conveying process.
Innovation Solution
A control device equipped with imaging devices, such as cameras, automatically records and evaluates the relative positions of elements in the conveyor system, workpieces, and workpiece carriers, ensuring accurate fitting and preventing errors during normal operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual test gauges are used to check skid pins, then the fitting accuracy can be verified, but the testing process is time-consuming and requires manual intervention
Solution Approach 1:
The patent replaces manual mechanical test gauges with an automated optical measurement system using cameras and image processing. The system captures images of skid pins and workpiece carriers, automatically processes these images to determine positions and distances, and compares them against tolerance ranges without requiring manual measurement operations.
Solution Approach 2:
The measurement system performs self-verification by automatically capturing images, processing them through evaluation algorithms, and determining compliance with tolerance specifications. The system autonomously completes the entire measurement and evaluation process without requiring continuous manual intervention or operation of mechanical test equipment.
2Reliability
If manual operation of mechanical slides is used for testing, then the skid pin positions can be checked, but operator errors and disruptions may occur
Solution Approach 1:
The patent replaces manual mechanical slide operations with an automated optical measurement system. Cameras capture images of the skid pins and workpiece carriers, and image processing algorithms automatically determine positions and distances, eliminating the need for manual mechanical operations and associated operator errors.
Solution Approach 2:
The system creates optical copies (images) of the physical components and performs measurements on these digital representations. This allows the measurement process to be decoupled from the physical components, enabling automated evaluation without direct manual manipulation of the test objects.
3Productivity
If continuous checking is performed during normal conveying operation, then production efficiency is maintained, but the measurement system must be highly automated
Solution Approach 1:
The patent implements continuous measurement during normal conveying operation by positioning cameras to capture images of skid pins and workpiece carriers as they move through the production line. The system processes images in real-time or near-real-time, maintaining continuous verification without interrupting the conveying process.
Solution Approach 2:
The patent replaces manual testing operations with an automated optical measurement system that can operate continuously during normal production. The system uses cameras and image processing algorithms to automatically capture, process, and evaluate measurements without requiring manual intervention or production stoppage.
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The aim of the invention is to provide a conveyor controller which allows a quick and reliable check of elements of a conveyor, a workpiece to be conveyed, and/or a workpiece support in order to achieve a good fitting precision during the interaction between the checked element and other elements of the conveyor, the workpiece to be conveyed, or the workpiece support. This is achieved in that the conveyor comprises one or more image-generating devices for generating at least one image, which represents at least one portion of the conveyor, a workpiece to be conveyed and/or a workpiece support. The conveyor also comprises an analyzing device, by means of which information on the relative position between at least one first element of the conveyor, the workpiece, or the workpiece support and at least one second element of the conveyor, the workpiece, or the workpiece support and/or information on the type of element of the conveyor, the workpiece, or the workpiece support can be ascertained from the at least one image.