Conveyor Laser Scanner Detecting Fallen Articles
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Solution Overview
Problem
Existing conveyor devices struggle to accurately recognize and correct the positioning of articles and containers of varying sizes and shapes on a conveyor belt, leading to disruptions when items fall or are incorrectly positioned, as they require adaptation for different container sizes and are not universally applicable.
Innovation Solution
A conveyor device equipped with an optical detection system using a laser scanner above the conveying plane to detect the volume of objects, allowing for the identification of missing, incorrectly positioned, or fallen items by comparing the detected volume to a defined area, which can trigger an error signal or shut off the conveyor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional monitoring devices are used to detect container position, then detection can be achieved, but the devices must be adapted for each specific container size and shape
Solution Approach 1:
The patent applies universality by using a single optical detection device with a camera that can detect and differentiate various container sizes, shapes, and positions without requiring physical adaptation. The system processes images to identify container characteristics universally, eliminating the need for multiple specialized detectors for different container types.
Solution Approach 2:
The system changes detection parameters (such as threshold values, detection zones, and evaluation criteria) through software rather than hardware modification. This allows the same physical device to adapt to different container specifications by adjusting detection parameters, resolving the contradiction between versatility and complexity.
2Reliability
If articles are not properly positioned on the conveyor, then handling disruptions occur, but detecting and correcting all positioning errors is difficult with existing systems
Solution Approach 1:
The patent replaces mechanical sensing systems with an optical detection system using a camera and image processing. This substitution enables non-contact detection of container position, orientation, and condition, making it easier to identify positioning errors and improving detection capability while maintaining conveyance reliability.
Solution Approach 2:
The system introduces an intermediary evaluation unit that processes camera images and determines container status. This intermediary layer translates raw visual data into actionable detection results, simplifying the detection process and improving the system's ability to identify positioning errors reliably.
3Measurement precision
If the detection area is positioned vertically above the conveying plane, then objects can be detected without distortion, but the detection device must be positioned higher
Solution Approach 1:
The patent positions the detection device in a vertical dimension above the conveying plane, using top-down imaging to eliminate perspective distortion. This dimensional change allows accurate detection of container position and orientation without the complexity of angled or side-mounted sensors, accepting the trade-off of increased height for improved measurement precision.
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
Enables universal recognition and correction of article positioning regardless of size or shape, preventing disruptions by accurately identifying and addressing mispositioned or fallen items, ensuring smooth handling and processing.
Implementation Method 1
an optical detection device which is arranged above the conveying plane and detects a partial area of a room above the conveying plane
Data Source
Figure 1~2
Figure 3
AI summary
A conveying device (10) for a plurality of articles or objects moved on a conveying level (18) is disclosed, which includes a detection device (14) for recognizing articles or objects that are missing, incorrectly positioned, and/or have fallen over on the conveying level (18). The detection device (14) comprises an optical detection device (16) arranged above the conveying level (18) and detecting a partial area of a space above the conveying level (18), with a downstream evaluation unit. Preferably, the optical detection device (16) is formed by a laser scanner (20), wherein an evaluation circuit detects and determines a volume range of the articles or objects within a defined area (24) above the conveying level (18).