Conveyor Package Tracking with Light Barrier Event Estimation
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Solution Overview
Problem
Existing methods for tracking packages on conveyor routes are prone to inaccuracies due to irregularities such as slipping, jamming, and pushing of packages, leading to uncertainty in position determination and interruptions in tracking.
Innovation Solution
An algorithm using a Viterbi algorithm within a Hidden Markov Model is employed to determine the most likely sequence of events causing light barrier patterns, considering system parameters like conveyor speed and geometry, to enhance tracking accuracy and minimize errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single photodetector is used to determine package position by detecting passage and calculating distance from conveyor travel, then the tracking system is simple to implement, but the position determination becomes highly inaccurate due to slippage, jumping, and temporary shifting of packages
Solution Approach 1:
The conveyor line is divided into multiple tracking zones with separate light barriers positioned at different locations. Instead of relying on a single photodetector, the system uses multiple detection points to create a sequence of events that collectively determine package position, thereby distributing the measurement function across multiple independent units.
Solution Approach 2:
The system continuously monitors light barrier signals and uses algorithmic processing to compare expected package positions with actual detection data. When discrepancies are detected (such as slippage or jumping), the system generates feedback to correct position calculations and maintain accurate tracking despite conveyor irregularities.
2Measurement precision
If multiple light barriers are deployed along the conveyor line to improve tracking accuracy, then position determination becomes more reliable, but the system complexity and cost increase significantly
Solution Approach 1:
Each light barrier serves multiple functions: it detects package passage, provides timing information for algorithmic processing, and contributes to the overall event sequence that determines both position and velocity. This multi-functionality reduces the need for additional specialized sensors.
Solution Approach 2:
The patent replaces complex mechanical tracking mechanisms with an algorithmic system that processes simple light barrier signals. Instead of using sophisticated physical measurement devices, the invention uses computational methods to extract precise position and velocity information from basic optical detection events.
3Reliability
If the tracking system continuously monitors all packages along the conveyor, then complete tracking information is obtained, but interruptions and errors occur due to package irregularities such as slippage, jamming, and pushing
Solution Approach 1:
The system establishes expected package positions and timing sequences in advance based on conveyor speed and package spacing. By comparing actual light barrier signals against these pre-calculated expectations, the system can anticipate and correct for irregularities before they cause tracking failures.
Solution Approach 2:
The algorithmic processing system converts potentially harmful tracking interruptions into useful information. When light barrier signals show unexpected patterns due to slippage or jamming, the system uses these anomalies to recalculate package velocity and position, ultimately improving tracking accuracy by adapting to real-world conveyor irregularities.
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 approach significantly improves the tracking rate of packages while maintaining a low error rate by accurately assigning package positions and handling irregularities, such as slipping and jamming, along the conveyor route.
Implementation Method 1
a conveyor line (10) with a conveying surface for transporting a sequence of packages (P1, P2, P3) is provided, the conveyor line including at least one light barrier (LS1, LS2, LS3) for detecting the packages
Data Source
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AI summary
In a method for tracking packages on a conveyor, the tracking rate of packages is to be maximized. This is achieved by specifying a method for tracking packages on a conveyor, wherein the method comprises the following steps: a) providing a conveyor (200) with a conveying surface for conveying a sequence of packages, wherein the conveyor includes at least one light barrier (LS1, LS2, LS3) for detecting the packages, b) detecting (210) a light barrier pattern (1) by means of the light barrier (LS1, LS2, LS3), wherein the light barrier pattern (1) is caused by the sequence of packages, c) detecting (220) a conveying velocity of at least a section of the conveyor, d) estimating (230) a sequence of events that caused the light barrier pattern (1) with the highest probability, taking into account the conveying velocity of the conveyor.by means of an algorithm, wherein the algorithm comprises the following further steps: e) creating (240) a list of possible event sequences, f) sorting (250) the event sequences according to their probability of occurrence, g) extending (260) the most probable event sequence by all possible subsequent events, determining the probability of the event sequence for each extension, h) inserting (270) the extensions as a new event sequence into the list of event sequences, i) repeating (280) steps g) to h) until the most probable event sequence completely maps the detected light barrier pattern (1).