Conveyor Pinch Point Detection Using Multi-Angle Imaging

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Solution Overview

Problem

Modern environments with conveyors pose a risk of pinch points, which can cause injuries to personnel as they handle items on or between conveyors, necessitating an efficient method to detect these hazards.

Innovation Solution

A device equipped with a container housing imaging devices, lighting elements, and a battery, which images markers on conveyors and analyzes image data from intersections to determine if gaps exceed a threshold distance, indicating potential pinch points.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual inspection methods are used to check for pinch points, then personnel can directly assess hazards, but the process is time-consuming and labor-intensive

Engineering Contradiction:

Improveinspection efficiencyVSAvoidtime required for pinch point detection

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent replaces manual mechanical inspection with an automated imaging system using cameras and image processing algorithms. The device captures images of conveyor intersections and automatically analyzes them to detect pinch points, eliminating the need for personnel to physically inspect each location and significantly reducing inspection time while maintaining accuracy

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system performs self-inspection by automatically capturing, processing, and analyzing images of conveyor intersections. The image processing algorithm autonomously identifies pinch points without human intervention, allowing the system to inspect multiple locations independently and efficiently, thereby improving productivity and reducing time loss

Inventive Principle:

Principle #25Self-service

2Reliability

If comprehensive inspection of all conveyor intersections is performed, then all pinch points are detected, but the complexity of the inspection system increases

Engineering Contradiction:

Improvepinch point detection accuracyVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent employs a universal imaging device that can inspect multiple conveyor intersections with a single setup. The system uses standardized image processing algorithms that work across different intersection configurations, allowing one device to perform comprehensive inspection throughout the facility without requiring complex specialized equipment for each location, thus maintaining reliability while managing system complexity

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system creates visual copies (images) of conveyor intersections and analyzes these digital representations to detect pinch points. By working with image data rather than physically interacting with each intersection, the system achieves comprehensive detection across multiple locations without proportionally increasing physical system complexity, as the same imaging and processing infrastructure serves all inspection points

Inventive Principle:

Principle #26Copying

3Productivity

If automated imaging devices are used to detect pinch points, then inspection efficiency is improved, but the device complexity and cost increase

Engineering Contradiction:

Improveinspection throughputVSAvoiddevice structural complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent combines multiple functions into a single integrated device: the imaging device captures images, the image processing unit analyzes them, and the system outputs pinch point detections. By merging data capture, processing, and analysis functions into one unified system rather than separate components, the device achieves high inspection throughput while managing structural complexity through functional integration

Inventive Principle:

Principle #5Merging (Combining)

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

The device effectively identifies pinch points between conveyors, reducing the risk of injury and improving the throughput of items by allowing for the efficient detection and mitigation of hazardous gaps.

Implementation Method 1

a first imaging device is arranged to image a marker disposed between a first conveyor and a second conveyor

Methodology Applied

Scientific EffectLight reflection: Reflection

Implementation Method 2

The lighting element(s) are arranged to output light in a direction towards the second opening such that the intersection is illuminated when imaged

Methodology Applied

Scientific EffectLight emission: Light

Data Source

PatentUS12289539B1Device for determining pinch point(s) along conveyor(s)

Publication Date: 2025.04.29 AMAZON TECH INC

AI summary

A device includes a battery, a container, a frame, a first imaging device disposed at least partially within the container and coupled to the frame, a second imaging device disposed at least partially within the container and coupled to the frame, and a third imaging device disposed at least partially within the container and coupled to the frame. The first imaging device is oriented in a first direction, the second imaging device is oriented in a second direction that is different than the first direction, and the third imaging device is oriented in the second direction.