Conveyor Roller Parcel Detection Using Adjustable Side Sensors
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Solution Overview
Problem
Conventional infrared sensors in conveyor systems have limitations in detecting parcels of varying heights, necessitating a minimum allowable height specification for optimal function, which restricts flexibility and efficiency.
Innovation Solution
An object detection system for conveyors utilizing a sensing unit with an emitter, reflector, and receiver, where the emitter emits signals that are reflected off the roller surface and adjusted by a rotating knob, allowing for angles between 45-90 degrees, and a lighting unit that operates based on signal reception or obstruction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If infrared sensors are positioned above rollers to detect parcel presence, then parcel detection capability is improved, but detection reliability deteriorates for parcels of varying heights
Solution Approach 1:
The sensing unit is repositioned from above the rollers to the side of the rollers, changing the spatial dimension of detection. This side-mounted configuration allows the emitter and receiver to detect parcels at various heights along the roller surface, eliminating the height limitation inherent in top-mounted sensors while maintaining accurate parcel presence detection
Solution Approach 2:
The roller surface acts as an intermediary element in the detection process. The emitter projects infrared signals onto the roller surface, and the reflected signals are captured by the receiver. This intermediary arrangement enables indirect detection of parcels at any height on the roller, resolving the reliability issue for varying parcel heights while preserving detection precision
2Device complexity
If a fixed sensing configuration is used, then device complexity is reduced, but adaptability deteriorates for different parcel heights
Solution Approach 1:
The sensing unit incorporates adjustable components including a rotatable emitter with angle adjustment mechanism and a movable receiver along the roller surface. These dynamic elements allow the detection system to adapt to different parcel heights and positions without changing the overall device structure, achieving versatility while maintaining relatively simple device complexity
Solution Approach 2:
The side-mounted sensing unit with adjustable emitter angle and receiver position serves multiple detection functions simultaneously - it can detect parcels of any height, determine parcel presence, and monitor parcel position along the roller. This multi-functional design achieves high adaptability for different parcel configurations while avoiding the need for multiple separate sensing systems
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 accurate detection of parcels across a wider height range, enhancing operational flexibility and efficiency by adjusting signal angles and providing real-time notification of parcel presence or absence.
Implementation Method 1
the surface of the roller is configured to reflect the one or more signals emitted by the at least one emitter
Data Source
AI summary
An object detection system for a conveyor, where the object detection system comprises at least one sensing unit installed at a first side of at least one roller assembly of the conveyor. The at least one sensing unit comprises at least one emitter configured to emit one or more signals towards a surface of a roller of the at least one roller assembly. The surface of the roller reflects the one or more signals. Further, a knob coupled with the at least one emitter, rotates the at least one emitter to adjust one or more angles of the one or more signals. Thereafter, at least one reflector installed at a second side of the at least one roller assembly, configured to receive the one or more signals reflected from the surface of the roller and reflect the one or more signals towards the at least one receiver.