Conveyor Sensor Integration for Object Detection
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Solution Overview
Problem
Conventional methods for monitoring occupancy and position of objects on conveyor devices with individual compartments are costly, error-prone, and inefficient, especially at higher conveying speeds, often requiring multiple sensors and complex image processing.
Innovation Solution
Integration of a sensor element, such as a microwave resonator or capacitive electrode, directly into the conveying elements of the conveyor device, which follows the movement and provides continuous, reliable detection of object presence and position with minimal installation effort, and is insensitive to dust and dirt.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single camera is positioned at a relevant section of the conveyor to capture passing objects, then the system cost is reduced, but the image processing complexity increases and detection reliability deteriorates at higher conveyor speeds
Solution Approach 1:
The patent divides the detection function into multiple sensor elements distributed at different positions along the conveyor. Each sensor element independently detects objects in its specific compartment, eliminating the need for complex image processing of entire conveyor scenes while maintaining high detection reliability at various conveyor speeds.
Solution Approach 2:
The patent replaces optical camera-based detection with microwave resonance-based sensor elements. This substitution enables continuous, real-time detection without the limitations of frame-rate cameras, ensuring reliable detection even at high conveyor speeds while reducing overall system complexity.
2Measurement precision
If multiple sensors are arranged on the conveyor belt to detect objects, then detection precision is improved, but the device complexity and installation cost increase
Solution Approach 1:
The patent implements a modular sensor system where identical sensor elements are distributed at specific intervals corresponding to compartment positions. Each sensor element is a self-contained unit with standardized structure, simplifying both the individual component design and the overall system integration while maintaining high detection precision.
Solution Approach 2:
The sensor elements are designed as universal, multi-functional units that can detect various object properties (presence, position, dimensions) using microwave resonance principles. This universality allows the same sensor design to be deployed throughout the conveyor system, reducing device complexity compared to using multiple specialized sensors.
3Loss of information
If a camera system is used to monitor conveyor occupancy, then object position information can be obtained, but the system cannot track subsequent changes and requires extensive image processing
Solution Approach 1:
The patent employs sensor elements that continuously monitor their respective compartments throughout the conveyor operation. Unlike frame-based camera systems that capture discrete moments, the microwave resonance sensors provide continuous detection, enabling real-time tracking of object position changes without requiring repeated image processing.
Solution Approach 2:
The patent replaces computationally intensive image processing with direct microwave resonance measurement. The sensor elements directly measure object properties through physical interaction with microwave fields, providing immediate detection results without the need for complex image analysis algorithms and significantly reducing processing time.
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 precise and reliable detection of object occupancy and position across multiple compartments with reduced complexity and cost, improving the monitoring of conveyor devices without the need for extensive additional infrastructure.
Implementation Method 1
The sensor element is either a resonator for detecting a microwave resonance
Implementation Method 2
The sensor element is either a resonator for detecting a microwave resonance or a capacitive electrode
Data Source
Figure 1~2
Figure 3~4
AI summary
A sensor (10) for a conveyor (100) carrying objects (104) on a plurality of successively moving conveyor elements (102) is described, each with a discharge device (108) for selectively removing the object (104) from a conveyor element (102). The sensor (10) comprises a sensor element (12) integrated into the conveyor (100) and an evaluation unit (14) for signals from the sensor element (12). The sensor element (12) is integrated into a conveyor element (102) and includes a resonator (16) for detecting a microwave resonance or a capacitive electrode (18). The evaluation unit (14) is designed to detect objects (104) located on the conveyor element (102) based on changes in the resonance properties or the capacitance.