Conveyor System State Detection via Image Analysis
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Solution Overview
Problem
Conveyor system maintenance is hindered when mains power is unavailable, as communication through the data bus is disabled, limiting access to error data, and visual cues from light sources are insufficient for determining the system's state due to human limitations.
Innovation Solution
A method and apparatus that utilize an image capturing module to receive and analyze image frames from light sources, comparing pixel characteristics to reference data to determine the conveyor system's state, generating a detection result to express the system's status, even in power-outage scenarios.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the technician uses visual monitoring of light sources to determine system state, then the system can operate without data bus access, but the information transmission capacity is limited by human visual capacity and cognitive skills
Solution Approach 1:
The patent replaces the human visual-cognitive system with an automated image processing system. The image capturing module captures light source patterns, and image processing circuitry automatically analyzes pixel characteristics to determine system state, substituting human eyes and brain with mechanical/optical detection and digital processing components.
Solution Approach 2:
The patent introduces an intermediary image processing system between the light sources and the technician. Instead of the technician directly observing light sources, the image processing circuitry acts as an intermediary that captures, processes, and interprets the light patterns, converting visual information into actionable diagnostic data.
2Reliability
If the data bus communication is disabled during power outage, then the system can operate on reserve power, but the technician cannot access error data from controllers
Solution Approach 1:
The patent introduces an intermediary image processing system that captures information from light sources without requiring data bus access. The image capturing module and processing circuitry serve as intermediaries that can obtain system state information through optical signals even when electronic communication paths are unavailable.
Solution Approach 2:
The patent replaces electronic data bus communication with an optical-mechanical detection system. Instead of accessing error data through electronic controllers and data buses, the system uses image capturing modules and pixel analysis to determine system state, substituting electronic communication with optical detection and digital image processing.
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 effective determination of the conveyor system's state by converting visual information from light sources into actionable data, facilitating maintenance even without access to the data bus, thereby improving maintenance efficiency during power outages.
Implementation Method 1
receiving a plurality of image frames from an image capturing module
Data Source
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AI summary
The invention relates to a method for determining a state of a conveyor system (100), the method comprises: receiving (210) a plurality of image frames (300) from an image capturing module (450); determining (220) at least one characteristic of a number of pixels from each of the plurality of image frames (300); comparing (230) the determined at least one characteristic of the number of the pixels to reference data; setting (240), in accordance with a comparison (230) of the determined at least one characteristic of the number of the pixels to the reference data, a detection result to express the state of the conveyor system (100). The invention also relates to an apparatus (150, 160), a computer program product, and to a system thereto.