Article Counting Scale with Adaptive Tolerance Control
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Solution Overview
Problem
Current methods for checking article counts by weighing, such as passive and active methods, face limitations including low quality control, random tolerance acceptance, and inability to adapt to varying quantities or low weights, with existing systems requiring manual data entry and lacking centralized management.
Innovation Solution
A method and device that allow for centralized management of article weights across multiple scales, using a remote computer system to set tolerance ranges based on average unit weights and quantities, with an independent indicator unit for simplified interfacing and error-free data exchange, enabling precise control and tracking of article counts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a 5% tolerance is used in the active method, then the control is safe and transparent to the operator, but the absolute tolerance increases with quantity and can exceed the unit weight of the item
Solution Approach 1:
The patent applies dynamics by making the tolerance adaptive rather than fixed. The system dynamically adjusts the tolerance based on the quantity of items being counted, using statistical methods to calculate appropriate tolerance levels that maintain precision regardless of item quantity. This resolves the contradiction by allowing the tolerance to change according to the specific counting scenario.
Solution Approach 2:
The patent changes the tolerance parameter from a fixed percentage to a dynamically calculated value based on statistical analysis of the items being counted. By modifying how the tolerance parameter is determined (using mean, standard deviation, and confidence intervals), the system maintains measurement precision across different quantities while preserving control safety.
2Quantity of substance
If the scale range value is forced to be used, then the measurement coverage is maximized, but the precision decreases for small quantities of items
Solution Approach 1:
The patent applies dynamics by enabling the scale to dynamically adjust its measurement range based on the quantity and characteristics of items being counted. Rather than forcing a fixed scale range, the system adapts the measurement parameters to match the actual counting needs, thereby maintaining precision for small quantities while preserving coverage for large quantities.
Solution Approach 2:
The patent changes the measurement parameters (such as tolerance levels and expected weight ranges) based on the quantity of items. By adjusting these parameters dynamically, the system optimizes precision for each specific counting scenario rather than being constrained by a fixed scale range setting.
3Ease of manufacture
If manual data entry is required for each item, then the system is flexible and easy to implement, but the productivity and accuracy decrease
Solution Approach 1:
The patent applies self-service by enabling the system to automatically gather, process, and analyze item data without requiring manual data entry. The weighing system autonomously collects weight information, retrieves item characteristics from databases, performs statistical analysis, and generates counting results automatically, thereby dramatically improving productivity while maintaining ease of use through automated workflows.
Solution Approach 2:
The patent replaces the manual mechanical process of data entry with an automated electronic system. By substituting human operators with automated data collection and processing mechanisms (sensors, databases, and algorithms), the system maintains simplicity of implementation while dramatically increasing counting efficiency and accuracy.
4Ease of operation
If the tolerance is accepted or refused randomly in the passive method, then the operator has flexibility, but the quality level remains minimal and monitoring is not possible
Solution Approach 1:
The patent applies feedback by implementing a systematic monitoring mechanism that tracks each counting decision. The system provides feedback on whether items are accepted or rejected based on statistical criteria, allowing operators to understand the rationale behind each decision. This feedback loop enables quality monitoring and ensures consistent application of tolerance standards while preserving operator flexibility to override decisions when needed.
Data Source
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AI summary
The method involves performing communication between an embarked weighting system (105) and a terminal (110) e.g. personal computer, for obtaining information representative of constant, tolerance and limit values. Weight range is fixed based on a product of number of items by average weights and the limit values. Number of current items representing a weight within the weight range is counted by the weighting system until the number of items reaches specific value. A signal representative of end of counting of number of current items is transmitted to the terminal. An independent claim is also included for a device for counting items.