Dynamic Code Reader Control for Changing Conveyor States
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Solution Overview
Problem
Existing code readers fail to adapt to changes in the conveyance state of workpieces during operation, leading to potential reading errors due to fixed capturing conditions.
Innovation Solution
A controller system that dynamically determines control parameters for cameras or code readers based on the conveyance state and installation information, ensuring optimal capturing and decoding processes even when the conveyance state changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If fixed capturing conditions are set before operation, then the code reader can operate stably under constant conveyance state, but reading errors occur when the conveyance state changes
Solution Approach 1:
The patent implements dynamic adjustment of capturing conditions by continuously monitoring the conveyance state and automatically modifying capturing parameters (such as exposure time, gain, or triggering timing) based on detected changes in workpiece conveyance speed or position. This allows the code reader to adapt to varying conveyance states in real-time, preventing reading errors that would occur with fixed capturing conditions.
2Reliability
If capturing conditions are adjusted dynamically based on conveyance state, then reading accuracy is maintained under varying conveyance conditions, but system complexity increases
Solution Approach 1:
The patent employs a feedback mechanism where the detection sensor continuously monitors the conveyance state (position, speed) and feeds this information back to the control unit. The control unit then automatically adjusts capturing conditions based on this feedback, creating a closed-loop system that maintains reading accuracy without requiring complex manual intervention or overly sophisticated control architecture.
Solution Approach 2:
The code reading system performs self-adjustment by automatically detecting conveyance state changes and modifying its own capturing parameters without external intervention. The system monitors its operating environment and autonomously optimizes its performance, reducing the need for complex external control systems or manual recalibration.
3Measurement precision
If multiple detection sensors and cameras are used to monitor conveyance state, then accurate real-time adjustment is achieved, but device complexity and cost increase
Solution Approach 1:
The patent designs the detection sensor and camera system to serve multiple functions: the detection sensor not only monitors conveyance state for capturing condition adjustment but also potentially triggers the capturing sequence and provides positional information for code location. The camera serves both for capturing the code image and for verifying workpiece presence. This multi-functionality reduces the need for separate dedicated components for each function, thereby reducing overall system complexity while maintaining measurement precision.
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 system effectively suppresses reading errors by adjusting control parameters in real-time, ensuring accurate code capture and decoding regardless of conveyance state fluctuations.
Implementation Method 1
one or a plurality of cameras that generate images based on reflected light from a code attached to a workpiece
Data Source
AI summary
Occurrence of a reading error is suppressed even in a case where a conveyance state of a workpiece changes during operation. The controller includes an acquisition unit that acquires a detection signal of the workpiece, a conveyance speed of a conveyor, and installation information indicating relative position and posture of each camera with respect to the conveyor, a recognition unit that recognizes a conveyance state of the workpiece based on the detection signal and the conveyance speed, a processing determination unit that determines a control parameter corresponding to a conveyance position of the workpiece on the conveyor for each camera based on the conveyance state and the installation information of each camera, and a communication unit that transmits the control parameter determined by the processing determination unit to each corresponding camera.