Egg Count Sensor with Multi-Row Detector Array
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Solution Overview
Problem
Existing object counting devices struggle to accurately count objects, particularly rounded objects like eggs, when they move in the opposite direction to the conveying device, leading to counting errors due to their inability to distinguish movement direction.
Innovation Solution
A counting device with multiple detector rows that allow objects to pass through both rows in regular relative movement, enabling detection and identification of the object's direction of movement by comparing signals from adjacent detectors, and a modular design to adapt to varying conveyor widths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single row of detectors is used to count objects on a conveyor belt, then the device complexity is reduced, but the measurement precision of object movement direction deteriorates
Solution Approach 1:
The patent transitions from a single-row detector arrangement to a two-dimensional grid arrangement with multiple rows and columns of detectors. This dimensional expansion enables the system to detect not only the presence of objects but also their movement direction by comparing signals across different spatial positions, thereby resolving the contradiction between device simplicity and measurement precision.
Solution Approach 2:
The detector array is segmented into multiple rows and columns, with each detector element independently detecting objects at its specific position. This segmentation allows the system to analyze spatial patterns of detected objects across different detector elements, enabling movement direction determination while maintaining manageable device complexity through modular detector units.
2Productivity
If rounded objects are conveyed on a conveyor belt, then the productivity of egg collection is improved, but the reliability of counting deteriorates due to objects moving independently and rolling in opposite directions
Solution Approach 1:
The system uses feedback from multiple detector elements to track object movement patterns. By continuously monitoring which detectors register objects and comparing this information across time intervals, the system can determine whether objects are moving with or against the conveyor direction, thereby maintaining counting reliability even when rounded objects roll independently.
Solution Approach 2:
The patent implements a dynamic counting approach that adapts to the actual movement behavior of rounded objects. Instead of assuming objects always move in the conveyor direction, the system dynamically determines movement direction based on real-time detector signals, allowing accurate counting regardless of whether objects roll forward or backward on the conveyor belt.
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 device reliably counts objects even when they move in the opposite direction, reducing counting errors and providing additional data on production processes, including irregular movements and product quality, enhancing production control and animal welfare monitoring.
Implementation Method 1
each of which has a locally limited detection area, which can detect electromagnetic radiation, in particular light in the visible or infrared range, from the detection area
Data Source
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Figure 3
AI summary
The device has two detectors, where later detector has locally limited detection range, and an electromagnetic radiation to detect particularly light within the visible or infrared range from the detection range. The evaluating unit is coupled with the later detector and is designed to process the signals of the later detector, and determine the presence of an object in the detection range of the later detector due to the signal of each detector. Independent claims are also included for the following: (1) a demand-driven transportation device for objects particularly eggs (2) a device for transporting and counting and/or quality supervising of eggs.