Fallen Container Detection Using Multi-Level Optical Sensors
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Solution Overview
Problem
Conveyor systems that merge into a wheel for serially loading containers, such as bottles or tubes, face challenges in detecting fallen containers due to their height-to-width ratio and reflective materials, leading to misfeed errors and operational inefficiencies.
Innovation Solution
A reliable optical detection system using at least two sensors, with a lower sensor positioned proximate an intake zone and an upper sensor above the container height, to detect fallen containers within a rotating wheel's pockets, ensuring accurate detection of different orientations and positions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single lower sensor is used to detect fallen containers, then the device complexity is reduced, but the detection reliability deteriorates because it cannot distinguish between upright and fallen containers when queues are more than one container deep
Solution Approach 1:
The detection system is segmented into multiple sensor levels: lower sensors positioned at container diameter height and upper sensors positioned above container height. This segmentation allows the system to differentiate between upright and fallen containers by checking which sensor levels are triggered, resolving the reliability issue when containers are queued more than one deep.
Solution Approach 2:
The solution adds a vertical dimension to sensor placement by positioning sensors at different heights (lower sensors at container diameter level, upper sensors above container height). This multi-level vertical arrangement enables the system to detect container orientation by determining which vertical levels are blocked, thereby improving detection reliability without excessive complexity.
2Reliability
If vertically stacked pairs of front and back sensors are used to detect fallen containers, then the detection capability improves, but the device complexity increases and detection reliability deteriorates when queues are more than one container deep
Solution Approach 1:
The sensor system is divided into functionally distinct lower sensors and upper sensors positioned at different vertical levels. Lower sensors detect containers at diameter height while upper sensors detect containers above that level. This segmentation creates a hierarchical detection structure that improves reliability by providing multiple detection levels without requiring complex sensor pairs at every position.
Solution Approach 2:
The multi-level sensor arrangement serves multiple functions: detecting fallen containers, detecting queues deeper than one container, and providing information about container orientation. This universal sensor configuration replaces the need for specialized sensor pairs for each detection scenario, reducing overall device complexity while maintaining or improving detection reliability.
3Device complexity
If sensors are positioned at fixed heights to detect fallen containers, then the device complexity is minimized, but the adaptability deteriorates when containers have varying orientations, positions, or when transparent/translucent materials with labels and varying fluid content are used
Solution Approach 1:
The system uses multiple vertical levels of sensors (lower sensors at container diameter height, upper sensors above container height) to detect containers in various orientations and positions. This multi-level vertical arrangement provides adaptability to different container orientations and queue depths without requiring complex adjustable positioning mechanisms, thus maintaining simplicity while improving versatility.
Solution Approach 2:
The sensor system provides feedback about container presence and orientation at different vertical levels. By monitoring which sensor levels are triggered, the system can adapt its detection logic to account for varying container orientations, positions, and queue configurations, improving versatility without adding mechanical complexity to sensor positioning.
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 enhances detection reliability and prevents misfeed errors by accurately identifying fallen containers and blockages, allowing for efficient operation and reduced downtime.
Implementation Method 1
at least one lower sensor that is positioned proximate an intake zone and/or loading position configured to project an optical signal across a container travel path
Data Source
AI summary
Systems and apparatus with circuits that are configured to detect fallen containers upstream or proximate an intake zone suitable for automated evaluation apparatus using different sensors, including at least one lower sensor and at least one upper sensor which is positioned to project an optical signal at a height corresponding to a top portion of an upright container to thereby allow an increased reliability in detection of different orientations and positions of fallen containers. An optional second lower sensor may be used which is longitudinally spaced apart from the first lower sensor and the lower sensors can transmit optical signals across the container travel path that do not intersect.