Automated Gauge Dial Reading via Image Processing

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Solution Overview

Problem

Manual inspection of analog gauges in challenging environments, such as hazardous or hard-to-access locations, is costly, time-consuming, and laborious, making it difficult to obtain and report readings efficiently.

Innovation Solution

A method and system utilizing a processor to identify gauge dial patterns, generate line patterns approximating needle patterns, determine deflection angles, and convert them into readable formats, allowing for automatic recognition and reporting of gauge readings, which can be acted upon remotely.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If manual inspection of analog gauges is performed, then reading can be obtained, but it is costly, time-consuming, and laborious

Engineering Contradiction:

Improveinspection efficiencyVSAvoidtime required for manual inspection

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The patent uses image copying to capture the gauge dial and needle, then processes the copied image data to determine the reading. This eliminates the need for manual physical inspection while maintaining reading accuracy, directly resolving the contradiction between inspection efficiency and time loss.

Inventive Principle:

Principle #26Copying

Solution Approach 2:

The patent replaces manual mechanical inspection with an automated image processing system that uses cameras and computer vision algorithms to read gauge values. This substitution eliminates human labor and time consumption while improving productivity.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If manual inspection is performed in hazardous environments, then reading can be obtained, but safety risks increase

Engineering Contradiction:

Improvereading accuracyVSAvoidsafety risks in hazardous environments

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent introduces an intermediary image processing system that captures gauge information remotely and processes it automatically. This intermediary system allows reading acquisition without direct human exposure to hazardous environments, maintaining both reading accuracy and safety.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

By copying the gauge visual information through cameras and processing it computationally, the system obtains accurate readings without requiring personnel to physically access hazardous areas, thus eliminating safety risks while preserving reliability.

Inventive Principle:

Principle #26Copying

3Ease of operation

If manual inspection is performed in hard-to-access areas, then reading can be obtained, but accessibility difficulties increase

Engineering Contradiction:

Improveease of gauge inspectionVSAvoidcomplexity of inspection system

Core Design Contradiction:

Ease of operationVSDevice complexity

Solution Approach 1:

The patent replaces complex manual inspection procedures with automated image capture and processing systems. While the technology itself has complexity, it dramatically simplifies the inspection operation by eliminating the need for physical access to hard-to-reach gauges, improving ease of operation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system creates visual copies of gauge readings through remote imaging, allowing inspection of hard-to-access areas without requiring physical presence. This copying approach simplifies the operational complexity by enabling remote observation and automated data extraction.

Inventive Principle:

Principle #26Copying

4Productivity

If multiple analog gauges in different locales are inspected manually, then all readings can be obtained, but labor requirements increase

Engineering Contradiction:

Improvereading acquisition rateVSAvoidease of automated reading

Core Design Contradiction:

ProductivityVSEase of operation

Solution Approach 1:

The patent develops a universal image processing system that can read multiple different types of analog gauges across different locations through standardized image capture and recognition algorithms. This multi-functional approach increases productivity by handling multiple gauges simultaneously while maintaining ease of operation through automated processing.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system substitutes manual inspection labor with automated computer vision technology that can process multiple gauge images simultaneously. This substitution dramatically increases reading acquisition rate while keeping the operation simple through centralized automated processing.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS10970584B2Systems, devices, and methods for evaluating readings of gauge dials

Publication Date: 2021.04.06 INTELLIGENT SECURITY SYSTEMS CORP

AI summary

A method includes identifying, by a processor, a gauge dial pattern in a first file based on a gauge dial template in a second file; identifying, by the processor, a needle pattern in the first file; generating, by the processor, a line pattern that approximates the needle pattern; determining, by the processor, a deflection angle of the needle pattern with respect to the gauge dial pattern based on the line pattern; converting, by the processor, the deflection angle into a reading of the gauge dial pattern based on the gauge dial template; and taking, by the processor, an action based on the reading.