Laser Distance Sensor for Automated Egg Counting on Conveyor
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Solution Overview
Problem
Current automated systems for monitoring egg production in poultry houses face challenges such as high runtime complexity, complex setup processes, and inaccuracy due to dependencies on egg shape, size, contrast, and reflectance, especially when eggs are covered by feathers or droppings.
Innovation Solution
A system utilizing a conveyor with a laser sensor that measures distance fluctuations to identify eggs, eliminating the need for visual recognition algorithms and complex setups by detecting minima in distance measurements, which resemble an oval shape over time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If visual recognition algorithms are used to count eggs, then automated egg counting is achieved, but algorithm runtime complexity increases and setup becomes complex
Solution Approach 1:
The patent extracts the essential characteristic needed for egg detection (distance/height variation) from the complex visual recognition approach. By using a laser sensor to measure only the vertical distance between the conveyor belt and eggs, the system isolates the critical detection parameter, eliminating the need for complex image processing algorithms and reducing setup complexity while maintaining automated counting capability.
Solution Approach 2:
The patent replaces the optical/mechanical visual recognition system with a laser-based distance measurement system. This substitution transforms the detection mechanism from analyzing complex visual patterns to measuring simple distance variations, thereby reducing algorithmic complexity and simplifying the overall system setup while achieving the same automated counting function.
2Extent of automation
If infrared active sensor array is used to detect eggs, then automated detection is achieved, but accuracy decreases when eggs are covered by feathers and droppings
Solution Approach 1:
The patent extracts the critical geometric property (distance from conveyor) that remains constant regardless of egg surface conditions. By measuring only the vertical distance between the conveyor belt and the egg surface, the system eliminates dependency on egg reflectance, color, or surface coverage characteristics, thereby maintaining high detection accuracy even when eggs are covered by feathers or droppings.
Solution Approach 2:
The patent changes the detection parameter from optical properties (reflectance, color, intensity) to a geometric parameter (distance/height). This parameter transformation makes the detection process independent of egg surface conditions such as feathers or droppings, as the vertical distance measurement remains valid regardless of what covers the egg surface.
3Extent of automation
If visual recognition or infrared sensing is used, then automated counting is possible, but system accuracy depends on egg characteristics such as shape, size, and contrast
Solution Approach 1:
The patent extracts the invariant geometric characteristic (distance variation) from the variable egg characteristics (shape, size, color, contrast). By focusing measurement on the vertical distance between the conveyor and eggs, the system identifies a parameter that consistently varies with egg presence regardless of individual egg differences, thereby achieving reliable automated counting independent of egg-specific characteristics.
Solution Approach 2:
The patent transforms the detection approach by changing from optical parameters (affected by egg shape, size, color, contrast) to a geometric parameter (distance). This parameter change ensures that all eggs produce a detectable distance signal regardless of their individual characteristics, thereby improving the reliability and consistency of automated counting across diverse egg types.
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
This approach provides accurate egg counting without relying on egg characteristics, reducing algorithm complexity and setup requirements, ensuring reliable monitoring of poultry house egg production.
Implementation Method 1
at least one laser sensor directed in direction of said conveyor for measuring distance of said conveyor's surface and poultry eggs conveyed thereupon
Data Source
AI summary
Systems and methods for monitoring poultry house egg production. The system includes: a conveyor for conveying poultry eggs; at least one laser sensor directed in direction of said conveyor for measuring distance of said conveyor's surface and poultry eggs conveyed thereupon; a computer coupled with said at least one lase sensor; wherein, number of poultry eggs passed through said conveyor at a given moment is determined by identifying and analyzing fluctuations in measured distance from said at least one laser sensor.