Linear Camera Image Acquisition Synchronization on Conveyor Belts
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Solution Overview
Problem
Existing image acquisition systems for conveyor belts struggle with accurately setting linear camera parameters to match the instantaneous speed and conditions of the conveyor belt, leading to distorted images and incorrect code reading, especially during speed variations or temporary stops.
Innovation Solution
The method synchronizes image acquisition frequency with the pulses from an advance sensor, allowing for precise adjustment of sensitivity and focus based on the object's position, independent of conveyor belt speed, and uses a trigger event to initiate and end image acquisition, ensuring correct image capture even during speed changes or stops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If image acquisition frequency is adjusted based on conveyor belt speed, then image acquisition can adapt to speed variations, but image distortion occurs during speed changes or stops due to parameter mismatch
Solution Approach 1:
The system continuously monitors the actual position of objects on the conveyor belt using an advance sensor and feedback controller, then adjusts the linear camera parameters in real-time based on this feedback. The feedback controller calculates the actual speed and position of objects and dynamically adjusts acquisition frequency, sensitivity, and focus to maintain image quality during speed variations and stops.
Solution Approach 2:
The patent implements dynamic parameter adjustment where the linear camera's acquisition frequency, sensitivity, and focus are continuously adapted based on real-time conveyor belt conditions. Instead of fixed parameters, the system dynamically modifies these settings in response to changing object positions and speeds, enabling accurate image capture throughout the entire object passage.
2Productivity
If linear camera parameters are adjusted for high speed acquisition, then productivity increases, but camera saturation occurs during stops or slow movements causing loss of information
Solution Approach 1:
The system dynamically adjusts the linear camera parameters including acquisition frequency, sensitivity, and focus based on real-time object position and conveyor speed. When objects are detected or the conveyor slows/stops, the system automatically reduces acquisition frequency and adjusts sensitivity to prevent camera saturation while maintaining information capture, thereby ensuring reliable code reading across all operating conditions.
3Device complexity
If fixed parameters are used for image acquisition, then device complexity is reduced, but measurement precision deteriorates during speed variations
Solution Approach 1:
The patent employs a feedback controller that continuously monitors object position using an advance sensor and automatically adjusts linear camera parameters. This feedback mechanism enables precise position detection and accurate image acquisition during speed variations without requiring complex manual intervention, as the system self-regulates based on real-time measurements.
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 ensures undistorted image acquisition and accurate code reading across varying conveyor belt conditions, preventing camera saturation and maintaining image quality during speed fluctuations and temporary stops.
Implementation Method 1
setting at least one image acquisition parameter of the linear camera in function of the position of the object on the conveyor belt, said position being calculated by the linear camera, or by the control device, by counting the pulses of the signal of the advance sensor
Implementation Method 2
The image is acquired by storing subsequent scans, each of which represents a very thin 'line' of the whole image. The movement of the supporting plane, or of the object, at the fixed reading station, enables successive lines of the image to be acquired
Data Source
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AI summary
A method for image acquisition of an object (3) in transit on a movable supporting surface (2), comprises the following steps : - arranging at least one optical device for image acquisition comprising a respective linear camera (1) associated with a lighting device (5); detecting a presence signal of said object (3) in a preset position on said movable supporting surface (2), and signals indicating at least one dimension and/or the position of said object (3) on said movable supporting surface (2), said signals being generated by at least one sensor (6; 7) arranged upstream of said linear camera (1) in the advancing direction (A) of said movable supporting surface (2); detecting a "trigger event" signal, generated on the basis of said presence signal, said linear camera (1) starting to acquire an image of said object (3) on the basis of said "trigger event" signal,- - starting to acquire an image of said object (3) by said linear camera (1), when said object (3) has travelled a preset distance (D) from said preset position, said distance (D) being calculated by an advance sensor (8) suitable for generating a signal comprising an electric pulse at each preset movement of said movable supporting surface (2), said method further comprising setting a mode for image acquisition of said linear camera (1) on the basis of a resolution of said advance sensor (8).