Occupancy Detection via Adjustable Sensor Positioning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing systems for determining the degree of occupancy of transport devices in container treatment plants face challenges with complex and costly sensor setups, especially when handling non-cooperative container surfaces, leading to unreliable detection and increased operational costs due to the need for frequent adjustments with different container types.
Innovation Solution
A device using simple, process-stable components without intelligent detection devices like cameras or laser technology, employing two detection devices to indirectly measure occupancy based on their positions, allowing for reliable detection regardless of container type and conveyor belt width, with minimal calibration effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If camera systems or intelligent sensors are used to detect occupancy, then detection capability is improved, but device complexity and cost increase
Solution Approach 1:
The patent extracts the essential function of occupancy detection from complex camera systems and implements it using simple detection devices that only need to detect the presence or absence of containers at specific positions, eliminating the need for sophisticated image processing and analysis
Solution Approach 2:
The patent replaces expensive, complex intelligent sensors with inexpensive, simple detection devices that have no moving parts and require minimal maintenance, achieving reliable occupancy detection at a fraction of the cost of camera systems
2Measurement precision
If camera systems are used to detect occupancy, then detection coverage is improved, but reliability decreases for non-cooperative surfaces
Solution Approach 1:
The patent replaces optical detection methods (cameras) that struggle with non-cooperative surfaces with a mechanical positioning system where detection devices are fixed at predetermined positions, reliably detecting container presence regardless of surface characteristics
Solution Approach 2:
The detection devices automatically detect container presence at their fixed positions without requiring adjustment or calibration for different container types, providing consistent reliable operation across various container surfaces
3Measurement precision
If complex sensors with special software are used, then detection accuracy is improved, but ease of operation deteriorates due to setting effort
Solution Approach 1:
The patent divides the conveyor belt into multiple predetermined detection positions with dedicated detection devices, where each device is fixed at a specific location and only needs to detect presence at that position, eliminating the need for global calibration
Solution Approach 2:
The patent changes the detection approach from requiring adjustable parameters (camera focus, lighting, software thresholds) to fixed physical positions where detection devices inherently detect container presence through their predetermined location
4Measurement precision
If adjustment work is performed for new container types, then detection accuracy is maintained, but productivity decreases due to downtime
Solution Approach 1:
The patent creates a universal detection system where detection devices at fixed positions can detect all container types without adjustment, as the predetermined positions cover the entire conveyor belt width and detect presence regardless of container dimensions
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
A device (23) and a method for determining the occupancy level of a transport device (20) are provided. The device (23) comprises an adjustment device (28) for adjusting at least one detection device (25, 26) such that the at least one detection device (25) detects the transport device (20) without transported goods after detecting goods transported by the transport device (20), or vice versa, and a determination device (29) for determining a current occupancy level of the transport device (20) based on the position of the at least one detection device (25, 26) set by the adjustment device (28).