Optical Container Tracking on Multi-Lane Filling Conveyors
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Solution Overview
Problem
Existing container tracking methods in filling plants face challenges such as asynchronicity due to conveyor vibrations and inclines, and are not effective on multi-lane conveyors with amorphous container movement. Additionally, post-synchronization is technically demanding and limited by environmental conditions and sensor placement.
Innovation Solution
The method involves using at least one area-imaging sensor with a stationary imaging region to capture time-staggered images of containers as they move through the filling plant. The images are electronically evaluated to extract tracking data, including identification and location information, which are assigned to individual containers without requiring synchronization with the conveyor movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional conveyor-based tracking with rotary encoders is used, then tracking is possible on simple single-lane conveyors, but tracking becomes unreliable due to asynchronicity caused by vibrations, inclines, and guide rail contacts
Solution Approach 1:
The patent replaces the mechanical conveyor-based tracking system with an optical imaging system. Instead of using rotary encoders on drive axles to track container positions, the system uses area-imaging sensors to capture images of containers and electronically determines their positions. This substitution eliminates the asynchronicity problems inherent in mechanical conveyor tracking while providing more reliable and flexible container position monitoring.
Solution Approach 2:
The patent introduces images as an intermediary medium for tracking. Rather than directly measuring container position through mechanical means, the system captures images of containers and extracts position information from these images. This intermediary approach allows for indirect but accurate tracking that is not affected by conveyor vibrations or mechanical asynchronicity.
2Reliability
If post-synchronization using light barriers is implemented, then asynchronicity can be corrected, but additional technical effort and sensor maintenance are required
Solution Approach 1:
The patent replaces mechanical and optical synchronization devices (light barriers) with an electronic image processing system. The area-imaging sensors and electronic evaluation unit continuously monitor container positions without requiring physical synchronization interventions, thereby eliminating the technical effort and maintenance burden associated with light barriers while maintaining high tracking accuracy.
Solution Approach 2:
The imaging system operates continuously to track container positions, providing uninterrupted monitoring throughout the filling process. This continuous tracking eliminates the need for periodic synchronization interventions that would otherwise be required with light barriers, thereby simplifying system implementation and reducing maintenance requirements.
3Reliability
If light barriers are installed for resynchronization, then tracking can be maintained, but space requirements and sensor adjustment complexity increase
Solution Approach 1:
The area-imaging sensors serve multiple functions: they track container positions, monitor container orientation, and provide continuous tracking data for multiple lanes simultaneously. This multi-functionality eliminates the need for separate light barriers in each lane, thereby reducing space requirements and simplifying sensor placement while maintaining tracking continuity across the entire filling line.
4Productivity
If conventional tracking on multi-lane conveyors is attempted, then mass transport is possible, but tracking becomes impossible due to amorphous container movement and changing container order
Solution Approach 1:
The patent replaces mechanical conveyor-based tracking with an optical imaging system that can handle amorphous container movement. The area-imaging sensors capture images of containers in multiple lanes, and the electronic evaluation unit processes these images to accurately determine container positions and maintain identification even when containers move irregularly or change order, thereby enabling precise tracking on multi-lane conveyors.
Solution Approach 2:
The system transitions from one-dimensional linear tracking to two-dimensional spatial tracking by using area-imaging sensors that capture container positions across multiple lanes simultaneously. This dimensional expansion allows the system to track containers in complex multi-lane configurations with amorphous movement patterns, maintaining measurement precision despite changing container orders.
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 allows for accurate and independent tracking of containers along complex transport routes, including curves and multi-lane conveyors, without the need for resynchronization. It enhances tracking reliability and reduces technical effort, while also enabling precise control of inspection sensors and actuators.
Implementation Method 1
at least one area-imaging sensor with a stationary imaging region for jointly imaging several containers during their transport in images offset from one another in time
Data Source
AI summary
Described are a method and an apparatus for container tracking in a plant for producing and/or packaging containers and/or for filling the containers, in particular with beverages. The containers are transported through a stationary imaging region of at least one area-imaging sensor, which jointly images several containers in time-staggered images. The images are evaluated electronically and tracking data are extracted that are individually assigned to the containers, which include: identification information for identifying the respective container; and location information about a sequence of locations and associated stay times of the respective container. This makes it possible for the containers to be located and traced independently of relative movements with respect to the transport means used.