Optical Container Tracking for Unordered Multi-Lane Conveyors
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Solution Overview
Problem
Existing container tracking systems in filling plants face challenges such as asynchrony between containers and conveyors due to vibrations and inclines, and are not effective on multi-lane conveyors with unordered container movement. Additionally, resynchronization methods are complex, costly, and unreliable under certain conditions.
Innovation Solution
The method involves using a stationary imaging area with at least one planar imaging sensor to capture time-staggered images of containers, which are then electronically evaluated to extract tracking data including identification and location information. This approach allows for independent tracking of containers without requiring synchronization with the conveyor movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional conveyor-based tracking is used, then tracking is possible on single-lane conveyors, but tracking fails on multi-lane conveyors with unordered container movement
Solution Approach 1:
The patent replaces the mechanical conveyor-based tracking system with an optical imaging system. Instead of relying on encoder signals from conveyor drive axles, the system uses planar imaging sensors (cameras) to optically detect container positions and calculates tracking data through image evaluation, enabling tracking on multi-lane conveyors with unordered movement
Solution Approach 2:
The patent transitions from one-dimensional conveyor-position-based tracking to two-dimensional spatial tracking using planar imaging sensors. The imaging sensors capture container positions in x-y coordinates, and through time-staggered imaging and electronic evaluation, the system determines container trajectories and tracking data in multiple dimensions, enabling tracking of unordered container movement across multiple lanes
2Measurement precision
If resynchronization devices are installed to correct asynchrony, then container tracking accuracy is maintained, but device complexity and costs increase
Solution Approach 1:
The patent eliminates mechanical resynchronization devices (light barriers, reflective sensors) by replacing them with an optical imaging system that continuously captures container positions. The electronic evaluation unit processes images to detect container locations and calculate tracking data, maintaining accuracy without additional mechanical components
Solution Approach 2:
The patent creates optical copies (images) of containers through the planar imaging sensor system. Instead of using physical resynchronization devices, the system captures multiple images of containers at different positions and uses these optical copies to calculate tracking data, eliminating the need for reflective light barriers or other physical sensors
3Measurement precision
If resynchronization sensors are used to maintain tracking accuracy, then position data is reliable, but operational reliability decreases under certain environmental conditions
Solution Approach 1:
The patent replaces contact-based or proximity-based resynchronization sensors with non-contact optical imaging sensors. The planar imaging sensors capture container positions optically without physical contact, eliminating reliability issues associated with moisture, cleaning requirements, and maintenance of traditional sensors in harsh filling plant environments
Data Source
Figure 1
AI summary
A method and a device for container tracking in a system for manufacturing and/or packaging containers and/or for filling the containers, in particular with beverages, are described. The containers are transported through a stationary imaging area of at least one planar imaging sensor. This sensor images several containers together in time-staggered images. The images are electronically evaluated, and tracking data individually assigned to the containers is extracted. These data include: identification information for identifying the respective container; and location information about a sequence of locations and associated times of location of the respective container. This allows the containers to be located and traced independently of relative movements with respect to the means of transport used.