Optical Conveyor Product Counting via Beacon Detection
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Solution Overview
Problem
Current conveyor systems in industrial lines face challenges in ensuring continuous product flow and accurate counting of products, particularly when dealing with varying production rates and product formats, leading to potential imbalances and errors in downstream treatments.
Innovation Solution
A conveying device with primary and secondary beacons that delimit specific zones on the conveyor belt, allowing for real-time detection and counting of products using a camera or beam, enabling precise monitoring and regulation of product flow to maintain consistent product numbers across lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional sensors are used to detect products from the side, then the detection setup is simple, but the counting accuracy is insufficient and cannot ensure continuous stream verification
Solution Approach 1:
The patent replaces traditional mechanical contact sensors with an optical detection system consisting of a light source and a camera positioned above the conveyor. This optical system captures images of products from above, enabling accurate counting and verification of continuous streams without physical contact, thereby improving measurement precision while reducing mechanical complexity
Solution Approach 2:
The patent transitions from lateral product detection to vertical detection by positioning the camera above the conveyor belt. This dimensional change allows the system to capture complete product images from above, enabling accurate counting and verification of product continuity in the stream, overcoming the limitations of side-mounted sensors
2Productivity
If the conveyor speed is increased to match production rate, then productivity is improved, but product flow balance and continuity control becomes difficult
Solution Approach 1:
The patent implements a feedback control system where the camera continuously monitors product presence and counting in real-time. Based on this visual feedback, the system can detect gaps, extra products, or flow imbalances and trigger alerts or automatic speed adjustments, enabling the conveyor to maintain optimal productivity while ensuring continuous and balanced product flow
Solution Approach 2:
The patent enables dynamic adjustment of conveyor speed based on real-time product flow conditions. The system can accelerate or decelerate the conveyor belt response to maintain proper product spacing, prevent bottlenecks, and ensure continuous supply to downstream stations, thereby balancing productivity with flow reliability
3Measurement precision
If multiple sensors are deployed to verify product continuity, then measurement accuracy is improved, but device complexity and cost increase
Solution Approach 1:
The patent employs a single camera system that performs multiple functions: capturing product images, counting products in the stream, verifying continuity, and detecting flow imbalances. This multi-functional approach replaces the need for multiple specialized sensors, reducing system complexity while maintaining high measurement precision for continuous verification
Solution Approach 2:
The patent combines detection, counting, and verification functions into a single integrated optical measurement system. By merging these functions into one camera-based system, the patent eliminates the need for separate sensors for each function, thereby reducing device complexity and cost while achieving comprehensive stream monitoring
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
Ensures continuous and balanced product supply to downstream stations, reduces errors and downtime by providing immediate updates on product counts and allowing for adjustments in conveyor speed, thereby enhancing operational flexibility and productivity.
Implementation Method 1
at least one member for detecting said primary beacons and for counting the number of products at least in said main zone
Data Source
AI summary
A device for conveying products within an industrial line, comprising a conveyor transporting a stream of products along at least one line. The device comprises at least one main zone delimited by primary beacons and covering a segment of the stream; and above the conveyor, at least one member for detecting the primary beacons and for counting the number of products at least inside the main zone. Also a method for conveying products, in which a stream of products is transported along at least one line and, by means of primary beacons at least one main zone is delimited, covering a segment of the stream; the primary beacons are detected and the number of products in the main zone is counted.