Optical Counting Bar Products Conveyor Trigger
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Solution Overview
Problem
Conveyor devices for bar-shaped products rely on mechanical counting methods that are slow, unreliable, and prone to wear, necessitating a more reliable and minimally invasive solution for accurate product counting.
Innovation Solution
A method and device that utilize a camera and trigger signals to acquire and process images of bar ends on a conveyor element, with separators positioned at equidistant intervals to ensure accurate counting, and optional light source illumination to enhance image contrast, allowing for precise detection and counting of products without mechanical modifications.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If mechanical counting devices are used to count bar-shaped products, then the counting function is achieved, but the counting speed is slow and the reliability is low
Solution Approach 1:
The patent replaces mechanical counting devices with an optical measurement system consisting of a camera, trigger device, and evaluation device. The camera captures images of bar ends on the conveyor, the trigger device synchronizes imaging with conveyor position, and the evaluation device counts bars by analyzing image content. This substitution eliminates mechanical contact, improving both reliability and speed simultaneously.
2Reliability
If mechanical counting devices are used to count bar-shaped products, then the counting function is achieved, but the devices are subject to wear and require frequent maintenance
Solution Approach 1:
The patent replaces mechanical counting devices with an optical measurement system consisting of a camera, trigger device, and evaluation device. The camera captures images of bar ends on the conveyor, the trigger device synchronizes imaging with conveyor position, and the evaluation device counts bars by analyzing image content. This substitution eliminates mechanical contact, improving both reliability and speed simultaneously.
3Measurement precision
If images are acquired continuously to count all bar ends, then all products are detected, but products may be detected multiple times or missed due to timing misalignment
Solution Approach 1:
The patent employs periodic triggering based on conveyor belt position. The trigger device generates trigger signals at predetermined intervals corresponding to the conveyor's periodic motion, causing the camera to acquire images at synchronized moments. This periodic action ensures that each bar end is captured at the correct position without overlap or omission, simplifying the evaluation process while maintaining high detection accuracy.
4Measurement precision
If the camera captures a wide section of the conveyor to ensure all bars are visible, then complete coverage is achieved, but image distortion and occlusion increase
Solution Approach 1:
The patent employs periodic triggering based on conveyor belt position. The trigger device generates trigger signals at predetermined intervals corresponding to the conveyor's periodic motion, causing the camera to acquire images at synchronized moments. This periodic action ensures that each bar end is captured at the correct position without overlap or omission, simplifying the evaluation process while maintaining high detection accuracy.
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
Enables reliable and accurate counting of bar-shaped products with minimal mechanical modifications, ensuring products are detected once and only once, improving reliability and reducing errors compared to traditional mechanical counting methods.
Implementation Method 1
images are acquired by a camera, said image showing front ends of the products
Implementation Method 2
optional light source illumination to enhance image contrast
Data Source
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Figure 3~4
Figure 5~7
AI summary
A conveyor element (2) of a conveyor device conveys bar-shaped products (1) orthogonal to a longitudinal direction (x) of the bar-shaped products (1) in a conveying direction (y). A trigger device (3) provides a trigger signal (S) each time the conveyor element (2) has travelled a predetermined interval. Based upon the respective trigger signal (S), an image (B) is acquired by a camera (4), said image (B) showing front ends of the products (1) in a respective section of the conveyor element (2) corresponding at least to said predetermined interval. Based upon the acquired images (B), the number of bar-shaped products (1) conveyed by the conveyor element (2) is determined.