Camera-Based Throughput Measurement for Food Processing Lines
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Solution Overview
Problem
Existing food processing systems face challenges in accurately measuring throughput weight of varying food product items without manual intervention or incorporating load cells, which can increase costs and maintenance needs.
Innovation Solution
A computer-implemented method using a digital camera and throughput monitoring computing system to capture images, determine pixel counts, and calculate throughput weight based on pixel-weight correlation models, eliminating the need for manual weighing and load cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If load cells or scales are incorporated into the food processing system to measure throughput weight, then measurement accuracy is improved, but manufacturing expense increases, maintenance needs increase, and system reliability decreases
Solution Approach 1:
The patent replaces mechanical weighing systems (load cells, scales) with an optical measurement system using digital cameras and image processing algorithms. The system captures images of food product items on the conveyor, processes these images to determine pixel counts representing product mass, and calculates throughput weight without physical contact or mechanical sensors.
Solution Approach 2:
The patent creates a digital copy (image) of the physical food product items and processes this copy to extract weight information. By analyzing pixel data from captured images, the system derives throughput weight measurements without needing to physically weigh the items, thus avoiding the complexity and maintenance issues of mechanical weighing systems.
2Measurement precision
If manual sampling and weighing of food product items is performed to measure throughput, then measurement capability is achieved, but food safety risks increase and productivity decreases
Solution Approach 1:
The patent enables continuous, non-stop measurement of throughput weight by integrating the optical measurement system with the running conveyor belt. Food product items are measured in real-time as they move through the processing line, eliminating the need to stop production for manual sampling and weighing, thus maintaining continuous productivity while achieving accurate measurements.
Solution Approach 2:
The system performs automated measurement of throughput weight using image processing algorithms that automatically analyze captured images, count pixels representing food products, and calculate weight without human intervention. This eliminates the need for manual sampling operations that would interrupt production and pose food safety risks.
3Measurement precision
If manual intervention is used to remove sample food product items for weighing, then throughput measurement is achieved, but food safety implications arise and ease of operation worsens
Solution Approach 1:
The patent replaces manual sampling operations with an automated optical measurement system. Digital cameras capture images of food product items on the conveyor, and image processing algorithms automatically extract weight information from pixel data, eliminating the need for operators to manually remove and weigh samples.
Solution Approach 2:
The system performs self-service measurement by automatically capturing images, processing them to determine pixel counts, and calculating throughput weight without requiring operator intervention. This maintains operational simplicity while achieving accurate throughput measurements.
Data Source
AI summary
In some embodiments, a computer-implemented method of measuring throughput of a food processing system is provided. A computing system captures an image of a portion of the food processing system configured to carry one or more food product items. The computing system determines a set of pixels of the image that depict one or more food product items. The computing system determines a pixel count of the set of pixels, and determines a total product weight based on the pixel count. The computing system determines a throughput weight of the food processing system based on the total product weight.