Automated Pallet Inspection via Image Recognition
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Solution Overview
Problem
Automated container pallet inspection systems are needed to ensure proper strapping and alignment of loaded pallets to prevent defects and ensure product integrity, as manual inspection is labor-intensive and prone to errors.
Innovation Solution
A system comprising an image recorder supported above a conveyor, connected to a computer with software that captures images of pallets, compares them to manufacturing specifications, and determines compliance with manufacturing tolerances, using pattern recognition to assess strapping and alignment, and can control conveyor movement based on inspection results.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual inspection is used to check pallet strapping and alignment, then flexibility and adaptability are maintained, but labor intensity increases and inspection accuracy decreases
Solution Approach 1:
The patent replaces manual mechanical inspection with an automated optical inspection system using cameras and image processing software. The system captures images of pallets, automatically analyzes strapping and alignment compliance, and eliminates the need for manual visual inspection, thereby improving accuracy while managing complexity through automation.
Solution Approach 2:
The system creates digital copies (images) of the physical pallets for inspection. By capturing and analyzing images rather than physically handling or manually measuring each pallet, the system achieves high inspection accuracy without requiring complex manual measurement tools or procedures.
2Productivity
If automated conveyor movement is used to transport pallets, then productivity increases, but the ability to stop and inspect individual pallets decreases
Solution Approach 1:
The inspection system operates continuously as pallets move along the conveyor belt. Cameras capture images and software analyzes compliance in real-time without interrupting the continuous flow of pallets, maintaining both high productivity and reliable inspection through uninterrupted automated analysis.
Solution Approach 2:
The system provides immediate feedback by analyzing pallet images during conveyor movement and can trigger alerts or stop the conveyor when non-compliance is detected. This feedback mechanism ensures reliable inspection while maintaining overall system productivity through automated quality control integration.
3Manufacturing precision
If comprehensive inspection of all pallet parameters is performed, then manufacturing precision is ensured, but inspection time increases
Solution Approach 1:
The system performs comprehensive inspection of multiple pallet parameters (strapping, alignment, positioning) simultaneously through automated image capture and analysis. By using multiple cameras and software algorithms that process multiple features in parallel, the system ensures manufacturing precision without proportionally increasing inspection time.
Solution Approach 2:
The system captures images and begins analysis while pallets are still in motion on the conveyor, performing inspection actions before the pallet reaches the end of the line. This preliminary automated inspection eliminates the need for separate manual measurement steps, ensuring precision while reducing total inspection time.
Data Source
AI summary
An image recorder (18) supported above a conveyor (22) captures images of a top surface of the loaded pallet (30) supported on the conveyor (22). The image is transmitted to a computer (26). A software routine stored on a memory on the computer (26) compares the image to a manufacturing specification. The software routine determines whether the image is within a manufacturing tolerance of the manufacturing specification.