Particle Shape Analysis via Image Processing and Cloud Computing
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Solution Overview
Problem
Current methods for shape and size analysis of solid particles are limited by issues such as inaccurate results due to particle overlap, requirement for manual post-analysis, and incompatibility with digital infrastructure, especially in real-time industrial applications where catalyst fragments and raw materials' properties need precise characterization.
Innovation Solution
An image processing system utilizing cameras, micro-boards, and a cloud/web-service structure for local and remote computations, with LED lighting for homogeneous illumination, and a user-authenticated server to manage analysis and prevent errors, allowing offline operation and detailed shape and size analysis without internet connectivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional particle size analysis methods are used, then analysis can be performed on various samples, but measurement precision deteriorates due to particle overlap and manual post-analysis errors
Solution Approach 1:
The patent replaces manual mechanical particle analysis methods with automated image processing and computer vision technology. The system captures particle images using a camera and automatically analyzes size, shape, and distribution through software algorithms, eliminating manual measurement errors and particle overlap issues that plague traditional methods.
Solution Approach 2:
The patent creates digital copies of particles through high-resolution imaging. Instead of physically manipulating or measuring particles, the system captures optical images that serve as digital replicas, allowing for precise automated measurement of particle dimensions, area, perimeter, and shape factors without physical contact or particle disturbance.
2Productivity
If manual post-analysis is performed, then flexibility in analysis methods is maintained, but productivity deteriorates due to time-consuming manual processing
Solution Approach 1:
The patent implements self-service automation where the system performs its own analysis without human intervention. The image processing software automatically captures particles, processes images, calculates size and shape parameters, and generates reports autonomously. The system handles the complete workflow from image capture to analysis output without requiring manual post-processing, dramatically increasing productivity and eliminating time loss associated with manual analysis.
3Measurement precision
If simple image processing is used, then device complexity is reduced, but measurement precision deteriorates due to inability to handle overlapping particles
Solution Approach 1:
The patent applies preliminary action by implementing particle separation algorithms that detect and resolve overlapping particles before final measurement. The system identifies particle boundaries, separates touching or overlapping particles in the image, and assigns individual measurements to each particle. This preliminary processing step ensures accurate characterization even when particles overlap in the captured image, maintaining high measurement precision without requiring overly complex hardware.
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 precise, efficient, and accurate shape and size analysis of solid particles, preventing errors from overlap and providing instant reporting, suitable for real-time industrial use with customizable analysis settings and secure online operation.
Implementation Method 1
a camera that takes a picture of solid particles on the analysis tray
Implementation Method 2
LED light is a more preferable choice to ensure a more homogenous intensity distribution
Data Source
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AI summary
The present invention relates to the method and the system of performing shape and size analysis of all solid particles with image processing.