Sensor-Guided Container Filling for Consistent Produce Volume
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Solution Overview
Problem
Existing systems struggle to automate the filling of containers with items like fruit or vegetables, which vary in size and shape, leading to potential damage and inefficiencies in achieving a desired weight or volume without manual intervention.
Innovation Solution
A system comprising a container conveyor and an item conveyor, controlled by sensors and processors, adjusts the speed of the container conveyor based on item volume flux to precisely fill containers with a predetermined volume, using optical or 2D/3D cameras to monitor and control the filling process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If automated filling is used for items like fruit or vegetables, then productivity is improved, but manufacturing precision deteriorates due to non-uniform size and shape of items
Solution Approach 1:
The system dynamically adjusts the container conveyor speed based on real-time item detection data. The processor monitors item flow and automatically modulates conveyor speed to maintain consistent fill volumes despite variations in item size and shape, enabling automated operation while preserving filling precision.
Solution Approach 2:
The system employs sensors to detect items on the conveyor and provides feedback to the processor, which then adjusts the container conveyor speed accordingly. This closed-loop control ensures that filling accuracy is maintained through continuous monitoring and automatic speed adjustment based on actual item flow conditions.
2Productivity
If container conveyor speed is increased, then productivity is improved, but manufacturing precision deteriorates as filling consistency decreases
Solution Approach 1:
The container conveyor operates with dynamically adjustable speed rather than fixed speed. The processor automatically modulates the conveyor speed in real-time based on detected item flow characteristics, allowing the system to maintain optimal filling consistency across varying production rates.
Solution Approach 2:
The system changes the operational parameter (conveyor speed) dynamically based on detected conditions. By adjusting the conveyor speed parameter in response to item flow variations, the system maintains consistent fill volumes while adapting to different productivity requirements.
3Manufacturing precision
If manual item placement is used, then manufacturing precision is improved for delicate items, but productivity deteriorates due to labor intensity
Solution Approach 1:
The system uses automated detection and speed control to enable self-regulating filling operations. The processor automatically adjusts conveyor speed based on item detection, allowing the automated system to handle delicate items with appropriate care while maintaining high throughput without manual intervention.
Data Source
AI summary
A system for filling containers with loose items can include a container conveyor configured to move containers to a container filling location, an item conveyor having a downstream end disposed above the container conveyor at the container filling location, one or more sensors configured to detect the items moving on the item conveyor, and one or more processors in communication with the container conveyor and the one or more sensors. The one or more processors can be configured with computer-executable instructions to receive signals from the one or more sensors and to control a speed of the container conveyor based on the signals received from the one or more sensors.