Thermal Imaging for Upside-Down Egg Detection
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Solution Overview
Problem
Conventional methods for detecting upside-down eggs in poultry processing are prone to inaccuracies and inefficiencies due to complex designs and misalignment issues, leading to potential damage during in ovo injections.
Innovation Solution
An apparatus and method utilizing shortwave infrared light to create a tailored heat flux that differentiates the air cell temperature from other egg constituents, allowing for accurate detection of egg orientation through thermal imaging.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional candling techniques with multiple photodetectors and photoemitters are used, then air cell position can be detected, but the apparatus becomes complex and prone to misalignment errors
Solution Approach 1:
The patent extracts the detection function from multiple photodetectors and photoemitters to a single thermal camera. Instead of using multiple active sensing elements that require precise alignment, the invention uses passive thermal imaging to detect temperature differences caused by air cell position, eliminating the need for complex optical alignment systems.
Solution Approach 2:
The patent replaces the mechanical/optical alignment system (multiple photodetectors and photoemitters requiring precise positioning) with a thermal imaging system. The thermal camera captures temperature distribution across the egg surface, and image processing algorithms automatically identify air cell position based on thermal patterns, eliminating mechanical alignment requirements.
2Area of stationary object
If multiple photodetectors and photoemitters are arranged to cover all eggs in a tray, then detection coverage is improved, but processing speed decreases due to line-by-line processing
Solution Approach 1:
The patent merges multiple detection points into a single wide-field thermal camera view. Instead of processing eggs line-by-line through multiple photodetector arrays, the thermal camera captures the entire tray of eggs simultaneously, allowing parallel processing of all eggs in a single frame, thereby dramatically increasing throughput.
Solution Approach 2:
The patent transitions from one-dimensional line-by-line detection (multiple photodetector rows processed sequentially) to two-dimensional simultaneous imaging (thermal camera capturing entire tray at once). This dimensional change enables parallel processing of all eggs regardless of tray size, maintaining high productivity even as coverage area increases.
3Productivity
If in ovo injection is performed on upside down eggs, then processing continues without interruption, but embryo damage or death occurs
Solution Approach 1:
The patent performs preliminary detection of air cell position using thermal imaging before the in ovo injection process. By identifying upside-down eggs in advance through thermal pattern recognition, the system can flag or reject these eggs before needle insertion, preventing embryo damage while maintaining continuous processing of properly oriented eggs.
Solution Approach 2:
The patent implements a feedback mechanism where thermal image data is processed to identify egg orientation, and this information feeds back to control the injection process. The system uses real-time thermal detection results to adjust processing, preventing injection into upside-down eggs while allowing continuous processing of correctly oriented eggs, thus eliminating harm without stopping productivity.
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 rapid and accurate detection of upside-down eggs, reducing the risk of embryo damage and improving processing efficiency by distinguishing the air cell temperature from other egg parts.
Implementation Method 1
a heating module with infrared coating (IRC) lamps that expose the eggs
Implementation Method 2
expose the batch of eggs to a tailored heat flux such that only the temperature inside air cells of the eggs is substantially increased
Implementation Method 3
an imaging module with a thermal camera configured to capture thermal images of the batch of eggs
Data Source
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AI summary
An apparatus to identify upside-down eggs of a batch of eggs includes a heating module configured to expose an air cell in each egg of the batch of eggs to a radiation flux. The apparatus also includes an imaging module with a thermal camera configured to capture thermal images of the batch of eggs when the eggs are not exposed to the radiation flux. The apparatus further includes an analyzer module configured to detect the presence of a heated zone in the air cell of each egg from the thermal images and identify upside-down eggs based on the presence of the heated zone. A method to identify upside-down eggs from a batch of eggs includes heating the batch of eggs with a radiation source, such as an infrared source, so as to generate a hot zone inside an air cell of each egg without significantly heating the rest of the eggs. Thermal images of the eggs are captured while the eggs are not exposed to the radiation source, analyzed to detect the presence of the hot zone and to identify the upside down eggs.