Thermal Imaging and Load Cell System for Incompletely Dried Material Detection
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Solution Overview
Problem
Existing methods for detecting and removing incompletely dried materials from drying processes are subjective and prone to errors, and image-based systems face challenges with non-uniform transfer speeds, making it difficult to accurately and automatically sort materials.
Innovation Solution
A system utilizing a load cell to measure material weight and a thermal imaging camera to analyze temperature information, allowing for precise detection and automatic removal and recovery of incompletely dried materials through a controlled transfer and sorting process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If visual check by naked eyes is used to distinguish incompletely dried material, then the method is simple to operate, but the detection accuracy is low due to subjective judgment
Solution Approach 1:
The patent replaces the mechanical visual inspection system with an automated detection system using a thermal imaging camera and load cell. The thermal imaging camera captures temperature distribution images, and the load cell measures weight, providing objective quantitative data to replace subjective human judgment and achieve precise automatic detection.
Solution Approach 2:
The patent introduces a thermal imaging camera as an intermediary device between the material and the detection system. The camera captures thermal radiation from the material, converting temperature information into visible images that can be automatically analyzed, thus mediating the detection process between the physical material and the evaluation system.
2Measurement precision
If thermal imaging camera is used to photograph material for detection, then detection accuracy is improved, but it is difficult to effectively photograph due to non-uniform transfer speed
Solution Approach 1:
The patent performs preliminary action by stopping the transfer device before photographing the material. This ensures the material is stationary during thermal imaging capture, eliminating blur and ensuring clear, effective photographs regardless of transfer speed variations. The stopping action precedes the detection to create optimal conditions.
Solution Approach 2:
The patent dynamically adjusts the transfer device operation by stopping it during the photographing phase and resuming after detection. This dynamic control allows the system to adapt between transport mode and detection mode, ensuring successful imaging while maintaining overall system productivity.
3Measurement precision
If thermal imaging camera system is used for detection, then detection precision is improved, but automatic removal and in-situ application cannot be realized
Solution Approach 1:
The patent merges the detection system (thermal imaging camera and load cell) with the removal system (transfer device control) into an integrated automated system. The control unit receives detection results and automatically controls the transfer device to remove incompletely dried material, combining detection and removal functions into a unified automated process.
Solution Approach 2:
The patent implements feedback control where the detection results from the thermal imaging camera and load cell are fed back to the control unit, which then automatically adjusts the transfer device to remove defective material. This closed-loop feedback system enables automatic removal based on real-time detection, achieving in-situ application without manual intervention.
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
The system enables precise detection and automatic removal of incompletely dried materials, improving accuracy and reducing material loss by distinguishing between completely and incompletely dried materials based on weight and temperature analysis.
Implementation Method 1
a load cell measuring a weight of the material transferred through the transfer device
Implementation Method 2
a thermal imaging camera photographing the material received by the material receiving unit
Implementation Method 3
an incompletely-dried-material determining unit acquiring temperature information of the material photographed by analyzing image data photographed by the thermal imaging camera
Data Source
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AI summary
Disclosed herein is a system for detecting, removing, transferring and recovering an incompletely dried material. The system includes a transfer device transferring the material subjected to a drying process, a load cell measuring a weight of the material transferred through the transfer device, a material receiving unit receiving the measured material from the load cell when the weight of the measured material is higher than weights of other materials or a preset reference weight, a thermal imaging camera photographing the material received by the material receiving unit, an incompletely-dried-material determining unit acquiring temperature information of the material photographed by analyzing image data photographed by the thermal imaging camera, and determining whether the photographed material is an incompletely dried material based on the acquired temperature information, and an incompletely-dried-material receiving unit receiving the incompletely dried material from the material receiving unit.