Virtual Overlay Generation for Packaging Machine Object Tracking

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Solution Overview

Problem

In manufacturing industries, particularly in the packaging sector, the complexity and unreliability of augmented reality implementations arise due to the difficulty in distinguishing and tracking numerous movable objects at high speeds, which poses challenges for image processing and effective interaction with packaging containers.

Innovation Solution

A method and system for generating a virtual overlay on a packaging machine that associates movable objects with object identifier data, determines their relative position in a physical coordinate system, maps this to a virtual coordinate system, and displays the virtual overlay in relation to the object's virtual target coordinate, enabling reliable tracking and interaction without the need for markers or complex image processing.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional image recognition processes are used to identify movable objects in packaging machines, then object identification can be achieved, but the system becomes complex and unreliable due to high speeds and difficulty in distinguishing objects

Engineering Contradiction:

Improvereliability of augmented reality implementationVSAvoidcomplexity of image processing techniques

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent introduces an intermediary coordinate mapping system that translates physical machine coordinates to virtual display coordinates. This mediator layer decouples the complex image processing from the augmented reality display, allowing reliable object tracking without requiring complex real-time image recognition of moving objects.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent segments the augmented reality system into distinct functional modules: object identification using existing machine data, coordinate system mapping, and virtual overlay display. This segmentation allows each module to be optimized independently, reducing overall system complexity while maintaining reliability.

Inventive Principle:

Principle #1Segmentation

2Measurement precision

If complex image processing techniques are implemented to track movable objects at high speeds, then object tracking accuracy can be improved, but the processing time and system complexity increase

Engineering Contradiction:

Improveprecision of object position trackingVSAvoidprocessing time for image data

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The patent performs preliminary actions by establishing the coordinate mapping relationship between physical and virtual systems in advance. Object identifiers and their corresponding virtual coordinates are pre-associated, allowing instant retrieval and display without requiring complex real-time image processing during high-speed operation.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces complex mechanical/image processing systems with a data-driven coordinate mapping approach. Instead of using cameras and image recognition algorithms to track objects, the system uses pre-established coordinate relationships and machine communication data to determine object positions, dramatically reducing processing time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If multiple movable objects are manipulated in the packaging machine, then productivity is improved, but distinguishing and tracking individual objects becomes more difficult

Engineering Contradiction:

Improvethroughput of packaging machineVSAvoiddifficulty of identifying individual objects

Core Design Contradiction:

ProductivityVSDifficulty of detecting and measuring

Solution Approach 1:

The patent applies local quality by assigning unique identifiers and specific virtual coordinates to each movable object or object position in the machine. This allows individual objects to be distinguished and tracked through their unique coordinate signatures, enabling effective monitoring of multiple objects simultaneously without increasing identification difficulty.

Inventive Principle:

Principle #3Local quality

Data Source

PatentUS11169597B2Method of generating a virtual overlay for a packaging machine

Publication Date: 2021.11.09 TETRA LAVAL HOLDINGS & FINANCE SA

AI summary

A method is disclosed for generating a virtual overlay for a packaging machine having a plurality of movable objects manipulating packaging containers, comprising associating the movable objects with respective object identifier data communicated in the packaging machine, determining a relative position of a target object amongst the movable objects in a physical coordinate system of the packaging machine based on the object identifier data, registering imaging data comprising at least part of the movable objects or a defined physical reference, mapping the relative position of the target object to a virtual coordinate system in an at least partly virtual environment viewed by a user, comprising correlating the relative position of the target object to the imaging data, whereby the target object is assigned to a virtual target coordinate in the virtual coordinate system, and displaying the virtual overlay in the virtual coordinate system in relation to the virtual target coordinate.