Vision-Based Article Counting and Aggregation System
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Solution Overview
Problem
Existing methods for counting and aggregating articles are inefficient and prone to errors, with mechanical systems being costly and photoelectric systems being bulky and susceptible to contamination, while secondary material feeding mechanisms require high precision and complex mechanical control.
Innovation Solution
A method and apparatus that uses a conveyor to drive an article stream into separate batches, counted using photo imaging, allowing for accurate aggregation into temporary storage bins, which are then combined to reach a target number, reducing the need for precise mechanical control and increasing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a photoelectric counting machine uses a multi-channel vibrating platform to convey and space out articles, then counting accuracy is improved, but the conveying mechanism becomes very bulky and inconvenient for arrangement in production environment
Solution Approach 1:
The patent replaces the complex mechanical photoelectric counting system with a vision-based counting system. A camera captures images of articles on the conveyor belt, and image processing algorithms count the articles without requiring mechanical spacing or multiple channels. This substitution eliminates the bulky vibrating platform while maintaining counting accuracy.
Solution Approach 2:
The patent creates an optical copy (image) of the article stream on the conveyor belt and performs counting on the copy rather than on the physical articles themselves. This allows counting to occur without interfering with the physical flow and spacing of articles, eliminating the need for bulky mechanical spacing mechanisms.
2Extent of automation
If a photoelectric sensor is placed close to an article channel to function, then counting capability is achieved, but the sensor is easily contaminated by dust brought by the articles, causing counting error
Solution Approach 1:
The patent introduces an optical intermediary (camera and image processing system) that counts articles from a distance without direct contact. The camera captures images of the articles on the conveyor belt, and software algorithms identify and count the articles in the images. This intermediary system eliminates the need for physical proximity to the article channel, preventing dust contamination while maintaining automated counting capability.
3Ease of manufacture
If a mechanical counting machine uses a turn plate with fixed recesses to contain articles, then the method is simple and cheap, but productivity is low and errors occur when articles do not fully fill the recesses
Solution Approach 1:
The patent uses a dynamic conveyor belt system that can adjust its speed and stopping positions to optimize article aggregation. The conveyor belt moves continuously and can be stopped at precise positions to collect exact numbers of articles, replacing the static turn plate with fixed recesses. This dynamic approach maintains mechanical simplicity while significantly improving productivity and accuracy.
Solution Approach 2:
The patent implements a feedback control system where the vision system counts articles in real-time and provides feedback to the conveyor control system. Based on this feedback, the conveyor adjusts its operation to collect the precise number of articles needed, eliminating the errors that occur with fixed recesses that may not be fully filled and improving overall productivity.
4Manufacturing precision
If a secondary material feeding mechanism is used to dispense additional articles one by one to reach target number, then the target number can be achieved, but working efficiency is low and high precision mechanical control is required
Solution Approach 1:
The patent replaces the secondary mechanical feeding mechanism with a vision-based counting system that can accurately count articles directly from the main conveyor stream. The image processing system identifies and counts individual articles without requiring them to be fed one by one by a secondary mechanism, thereby achieving target number accuracy while maintaining high working efficiency.
Solution Approach 2:
The patent maintains continuous operation of the main conveyor belt for article transport and counting, eliminating the need to stop the conveyor and use a secondary feeding mechanism. The vision system continuously captures images and counts articles in real-time, allowing the primary conveying action to continue uninterrupted, thus maintaining high productivity while achieving precise target numbers.
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
This approach simplifies article arrangement, enhances counting accuracy, reduces device size, and lowers manufacturing costs by allowing for higher material density and flexible batch formation, while detecting article damage and reducing dust interference.
Implementation Method 1
a photo capturing apparatus configured to perform continual photo capturing on a photo capturing area, so that all articles passing through the photo capturing area are at least captured once
Data Source
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AI summary
Disclosed is a method for counting and aggregating a pre-determined number of articles, which includes the following steps: step 1: driving, by a conveyor, an article stream to move to an end of the conveyor in a single layer state; step 2:conveying,by the conveyor, the article stream in a periodic motion, so that the article stream breaks after leaving the end of the conveyor, to form an article batch; step 3,after the articles in the article stream leave the conveyor, accurately counting the number of the articles; and step 4, when a total number of articles in a combination of temporary storage bin is the same as a target number, transporting all articles in the combination of temporary storage bin to a storage device. First, article batches are separately delivered to different temporary storage bins, and then the total number of articles in temporary storage bins in different combinations is calculated, so as to obtain with a combination in which the number of articles is the same as the target number, and then the combination is released to aggregate the target number of articles. The operation efficiency of device is greatly improved and the manufacturing cost of device is reduced.