Machine Vision Food Stacker for Precise Substrate Alignment

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Solution Overview

Problem

Existing food processing systems face challenges in ensuring accurate alignment and quality control of stacked substrates supporting food products, often requiring manual inspection that can lead to inconsistencies and inefficiencies.

Innovation Solution

A food product stacker equipped with a machine vision system that includes an imaging device and processor to capture and analyze substrate positions, automatically adjusting a stacking conveyor for precise alignment and rejecting defective products, thereby eliminating the need for manual inspection.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual inspection is conducted to ensure substrate alignment and food product quality, then quality control can be performed, but the system requires adequate space for operators and may lead to inconsistencies in stack quality

Engineering Contradiction:

Improvestack quality consistencyVSAvoidspace for operator

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The patent replaces manual mechanical inspection with an automated vision system comprising imaging devices and processors that capture and analyze substrate positions and food product quality, eliminating the need for operator space while ensuring consistent inspection standards

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The system performs self-inspection through integrated vision sensors and processing units that automatically detect substrate alignment and food product defects, enabling the equipment to monitor its own operation without external human intervention

Inventive Principle:

Principle #25Self-service

2Ease of operation

If manual inspection is used for both alignment and quality control, then multi-tasking can be performed, but it may lead to inadvertent omissions in controlling stacking alignment and food product quality

Engineering Contradiction:

Improvemulti-tasking capabilityVSAvoidalignment control accuracy

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The inspection system is divided into separate functional modules: one vision system component dedicated to substrate alignment detection and another dedicated to food product quality inspection, allowing each to be optimized independently and eliminating the distractions of multi-tasking

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system implements real-time feedback loops where vision sensors continuously monitor substrate positioning and food product conditions, with processors immediately analyzing the data and providing control signals to correct any deviations from quality standards

Inventive Principle:

Principle #23Feedback

3Area of stationary object

If a compact food processing system is designed, then space efficiency is improved, but it may be difficult to accommodate manual inspection and quality control functions

Engineering Contradiction:

Improvesystem footprintVSAvoidquality control accessibility

Core Design Contradiction:

Area of stationary objectVSEase of operation

Solution Approach 1:

The vision system performs multiple functions within a single integrated platform: substrate alignment detection, food product quality inspection, and defect identification, eliminating the need for separate manual inspection stations and reducing overall system footprint

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The imaging devices and processing units are nested within the existing food processing equipment structure, with sensors positioned to monitor substrates and products as they move through the processing line, maximizing space utilization without compromising inspection capability

Inventive Principle:

Principle #7Nested doll (Nesting)

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 ensures efficient and consistent substrate alignment, reduces system footprint, and automates quality control, allowing for a compact food processing line with reduced space and cost, while maintaining proper alignment and automatically directing rejected products for further processing.

Implementation Method 1

The imaging device has a field of view encompassing the support platform and is configured to capture an image of the substrate supporting the food product

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentUS20260048952A1Food product stacker with machine vision inspection and methods for the use thereof

Publication Date: 2026.02.19 PACPROINC LLC

AI summary

A food product stacker includes a support moveable between a support position and a release position. A machine vision system includes an imaging device and a processor. The imaging device has a field of view encompassing the support platform and is configured to capture an image of the substrate supporting the food product on the support platform, to process the image and determine a position of the substrate on the support platform, and to provide an offset output signal corresponding to the position of the substrate on the support platform. A stacking conveyor is positioned support and is configured to receive the substrate and food product when the support is moved to the release position. The stacking conveyor is moveable in response to the offset output signal. Methods of stacking substrates supporting a food product are also provided.