Vision Infeed Sensing for Non-Contact Conveyor Flow Control
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Solution Overview
Problem
Traditional manufacturing line sensors that detect product flow and population require physical contact, causing disturbances and inefficiencies, and are unable to accurately measure product movement or orientation, leading to potential damage and suboptimal flow patterns.
Innovation Solution
A camera-based system using optimized computer vision algorithms to detect product density and movement without physical contact, enabling precise control of conveyor speed and flow adjustments through automated feedback loops.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If mechanical contact sensors are used to detect product presence, then detection capability is provided, but product flow is disturbed and product damage may occur
Solution Approach 1:
The patent replaces mechanical contact sensors with a vision-based detection system using cameras and image processing algorithms. This substitution eliminates physical contact between sensors and products, thereby removing the harmful disturbance to product flow while maintaining accurate detection of product presence, movement, and density through optical means
2Device complexity
If Boolean contact sensors are used to detect product presence, then simple presence/absence detection is achieved, but product movement and density information is lost
Solution Approach 1:
The vision system replaces simple Boolean sensors with camera-based optical detection that captures rich visual data. Image processing algorithms analyze these visual inputs to extract not only presence/absence information but also product movement, density, orientation, and flow characteristics, thereby recovering lost information without requiring complex mechanical sensor arrays
Solution Approach 2:
The system transforms visual image data into multiple product parameters including position, velocity, density, and orientation by processing image sequences over time. This parameter extraction from optical data provides comprehensive product information that simple contact sensors cannot detect, enabling precise control decisions
3Reliability
If multiple contact sensors are deployed to monitor product flow, then detection coverage is improved, but system complexity and product flow disturbance increase
Solution Approach 1:
The patent merges multiple sensor functions into a single vision system. One or more cameras positioned to view the product flow can simultaneously detect product presence, movement, density, and orientation across the entire conveyor width, replacing what would otherwise require multiple distributed contact sensors and their associated wiring and control logic
Solution Approach 2:
The vision system performs multiple detection functions simultaneously: counting products, measuring spacing, detecting movement, identifying orientation, and monitoring flow density. This multi-functional capability provides comprehensive detection coverage that would require several specialized sensors, thereby reducing overall system complexity while improving reliability
Data Source
AI summary
A system and method for optimizing flow of a plurality of products along a conveyor includes a conveyor drive connected with the respect to the conveyor, the conveyor drive configured to modulate the speed of the conveyor. A camera positioned relative to the products on the conveyor. A processing unit is connected with respect to the camera and the conveyor drive, the processing unit defining a zone along the conveyor having a virtual longitudinal and lateral boundary within a section of the conveyor, the processing unit further determining relative product position metrics of the products within the zone and communicating with the conveyor drive to modulate the speed of the conveyor thereby optimizing a relative position of the products within the zone. In addition, the subject system may be used for inspection of conveyed products.