Automated Vision System for High-Speed Food Portioning Error Detection
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
High-speed portioning machines face challenges in accurately diagnosing cutting errors in food products, as subtle or rare inaccuracies can be difficult to detect, leading to increased raw material and operational costs due to potential malfunctions, which may develop into significant issues if not promptly addressed.
Innovation Solution
A system comprising a conveyance system, scanner, control system, cutter, and vision system that acquires and analyzes food product data to determine cutting paths, compares actual cutting paths with predetermined paths, and identifies deviations, allowing for remedial actions to restore alignment and optimize operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If high-speed portioning machines operate at over 200 pieces per minute, then productivity increases, but the ability to detect cutting errors deteriorates due to the speed at which portions pass by
Solution Approach 1:
The patent replaces manual visual inspection with an automated vision system using cameras and image processing algorithms. The vision system captures images of portions on the conveyor belt, automatically detects cutting errors through computer vision algorithms, and identifies deviations from predetermined cutting paths without requiring human operators to visually inspect each piece at high speed.
Solution Approach 2:
The patent introduces an intermediary automated detection system positioned between the portioning process and human operators. This intermediary system uses sensors and vision technology to monitor cutting accuracy in real-time, translating physical cutting deviations into detectable signals that can be analyzed automatically, thereby enabling error detection at high production speeds without direct human observation.
2Measurement precision
If operators manually monitor portions for cutting errors, then measurement capability is maintained, but productivity decreases due to the time required for manual inspection
Solution Approach 1:
The patent replaces manual inspection operations with automated vision-based measurement systems. Cameras and image processing algorithms continuously capture and analyze portion geometry, detecting cutting errors automatically without interrupting the high-speed production flow, thereby maintaining measurement precision while preserving productivity.
Solution Approach 2:
The patent implements continuous automated monitoring that operates without interruption throughout the portioning process. The vision system continuously captures images and analyzes cutting accuracy in real-time, eliminating the discontinuous nature of manual inspection where operators would need to stop or slow down to examine portions, thereby maintaining both measurement capability and production continuity.
3Manufacturing precision
If the alignment of actual cutting paths with predetermined paths deviates beyond set point, then manufacturing precision deteriorates, but the system complexity increases to detect and correct the deviation
Solution Approach 1:
The patent implements a feedback control system where the vision system continuously monitors actual cutting paths, compares them with predetermined paths, and provides feedback signals when deviations exceed acceptable tolerances. This feedback mechanism enables automatic detection and correction of alignment issues, maintaining manufacturing precision through a relatively simple add-on monitoring system rather than requiring complex real-time control modifications to the entire portioning machinery.
Data Source
AI summary
Workpieces WP are scanned at a scanning station (14) while being transported on a conveyor (12). A control system (18) analyzes the scanning data to develop a three-dimensional model of the workpiece WP and determine how to portion or trim the workpiece as desired. The cutting/trimming paths made through the workpiece is compared with the predetermined cutting paths to quantify the correspondence (or deviance) of the actual cutting paths from the predetermining cutting paths. This information is reviewed to determine whether the system (10) is operating property. If the alignment of the actual cutting/trimming paths with the predetermined cutting/trimming paths are not within a predetermined set point, the control system (18) seeks to determine the cause of the deviation as well as determine what remedial steps to take to restore the alignment of the actual cutting/trimming paths with the predetermined cutting/trimming paths.