Weighing and Counting Apparatus Using Image Processing
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Solution Overview
Problem
Conventional weighing and counting apparatuses face errors in counting articles due to uneven single weights and issues with articles being in close contact or overlapping, leading to processing capacity degradation when trying to align them for accurate counting.
Innovation Solution
A weighing and counting apparatus featuring shutters at hopper inlets, image processing units for capturing and analyzing article images, and control units to ensure accurate counting and weighing without reducing processing capacity, even with uneven article weights, by temporarily retaining articles in a spread or aligned state before feeding them into hoppers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If articles are aligned in a line before feeding into the hopper to enable accurate counting, then counting accuracy is improved, but processing capacity decreases
Solution Approach 1:
The patent uses an imaging device to create an optical copy (image) of the articles on the shutter. The image processing unit then analyzes this copy to count articles, rather than requiring physical alignment or sequential detection. This allows all articles to be captured and counted simultaneously in a single image frame, maintaining high processing capacity while achieving accurate counting even when articles are in close contact or overlapping.
2Productivity
If photosensors or photoelectric tubes are used to count falling articles, then counting can be performed without alignment, but errors occur when articles are in close contact or overlapping
Solution Approach 1:
Instead of using photosensors that detect articles sequentially as they fall, the patent uses an imaging device to capture a complete visual copy of all articles on the shutter simultaneously. The image processing unit then analyzes this copy to accurately count articles even when they are in close contact or overlapping, eliminating the counting errors inherent in sequential photoelectric detection while maintaining high processing capacity.
Solution Approach 2:
The patent transitions from one-dimensional sequential detection (photosensors detecting articles as they pass a single point) to two-dimensional simultaneous imaging (capturing all articles in a plane). This dimensional change allows the system to see the spatial relationships between articles and accurately count them even when overlapping, resolving the limitation of photoelectric tube methods.
3Device complexity
If conventional weighing and counting methods are used with uneven article weights, then processing is simple, but errors occur in the obtained number of articles
Solution Approach 1:
The patent uses image copying and processing to directly count articles based on their visual appearance and spatial arrangement, completely bypassing the weighing method. This eliminates the fundamental problem of weight-based counting errors that occur with uneven article weights, while the added complexity is minimal (just an imaging device and image processing unit) compared to the accuracy improvement.
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
Enables accurate combination calculation of article numbers and weights without compromising processing capacity, even when articles have varying weights and are in close contact or overlapping, by using shutters and image processing to ensure reliable counting and weighing.
Implementation Method 1
an image processing unit that calculates the number of articles based on an image of the articles captured from above the shutter
Data Source
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AI summary
A weighing and counting apparatus (1) for obtaining a combination of articles (X) based on the number and weight of articles (X) supplied to a plurality of hoppers (10) includes: a shutter (11) that is installed in an inlet port of the hoppers (10) and temporarily receives the articles (X) to be put into the hopper (10); an image processing unit (12) that calculates the number of articles (X) based on an image of the articles (X) captured from above the shutter (11); and a control unit (13) that operates the shutter (11) to put the articles (X) into the hopper (10) after the image of the articles (X) is acquired.