Programmable Zoned Array Counter for Object Detection
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Solution Overview
Problem
Existing object detection and counting systems in manufacturing, such as pharmaceutical pill dispensing machines, face challenges with accuracy due to constraints on feed rates, mechanical adaptations, and miscounts caused by shadows and interference, and lack the ability to accurately identify and count objects using image capture technology.
Innovation Solution
A system utilizing a programmable array of light sources and photo detectors to capture object images, compare them against known images for identification, and maintain counts, with the ability to determine object opacity and store diagnostic data for future use.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional optical counters are used to detect objects, then object detection is achieved, but accuracy deteriorates due to shadows and interference
Solution Approach 1:
The detection system is divided into multiple zones with multiple light sources and photo detectors arranged in arrays. Each zone independently detects objects, and the segmented detection results are combined to achieve accurate identification and counting, effectively eliminating shadows and interference from any single detection point
Solution Approach 2:
The patent introduces image capture as an intermediary step between detection and counting. By capturing images of detected objects and comparing them against known object images, the system verifies object identity and filters out false detections caused by shadows and interference before final counting
2Measurement precision
If feed systems with single file presentation and spaced objects are used, then discrete object detection is achieved, but device complexity and mechanical adaptations increase
Solution Approach 1:
The patent replaces mechanical feed system constraints with an optical detection system that can handle objects in various arrangements. The multiple light source arrays and photo detector arrays can detect objects whether they are in single file, spaced apart, or even bundled together, eliminating the need for mechanical adaptations to enforce specific feed patterns
Solution Approach 2:
The detection system is designed to be universal and adaptable to different object types, sizes, and feed patterns. The programmable array configuration allows the same system to detect discrete spaced objects, bundled objects, or objects in various arrangements without requiring mechanical reconfiguration, achieving discrete detection through optical rather than mechanical means
3Measurement precision
If triangulation methods with light sensitive elements are used, then measurement accuracy is improved, but device complexity increases due to multiple linear arrays and supplementary hardware
Solution Approach 1:
The patent merges multiple detection functions into a unified system. The light source arrays, photo detector arrays, and image capture capabilities are integrated into a single detection apparatus that simultaneously performs position detection, object identification, and counting, eliminating the need for separate triangulation systems and supplementary hardware like pin purge bars
4Extent of automation
If prior art detection systems are used, then object detection is achieved, but object identification and accurate counting are not provided
Solution Approach 1:
The patent implements feedback through image comparison. Detected objects are captured as images and compared against a database of known object images. This feedback mechanism verifies object identity before counting, ensuring that only correctly identified objects are counted and eliminating miscounts from undetected or misidentified objects
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 provides accurate object detection and counting, minimizes mechanical adaptations, and improves accuracy by using image analysis and pixel counts, enabling flexible configuration for various object dimensions and manufacturing equipment.
Implementation Method 1
an array of light sources and photo detectors to detect the presence of a passing object
Implementation Method 2
photo detectors to detect the presence of a passing object
Data Source
AI summary
The present invention is directed to a system and method for use in a computing environment to provide object counts by utilizing object images. Objects are detected and images are captured using a programmable array of light sources and photo detectors. The images are compared against known images to ascertain the identity of the objects and subsequently count the objects.