{"id":2316,"date":"2019-11-28T11:04:00","date_gmt":"2019-11-28T10:04:00","guid":{"rendered":"https:\/\/home.et.utwente.nl\/slootenvanf\/?p=2316"},"modified":"2019-12-04T10:16:33","modified_gmt":"2019-12-04T09:16:33","slug":"object-counting-with-distance-sensors","status":"publish","type":"post","link":"https:\/\/home.et.utwente.nl\/slootenvanf\/2019\/11\/28\/object-counting-with-distance-sensors\/","title":{"rendered":"Object counting with distance sensors"},"content":{"rendered":"\n<p>Learn how to count products on a conveyor belt with a distance sensor. This article explains how to use a distance sensor for counting objects. In this case, we have a conveyor belt with products, which we will count. This article is part of <a href=\"https:\/\/home.et.utwente.nl\/slootenvanf\/i40\/\">a lecture on use of sensors in Industry 4.0<\/a>.<\/p>\n\n\n\n<p>The setup looks like this:<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"741\" height=\"377\" src=\"https:\/\/home.et.utwente.nl\/slootenvanf\/wp-content\/uploads\/2019\/11\/conveyorbelt.jpg\" alt=\"\" class=\"wp-image-2267\" srcset=\"https:\/\/home.et.utwente.nl\/slootenvanf\/wp-content\/uploads\/2019\/11\/conveyorbelt.jpg 741w, https:\/\/home.et.utwente.nl\/slootenvanf\/wp-content\/uploads\/2019\/11\/conveyorbelt-300x153.jpg 300w\" sizes=\"auto, (max-width: 741px) 100vw, 741px\" \/><\/figure>\n\n\n\n<p>You can use any distance sensor for this. For example the ones below which are detailed in  separate tutorials:<\/p>\n\n\n\n<ul class=\"wp-block-list\"><li><a href=\"https:\/\/home.et.utwente.nl\/slootenvanf\/2019\/11\/18\/optical-ir-sensor-with-arduino\/\">A Sharp optical distance sensor<\/a><\/li><li><a href=\"https:\/\/home.et.utwente.nl\/slootenvanf\/2019\/11\/15\/using-an-ultrasonic-sensor-with-arduino\/\">A HC-SR04 ultrasonic distance sensor<\/a><\/li><li><a href=\"https:\/\/home.et.utwente.nl\/slootenvanf\/2019\/11\/19\/connected-distance-sensor-esp32-module\/\">An ESP32 module with a distance sensor (either optical or ultrasonic)<\/a><\/li><\/ul>\n\n\n\n<h4 class=\"wp-block-heading\">Start counting<\/h4>\n\n\n\n<p>Counting products can be added quite easily if you have a properly working distance sensor. Every time a product is in sight, and the previous state was \u201cnothing seen\u201d we can increase a counter.<\/p>\n\n\n\n<p>It is possible that readings contain glitches (short mis-reads, arrows in red in image below). So never trust a single reading.  To make it more robust,  we can count the number of consecutive measurements that have spotted a product.<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"266\" height=\"120\" src=\"https:\/\/home.et.utwente.nl\/slootenvanf\/wp-content\/uploads\/2019\/11\/error_readings.jpg\" alt=\"Mis-reads\" class=\"wp-image-2274\"\/><\/figure>\n\n\n\n<p>So we need 3 variables:  the product counter, a variable to count the number of consecutive measurements, and some variable which we can use to help determine if something was in sight. We use &#8216;height&#8217; for this last one, because we will mount the sensor above the belt. If the measured distance is less than the height, we assume an object was &#8216;seen&#8217;. Add these and make sure they get proper values.<\/p>\n\n\n\n<p>First, declare the variables at the top of the sketch (before <code>setup()<\/code>):<\/p>\n\n\n\n<pre class=\"wp-block-code\"><code>int height = 100; \/\/ you will have to calibrate this\nint count = 0; \/\/ counts products\nint product = 0; \/\/ keeps track how many consecutive measurements spotted a product<\/code><\/pre>\n\n\n\n<p>We will use variable <code>product<\/code> to count how many consecutive measurements have spotted a product. When it changes from 1 to 0, we know there was a product (products gets counted after it disappears out of sight). It works like this:<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"291\" src=\"https:\/\/home.et.utwente.nl\/slootenvanf\/wp-content\/uploads\/2019\/11\/counter-1024x291.jpg\" alt=\"How counting works\" class=\"wp-image-2321\" srcset=\"https:\/\/home.et.utwente.nl\/slootenvanf\/wp-content\/uploads\/2019\/11\/counter-1024x291.jpg 1024w, https:\/\/home.et.utwente.nl\/slootenvanf\/wp-content\/uploads\/2019\/11\/counter-300x85.jpg 300w, https:\/\/home.et.utwente.nl\/slootenvanf\/wp-content\/uploads\/2019\/11\/counter-768x218.jpg 768w, https:\/\/home.et.utwente.nl\/slootenvanf\/wp-content\/uploads\/2019\/11\/counter-1536x436.jpg 1536w, https:\/\/home.et.utwente.nl\/slootenvanf\/wp-content\/uploads\/2019\/11\/counter.jpg 1600w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><\/figure>\n\n\n\n<p>Now add if-statements to accomplish this:<\/p>\n\n\n\n<pre class=\"wp-block-code\"><code>if (distance>=height) { \/\/ nothing seen\n    if (product==1) { \/\/ change from 1>0: product no longer in sight confirmed\n        count++;\n        \/\/ display count\n        \/\/ display \"-\" (no product in sight)\n    }\n    product--; \/\/ one less measurement confirms presence of product\n    if (product&lt;0) product=0;\n  }\n  else { \/\/ product in sight\n    if (product==2) { \/\/ change from 2>3: product presence confirmed\n        \/\/ display \"PRODUCT\"\n    }\n    product++; \/\/ one more measurement confirms presence of product\n    if (product>3) product=3; \/\/ more than 3 confirmations is not necessary\n}<\/code><\/pre>\n\n\n\n<p>At the comments, add code to display messages. Eg. at &#8220;<code>\/\/ display count<\/code>&#8221; show the value of variable <code>count<\/code> on the display:<\/p>\n\n\n\n<pre class=\"wp-block-code\"><code>itoa(count, buf, 10); \/\/ put value into string buffer 'buf'\ndisplay.draw2x2String(0,5,\"    \"); \/\/ clear line\ndisplay.draw2x2String(0,5,buf);<\/code><\/pre>\n\n\n\n<p>Now do a test  (on the conveyor belt) to check if it works as expected.<\/p>\n\n\n\n<p>Try increasing the belt speed. If things do not work as expected, consider altering the timing of the loop  to increase or decrease the amount of measurements taken. The call to delay() at the end of the loop() can be used to change this. For example, the code below will do a measurement every 100ms (10 times a second). This does not consider the time it takes to do the measurement and to do the processing (this might take another 50ms or so).<\/p>\n\n\n\n<pre class=\"wp-block-code\"><code>void loop() {\n  \/\/ read distance:\n  unsigned int distance = ...\n\n  \/\/ do some processing &amp; display results ...\n\n  delay(100); \/\/ wait 100ms\n}<\/code><\/pre>\n\n\n\n<h4 class=\"wp-block-heading\">Complete solution<\/h4>\n\n\n\n<p>This is how it might look on the display:<\/p>\n\n\n\n<figure class=\"wp-block-image size-large\"><img loading=\"lazy\" decoding=\"async\" width=\"1024\" height=\"511\" src=\"https:\/\/home.et.utwente.nl\/slootenvanf\/wp-content\/uploads\/2019\/11\/ir_counter_display-1024x511.jpg\" alt=\"\" class=\"wp-image-2334\" srcset=\"https:\/\/home.et.utwente.nl\/slootenvanf\/wp-content\/uploads\/2019\/11\/ir_counter_display-1024x511.jpg 1024w, https:\/\/home.et.utwente.nl\/slootenvanf\/wp-content\/uploads\/2019\/11\/ir_counter_display-300x150.jpg 300w, https:\/\/home.et.utwente.nl\/slootenvanf\/wp-content\/uploads\/2019\/11\/ir_counter_display-768x383.jpg 768w, https:\/\/home.et.utwente.nl\/slootenvanf\/wp-content\/uploads\/2019\/11\/ir_counter_display.jpg 1200w\" sizes=\"auto, (max-width: 1024px) 100vw, 1024px\" \/><\/figure>\n\n\n\n<p>You can find complete code for each of the sensor-setups mentioned at the beginning of this article:<\/p>\n\n\n\n<ul class=\"wp-block-list\"><li>Sharp optical distance sensor (with Arduino Nano): <a href=\"\/slootenvanf\/div\/arduino\/ir_sensor_counter_with_display.ino\">ir_sensor_counter_with_display.ino<\/a><\/li><li>HC-SR04 ultrasonic distance sensor  (with Arduino Nano): <a href=\"\/slootenvanf\/div\/arduino\/ultrasonic_sensor_counter_with_display.ino\">ultrasonic_sensor_counter_with_display.ino<\/a><\/li><li>ESP32 module with ultrasonic distance sensor: <a href=\"\/slootenvanf\/div\/arduino\/ultrasonic_sensor_counter_with_display_esp32.ino\">ultrasonic_sensor_counter_with_display_esp32.ino<\/a><\/li><\/ul>\n\n\n\n<p>Our goal was to learn how to count products on a conveyor belt with a distance sensor. I hope you succeeded in this.<\/p>\n\n\n\n<h4 class=\"wp-block-heading\">References<\/h4>\n\n\n\n<ul class=\"wp-block-list\"><li><a href=\"https:\/\/www.instructables.com\/id\/Arduino-using-Ultrasonic-sensor-to-count-log-objec\/\" target=\"_blank\" rel=\"noreferrer noopener\" aria-label=\"Count Objects Using Arduino and Ultrasonic Sensor on a Production Conveyor : 3 Steps (opens in a new tab)\">Count Objects Using Arduino and Ultrasonic Sensor on a Production Conveyor : 3 Steps<\/a><\/li><\/ul>\n","protected":false},"excerpt":{"rendered":"<p>Learn how to count products on a conveyor belt with a distance sensor. This article explains how to use a distance sensor for counting objects. In this case, we have a conveyor belt with products, which we will count. This article is part of a lecture on use of sensors in Industry 4.0. The setup [&hellip;]<\/p>\n","protected":false},"author":1,"featured_media":2335,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_coblocks_attr":"","_coblocks_dimensions":"","_coblocks_responsive_height":"","_coblocks_accordion_ie_support":"","footnotes":""},"categories":[3],"tags":[245,243,228,244,231,161],"class_list":["post-2316","post","type-post","status-publish","format-standard","has-post-thumbnail","hentry","category-education","tag-algorithm","tag-count","tag-distance","tag-object","tag-product","tag-sensor"],"blocksy_meta":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v27.3 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Object counting with distance sensors - vanslooten.com<\/title>\n<meta name=\"description\" content=\"Object counting with distance sensors\" \/>\n<meta name=\"robots\" content=\"index, follow, max-snippet:-1, max-image-preview:large, max-video-preview:-1\" \/>\n<link rel=\"canonical\" href=\"https:\/\/home.et.utwente.nl\/slootenvanf\/2019\/11\/28\/object-counting-with-distance-sensors\/\" \/>\n<meta property=\"og:locale\" content=\"en_US\" \/>\n<meta property=\"og:type\" content=\"article\" \/>\n<meta property=\"og:title\" content=\"Object counting with distance sensors - 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