Automated Box Counting During Truck Unloading
Year
2023
Industry
Manufacturing, Logistics
Client
Van der wegen bakker
Overview
I developed a computer vision system to automatically count boxes during truck unloading in a warehouse. The goal was to replace manual counting with a reliable and accurate automated solution.
The challenge
During unloading, warehouse workers had to count boxes manually.
This process could lead to mistakes, especially when:
Lighting conditions change
Boxes overlap or partially block each other
Background activity creates distractions
The company needed a system that could count boxes accurately in real working conditions without changing existing equipment.
My solution
I built a vision-based counting system using video input from the unloading area.
A specific region of interest (ROI) was defined on the conveyor to focus only on the counting zone and ignore surrounding movement.
The system:
Detects boxes as they move through the ROI
Uses a virtual counting line
Increases the count only when a box fully crosses the line
This prevents double counting and missed detections.
A real-time visual overlay shows:
The ROI
The counting line
Detected boxes
Current total count
All counting results can be logged for reporting and inventory control.
The result
The warehouse received an automated box counting system that:
Reduces human counting errors
Works in real unloading conditions
Provides real-time visual verification
Supports operational reporting
Does not require hardware changes
The system improves unloading efficiency and provides consistent, auditable box counts.
System type :
Computer Vision • Industrial Automation • Logistics Monitoring
Role :
Vision Logic Design • ROI Configuration • Counting Algorithm Implementation
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Key features
Automatic box detection during unloading
ROI-based filtering to reduce false positives
Line-crossing logic to prevent double counting
Visual feedback with overlays and live count display
Designed for real warehouse environments (lighting, occlusion)
Tags :
Computer Vision,Warehouse Automation,Logistics Monitoring,Object Detection,Industrial Automation
