Camera-Based Product Counting Solution for Production LinesUse Hype Vision’s AI platform with brand-agnostic cameras for fast, accurate product counting on production lines. Real-time counting and alerts on-premise.
Accurate and fast product counting on production lines is a critical process. Hype Vision’s industrial computer vision platform automatically detects product quantities using your existing RTSP/ONVIF-compatible IP cameras.
This solution simplifies production tracking, minimizes errors, and accelerates workflows with real-time alerts and system integrations when needed.
Connect your existing IP cameras regardless of brand and perform product counting on production lines with Hype Vision’s AI models. The platform operates on-premise, delivering real-time counting and alerting capabilities.
The Challenge and Importance of Product Counting on Production Lines
Accurate and timely product counting is vital for quality control and production management. Manual counting is prone to errors and delays, negatively impacting operational efficiency.
Products moving at varying speeds across different conveyors require automated, reliable counting. Camera-based AI product counting solutions provide consistent accuracy, speed, and continuous monitoring.
How the Hype Vision Product Counting Solution Works
The Hype Vision platform connects to your existing IP/CCTV cameras that support RTSP or ONVIF protocols, independently of brand. The video feed is processed on-premise using real-time object detection models from the Hype-Model family.
These models detect and classify products on conveyors, logging each item accurately to automate product counts on the production line. The platform operates anonymously and complies with personal data protection regulations.
Optionally, industrial cameras and specialized lighting can be used during quality control phases. For urgent alerts and data sharing, Hype Vision offers integrations with WhatsApp, SMS, VMS pop-ups, and ERP/MES systems.
Example Alarm Scenario
The system triggers an alarm if the product count falls below the expected amount or inconsistencies arise from an unusually fast count.
For instance, if 100 products are expected to pass on the conveyor but the count records 90 or 120, real-time notifications are sent to relevant teams via WhatsApp.
Simultaneously, a pop-up alert appears on the VMS, production lines can be halted through PLC or relay outputs, and ERP/MES systems receive data to expedite intervention.
Camera and Lighting Requirements
Cameras used for product counting must support RTSP/ONVIF protocols, with resolution and frame rate aligned to production speed. Typically, 2-5 MP resolution and 15-30 frames per second are recommended.
Proper lighting is critical in industrial environments; additional LED lighting can enhance image quality, especially in low light or during fast-moving operations.
Adjusting the camera’s field of view to match the width of the production line is essential for accurate model performance. Industrial cameras specialized for quality control may be preferred when necessary.
Integration and Measured Outputs
The Hype Vision platform easily integrates with alarm systems, PLC/relay devices, and ERP or MES software. Data sharing with custom applications is enabled through REST API support.
Key measured outputs include total product count, instantaneous and time-based production speeds, count discrepancies, and operational performance reports.
These insights enable effective monitoring, reporting, and rapid identification of potential issues within production processes.
Pilot Process and Installation Steps
A typical pilot runs for 2 to 4 weeks, starting with connecting existing IP cameras and assessing the environment.
Next, a suitable AI model from the Hype-Model family is selected and optimized for the production setting.
During the pilot, the system performs real-time counting, is evaluated by pilot users, and fine-tuned as needed.
The production line is tested under multiple scenarios, finalizing alarm and integration configurations.
After successful pilot validation, system performance is confirmed, and recommendations for full deployment are provided.
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Frequently asked questions
What types of cameras are needed for product counting?
IP cameras that support RTSP/ONVIF protocols are suitable. Resolution and frame rate should match production speed, with appropriate lighting to ensure image quality.
Can the system work with my existing cameras?
Yes, the Hype Vision platform integrates with most RTSP/ONVIF-compatible cameras, regardless of brand.
How does the system issue alarms?
Alarm options include WhatsApp and SMS notifications, VMS pop-up alerts, PLC/relay outputs, and ERP/MES system integrations.
Does the platform ensure data security and compliance?
Yes, it operates on-premise and features anonymous modules that comply with personal data regulations.
How does the pilot process work?
During a 2-4 week pilot, existing cameras are evaluated, models optimized, and performance tested under real production conditions to ensure compatibility.
What can AI detect in your factory?
Let's review together which safety, quality and production analytics your existing security cameras can deliver.
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