3D Camera Dimensioning Using Single Pulse Time of Flight
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Solution Overview
Problem
Existing dimensioning systems require multiple light pulses and mechanical mechanisms to measure object dimensions, leading to inefficiencies and inaccuracies, especially when dealing with irregularly shaped objects and large volumes in packaging and manufacturing applications.
Innovation Solution
A 3-D camera system that uses a single light pulse to capture the entire surface of an object with a pixilated focal plane array, converting light into electronic signals to determine distances and generate a three-dimensional image, eliminating the need for moving components and enhancing accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple light pulses and mechanical mechanisms are used to measure object dimensions, then measurement coverage can be achieved, but measurement speed decreases and system complexity increases
Solution Approach 1:
The patent replaces mechanical scanning mechanisms with a stationary 3-D camera system that uses a single light pulse to capture the entire object surface simultaneously. The focal plane array detector captures all spatial information in one shot, eliminating the need for moving parts and multiple sequential measurements, thus dramatically increasing measurement speed while maintaining accuracy.
Solution Approach 2:
The patent transitions from 2-D imaging to 3-D imaging by incorporating time-of-flight information for each pixel. By measuring the time for light to travel to and from each point on the object, the system adds the third dimension (depth) to the traditional 2-D image, enabling complete 3-D dimensional measurement in a single capture.
2Measurement precision
If mechanical scanning mechanisms are used to measure irregularly shaped objects, then comprehensive surface coverage is achieved, but system complexity and error potential increase
Solution Approach 1:
The patent eliminates complex mechanical scanning mechanisms by using a stationary 3-D camera with a focal plane array. The entire object surface is captured in a single shot without any moving parts, reducing mechanical complexity while maintaining comprehensive surface coverage capability.
Solution Approach 2:
The patent combines multiple measurement functions into a single integrated 3-D camera system. The focal plane array simultaneously captures spatial position, depth information, and surface geometry for all points on the object in one measurement cycle, eliminating the need for separate mechanical scanning operations.
3Quantity of substance
If traditional optical scanning is used for high-volume packaging, then dimensional data can be collected, but errors in shipping cost calculations increase
Solution Approach 1:
The patent replaces traditional mechanical optical scanning with a digital 3-D imaging system using a focal plane array. This electronic capture method eliminates mechanical errors and provides more consistent, accurate dimensional measurements for high-volume packaging applications, directly improving shipping cost calculation accuracy.
Solution Approach 2:
The patent creates a digital 3-D copy of the object using the focal plane array detector. This digital representation accurately captures the object's dimensions and can be processed computationally to determine shipping costs, replacing error-prone mechanical measurement and calculation methods.
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 rapid, accurate measurement of objects of any size and shape, reducing errors in shipping cost calculations and quality control, while simplifying the measurement process and improving precision by sampling the reflected light's pulseshape.
Implementation Method 1
a pulsed light source 4a that creates a light pulse which reflects from an object 3
Implementation Method 2
measures the distance to every reflective point in its field of view with a single light pulse
Implementation Method 3
images the object illuminated by the light onto a pixilated, electronic light sensitive detector called a focal plane array. Each pixel converts the light into an electronic signal
Data Source
AI summary
A dimensioning system that determines the dimensions and volume of an object by using a three-dimensional camera that measures the distance to every reflective point in its field of view with a single pulse of light. The distance is computed by the time of flight of the pulse to each camera pixel. The accuracy of the measurement is augmented by capture of the laser pulse shape in each camera pixel. The camera can be used on an assembly line to develop quality control data for manufactured objects or on a moving or stationary system that weighs as well as dimensions the objects. The device can also ascertain the minimum size of a box required to enclose an object.