3D Image Detection for Irregular Load Wrapping Path
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Solution Overview
Problem
Existing wrapping apparatuses struggle with irregularly shaped loads, as they require a feeler arm that can cause collisions and are inefficient due to the need for detection travels and data storage, especially when load shapes change during wrapping.
Innovation Solution
A method using a device for capturing three-dimensional images to detect a cloud of points on the load, project them onto a reference plane, and calculate a local path for safe movement, allowing continuous wrapping without reconstructing edges or surfaces, and storing only local path data for efficient operation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a feeler arm is used to detect the load profile, then the apparatus can follow the perimeter of the load, but the apparatus cannot wrap loads with irregular shapes having protruding portions at different heights
Solution Approach 1:
The patent replaces the mechanical feeler arm system with a sensor-based detection system. Sensors (optical, laser, or other detection devices) are used to detect the load profile and generate data that defines the wrapping path, eliminating the need for mechanical feeler arms and their associated limitations.
Solution Approach 2:
The patent introduces an intermediary computational system that processes sensor data to define the wrapping path. Instead of direct mechanical contact, the system uses detected point cloud data as an intermediary to calculate and guide the wrapping trajectory, enabling adaptation to irregular shapes.
2Adaptability or versatility
If sensor means are used to detect load surfaces and edges, then the apparatus can wrap loads with irregular shapes, but the time required to carry out the wrapping increases due to detection travels
Solution Approach 1:
The patent performs detection travels at reduced speed before the actual wrapping operation to map the load profile. This preliminary action allows the system to pre-calculate the wrapping path and store the data, so that during the main wrapping operation, the apparatus can move at higher speed without real-time detection delays.
Solution Approach 2:
The patent dynamically adjusts the detection process based on the wrapping operation. The detection travel is performed at a first speed (reduced) for mapping, while the wrapping operation proceeds at a second speed (higher). The system dynamically switches between these operational modes, optimizing both detection accuracy and wrapping efficiency.
3Productivity
If the SLAM algorithm is used to process sensor data, then the peripheral outline and wrapping path can be calculated, but uncertainty in the reconstruction of the load shape remains
Solution Approach 1:
The patent incorporates feedback mechanisms where the detected load profile is continuously referenced during the wrapping operation. The system uses the stored detection data to verify and adjust the wrapping path in real-time, reducing uncertainties introduced by algorithms like SLAM and ensuring more reliable wrapping even for irregular shapes.
4Measurement precision
If detection travels are performed at reduced speed, then accurate data can be collected, but the overall wrapping time increases
Solution Approach 1:
The patent performs accurate detection at reduced speed as a preliminary step before the main wrapping operation. The detection data is collected and stored in advance, allowing the high-speed wrapping operation to proceed without repeating the slow detection process, thus maintaining both accuracy and productivity.
Solution Approach 2:
The patent dynamically adjusts operational speed based on the phase of the wrapping process. During the detection phase, the apparatus moves at a reduced speed to ensure accurate data collection. During the wrapping phase, the apparatus operates at higher speed, optimizing the balance between measurement precision and overall productivity.
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 quick and safe wrapping of loads with changing shapes by continuously updating local paths based on real-time data, reducing the risk of collisions and improving handling efficiency.
Implementation Method 1
a device for capturing three-dimensional images is used to detect a cloud of points of a portion of the load visible in the visual field of the device
Data Source
Figure 1~1a
Figure 2~2a
Figure 3~3a
AI summary
The method for wrapping a load with a film of wrapping material provides for preparing an apparatus (2) for wrapping said load (1) with a film of wrapping material provided with at least one device for capturing three-dimensional images, in a workplace wherein at least one said load (1) to be wound is arranged. The method provides for detecting, by means of said at least one device for capturing three-dimensional images, a cloud of points of a visible portion of said load (1) and for calculating, starting from said cloud of points, a local path that said apparatus (2) has to follow.