Barcode Scanning Tunnel Calibration for Conveyor Positioning
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Solution Overview
Problem
Existing dimensioning systems face challenges in accurately calibrating their position and orientation relative to conveyor belts, which affects the precision of dimension measurement and barcode reading, especially when dealing with varying package sizes and shapes.
Innovation Solution
A method and system that utilize a scanning tunnel with a collimated light source, optics, and a processor to determine distances and offsets across a conveyor structure, employing a reference structure for calibration, ensuring accurate alignment and measurement of package dimensions and barcode data.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual calibration methods are used to align the scanning system with the conveyor belt, then the system can be set up, but the measurement precision and alignment accuracy deteriorate due to human error and time-consuming adjustments
Solution Approach 1:
The system performs automatic self-calibration by detecting the conveyor belt surface and reference structures using optical scanners, calculating alignment parameters and offset distances computationally, and adjusting measurement coordinates without human intervention, thereby eliminating manual calibration errors while maintaining measurement precision
Solution Approach 2:
The system executes preliminary calibration actions automatically during system initialization or at predetermined intervals by scanning reference structures and computing alignment parameters before actual package measurement begins, ensuring measurement precision is established in advance without manual intervention
2Measurement precision
If the scanning system is fixed relative to the frame, then the system structure is simplified, but the measurement precision deteriorates when conveyor belt position varies
Solution Approach 1:
The system continuously scans the conveyor belt surface and reference structures to detect actual position and orientation, compares these measurements with predetermined calibration parameters, and computationally adjusts measurement coordinates to compensate for position variations, thereby maintaining measurement precision despite fixed physical mounting
Solution Approach 2:
The system dynamically changes measurement parameters including origin coordinates, axis orientations, and offset distances based on detected conveyor belt position and scanned reference structure locations, allowing the fixed scanning system to adapt to position variations through computational parameter adjustment rather than physical movement
3Productivity
If manual calibration adjustments are made, then the system can be aligned, but the calibration time and productivity are reduced due to repetitive manual intervention
Solution Approach 1:
The system automatically performs calibration by scanning reference structures, computing alignment parameters, and adjusting measurement coordinates without human intervention, eliminating the time loss associated with manual calibration adjustments and significantly improving calibration efficiency
Solution Approach 2:
The system replaces manual mechanical calibration adjustments with optical scanning and computational coordinate transformation, substituting human-operated mechanical alignment with automated optical-detection-and-calculate methodology, thereby reducing calibration time and improving productivity
4Measurement precision
If the light beam intersects the conveyor surface at a fixed angle, then the optical system is simplified, but the measurement precision deteriorates when packages of varying sizes and shapes are measured
Solution Approach 1:
The system changes the intersection angle of the light beam with the conveyor surface based on detected package characteristics such as height, width, and shape, allowing the optical system to optimize measurement precision for varying package types by adjusting beam angle parameters rather than requiring complex mechanical reconfiguration
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
Enhances the precision and accuracy of dimension measurement and barcode reading by automatically determining critical parameters during calibration, improving the system's ability to handle diverse package sizes and shapes with reduced human intervention.
Implementation Method 1
the optics system directs light from the source toward the conveyor structure so that the light extends across the conveyor structure transverse to the direction of travel and reflects from positions on the conveyor structure and positions on objects carried by the conveyor structure
Data Source
AI summary
An apparatus and method for calibrating a barcode scanning tunnel has a conveyor structure and a scanning system. The scanning system has a laser light source, an optics system, and a processor. In a calibration mode, the processor locates a central area of the conveyor structure and identifies a first location at which there is a height above the level of the central area according to a predetermined criteria. The processor identifies a second location that is offset, by a predetermined distance in a direction transverse to the direction of travel of the conveyor structure, from the first location.