Collimated Light Curtain Scanner for 3D Item Reconstruction
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Solution Overview
Problem
Existing data reading systems face inaccuracies in measuring object dimensions due to high surface reflectivity and optical occlusion issues, particularly when dealing with items like mirrors and aluminum cans, and are not effective in constructing accurate three-dimensional models of items moving through conveyor systems.
Innovation Solution
A compact, automated data reading system with a collimated design utilizing multiple height sensors arranged in a perpendicular configuration, combined with speed information, to minimize shadowing effects and accurately construct three-dimensional models of items passing through the system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If reflection based methods such as laser-based triangulation and stereo imaging are used to determine object dimensions, then dimensional information can be obtained, but measurement precision deteriorates when objects have high surface reflectivity or dark surfaces
Solution Approach 1:
The patent replaces optical reflection-based measurement methods with a mechanical/physical blocking method using light curtains. Instead of relying on light reflecting off the object surface, the system uses transmissive light curtains that are blocked by the object to measure dimensions. This substitution eliminates the harmful effects of high surface reflectivity and dark surfaces, as the measurement depends on light blockage rather than surface reflection properties.
Solution Approach 2:
The patent introduces light curtains as an intermediary measurement medium between the object and the detection system. Rather than directly measuring reflected light from the object surface, the light curtains serve as an intermediary that transits through or is blocked by the object, providing a reliable measurement signal that is not affected by the object's surface optical properties.
2Area of stationary object
If non-collimated optical systems are used for scanning, then coverage area is increased, but optical occlusion issues arise affecting measurement accuracy
Solution Approach 1:
The patent divides the scanning system into multiple discrete light curtain planes arranged in a collimated configuration. Each light curtain acts as an independent measurement plane, and together they provide comprehensive coverage of the scanning volume. This segmentation allows the system to maintain collimated geometry for accurate measurements while achieving extensive coverage through the arrangement of multiple planes.
Solution Approach 2:
The patent transitions from traditional two-dimensional optical scanning to a three-dimensional collimated light curtain system. By arranging light curtains in multiple dimensions and using collimated geometry, the system achieves both accurate dimensional measurements and comprehensive volumetric coverage without the occlusion problems of non-collimated systems.
3Measurement precision
If multiple imagers are positioned around a conveyor system to obtain barcode information and dimensional data, then measurement capability is improved, but device complexity increases
Solution Approach 1:
The patent designs the light curtain system to serve multiple functions simultaneously: it measures dimensional information, identifies object presence, and provides spatial positioning data. This multi-functionality reduces the need for separate specialized sensors and imagers, thereby reducing overall device complexity while maintaining comprehensive measurement capabilities.
Solution Approach 2:
The patent combines multiple measurement functions into a unified collimated light curtain system. Rather than using separate imagers and sensors positioned around the conveyor, the light curtains integrate dimensional measurement, object detection, and spatial mapping into a single coordinated system, reducing complexity while improving measurement precision.
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
The system provides enhanced accuracy in dimensional measurements and reduces occlusion issues, enabling precise three-dimensional modeling of items moving through the data reading zone, even under challenging surface conditions.
Implementation Method 1
A light curtain may be used to measure the height of an item as the item passes through a read zone of the scanner unit
Data Source
AI summary
A data reading system and method for constructing a three-dimensional model of an item passing through a read zone of the data reading system, the system including a plurality of light transmitters each operable to generate a light curtain across the read zone. As the items interrupt each of the light curtains, a height measurement of the item is obtained. Thereafter, the data reading system combines the height measurement data from each of the light curtains taken at various times, and generates a three-dimensional model of the item based on the obtained data.