Container Rotation for Barcode Reading on Moving Conveyor
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Solution Overview
Problem
Current ID readers struggle to accurately read marks on cylindrical portions of containers moving along a conveyor, especially when the field of view is limited, leading to incomplete capture and decoding of barcodes, and existing multi-camera solutions are complex and costly, with high failure rates at high conveyor speeds.
Innovation Solution
A device and method that uses a drive unit to spin containers within a reading area, allowing a high-speed camera to capture marks on a cylindrical surface, with retention and ejection mechanisms to ensure single-container processing and synchronization, enhancing reading accuracy and throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple ID readers or cameras are employed around the reading area to ensure mark capture, then the reliability of mark reading is improved, but the device complexity and cost increase significantly
Solution Approach 1:
The patent applies the dynamics principle by rotating the container itself rather than moving the camera or reader. The container is spun on its axis using a drive roller, bringing different portions of its cylindrical surface sequentially into the fixed camera's field of view. This dynamic approach eliminates the need for multiple stationary cameras while ensuring complete mark capture.
Solution Approach 2:
The patent uses a high-speed camera to capture multiple images of the rotating container at different rotational positions. These sequential images are then stitched together computationally to create a complete view of the mark around the entire container circumference, effectively copying the mark's appearance from multiple angles without needing multiple physical cameras.
2Productivity
If the conveyor speed is increased to maintain high throughput, then the productivity is improved, but the difficulty of detecting and measuring the mark increases
Solution Approach 1:
The system uses periodic action by rotating the container at a controlled speed and synchronizing the camera's image capture with specific rotational positions. The container completes full rotations in a periodic manner, allowing the high-speed camera to capture marks at optimal moments during each rotation cycle, ensuring reliable detection even at high conveyor speeds.
Solution Approach 2:
The system incorporates feedback through synchronization between the container rotation and camera triggering. The rotation speed and camera capture timing are coordinated so that images are taken at the correct rotational positions, allowing the system to adapt to varying conveyor speeds while maintaining mark reading accuracy.
3Area of stationary object
If a larger sensor is used to expand the field of view in the widthwise direction, then the field of view is improved, but the manufacturing cost increases due to less-conventional hardware
Solution Approach 1:
Instead of using a larger sensor to expand the field of view, the patent uses dynamic rotation of the container to bring different portions of its surface into the camera's field of view sequentially. This approach maintains a compact, conventional camera setup while achieving complete mark coverage through temporal rather than spatial expansion.
Solution Approach 2:
The patent transitions from a spatial solution (larger sensor covering more area simultaneously) to a temporal solution (rotating the container to present different areas at different times). By adding the time dimension through rotation, the system achieves complete mark capture with a standard sensor size.
4Area of stationary object
If the field of view is enlarged to cover the entire line width, then the field of view is improved, but the measurement precision decreases due to reduced resolution for accurate imaging and decoding
Solution Approach 1:
The container rotation dynamically positions different portions of the mark at optimal distances from the camera during the rotation cycle. This ensures that when images are captured, the mark is imaged at high resolution without requiring an enlarged field of view, maintaining both complete coverage and decoding 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
Ensures 100% capture and decoding of marks on containers moving at high speeds, maintaining high throughput by synchronizing container rotation with camera imaging, reducing complexity and cost compared to multi-camera systems.
Implementation Method 1
A drive unit is provided in the reading area, configured to apply friction to a lateral surface of the container, so as to rotate the container around a vertical axis of the container
Data Source
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Figure 1B
Figure 2
AI summary
Device and method of reading a mark printed on containers moving along a conveyor (102), wherein the mark (112) is printed on a lateral portion (114) of the container (110). The device (100) comprises a drive unit for applying torque on a container (110) in a reading area (104) to generate rotation along its vertical axis (118), and a camera (120) for reading the mark (112) while the container (110) is spinning. The drive unit (130) comprises a motor (134) and a spinner (132) disposed at a first zone (106) of the reading area (104) for applying torque on a lateral wall of the container (110). The device (100) comprises a pushing assembly, e.g. an air knife (140) applying high-pressure air flow (142) that drives the container (110) towards the first zone (106) to ensure rotational movement of the container (110). The device allows safe capture of the mark (112) at high line feeding speeds.