Conveyor Gap Light Arrays for In-Motion Package Dimensioning
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Solution Overview
Problem
Fulfillment centers face inefficiencies in processing and handling large volumes of packages due to challenges in robotic handling, measurement, and identification of items, particularly when items need to be measured and identified at various stages of processing, which can create bottlenecks and require manual intervention.
Innovation Solution
A system combining scanning cameras and item dimensioning light arrays in a compact space that allows for the identification and measurement of items while they are in motion, using cameras disposed below a gap between conveyor belts to scan machine-readable codes and light arrays to measure dimensions, enabling efficient processing and reduced manual effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If robotic equipment is used to handle items, then handling efficiency is improved, but the ability to measure and identify items accurately deteriorates
Solution Approach 1:
The system performs measurement and identification actions before the item reaches the robotic handling station. By using optical scanners and cameras to capture item dimensions and codes while items are still on the conveyor, the system prepares data in advance, allowing robotic equipment to handle items without interruption while measurement accuracy is maintained through dedicated sensing equipment.
Solution Approach 2:
The system separates the measurement and identification functions from the robotic handling function. Optical scanners, cameras, and light arrays are positioned independently along the conveyor path to perform measurements, while robotic equipment operates separately at handling stations. This segmentation allows each subsystem to optimize its performance without interfering with the other.
2Measurement precision
If items are stopped for measurement and identification, then measurement accuracy is improved, but processing speed deteriorates
Solution Approach 1:
The system maintains continuous item flow through the fulfillment center by performing all measurement and identification operations while items are in motion on the conveyor. Optical scanners and cameras continuously scan items as they pass, eliminating stopping points and maintaining uninterrupted processing speed while still capturing accurate measurement data.
Solution Approach 2:
The system replaces mechanical measurement methods that would require stopping items with optical sensing methods. Light arrays and cameras non-contactfully measure item dimensions and scan codes while items move along the conveyor, substituting mechanical intervention with optical detection to maintain both speed and accuracy.
3Measurement precision
If manual intervention is used for measurement and identification, then measurement accuracy is improved, but labor requirements increase
Solution Approach 1:
The system enables items to be automatically measured and identified without human intervention. Optical scanners and cameras autonomously capture item data, the controller automatically processes measurements and compares them against packaging requirements, and the system self-regulates the packing process based on measured dimensions, eliminating the need for manual measurement while maintaining accuracy.
Solution Approach 2:
The system replaces manual measurement and identification operations with automated optical sensing equipment. Cameras and light arrays perform functions previously requiring human eyes and hands, while computer vision algorithms and control systems replace human decision-making, eliminating labor requirements while preserving or improving measurement precision.
4Measurement precision
If separate stations are used for scanning and dimensioning, then measurement accuracy is improved, but system complexity increases
Solution Approach 1:
The system merges the scanning and dimensioning functions into a single integrated measurement station along the conveyor path. Optical scanners for code identification and light arrays for dimensional measurement are positioned in close proximity and controlled by a single controller, combining multiple functions into one compact unit that reduces system complexity while maintaining the measurement accuracy of dedicated sensors.
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
Improves processing speed and throughput in fulfillment centers by allowing items to be measured and identified simultaneously while in motion, reducing bottlenecks and enhancing logistics efficiency.
Implementation Method 1
a first light emitting array and a first light receiving array... The controller may be configured to determine a length of time of light interruption between the light emitting array and the light receiving array
Implementation Method 2
One or more cameras may be disposed below the gap... configured to identify the item by scanning a machine-readable code
Data Source
AI summary
Systems, methods, and computer-readable media are disclosed for scanning and dimensioning items in motion. In one embodiment, an example system may include a first camera oriented along a vertical axis towards a gap between a first surface and a second surface, a first light emitting array positioned to emit light towards the gap, and a first light receiving array aligned with the light emitting array and configured to detect the light. The first light emitting array and the first light receiving array may be offset from the vertical axis, and the system may be configured to determine a first dimension of an item passing over the gap using the first light emitting array and the first light receiving array.