Conveyor Scanner Using Overlapping Camera Fields for 3D Shape Detection
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Solution Overview
Problem
Current position determination and 3D measurement technologies for products on conveyor belts are costly and require significant computing power, mechanical adjustments, and calibration efforts, especially when dealing with irregularly shaped products and varying conveyor belt widths.
Innovation Solution
A scanner system using a camera field with multiple cameras and two-dimensional optical sensors that image the same scene from different directions, allowing for quick and efficient determination of product position and shape without influencing the depth of field, and calculating height profiles from overlapping recording areas to create a three-dimensional representation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If single-line scanners with a single pixel row are used, then the scanner can determine height profiles along a scanning line, but the device becomes very expensive due to low sales figures and requires very precise mechanical adjustment
Solution Approach 1:
The patent divides the scanning function into multiple independent line scanners arranged in parallel, each covering a portion of the product belt width. This segmentation allows each scanner to operate independently with relaxed alignment tolerances while collectively providing complete coverage, resolving the contradiction between measurement precision and mechanical adjustment complexity
Solution Approach 2:
The patent combines multiple line scanners into a scanning unit that functions as a single system. By merging the data from multiple scanners with relaxed individual alignment requirements, the system achieves the measurement precision of a single scanner without the mechanical adjustment complexity, as the combined field of view covers the entire product belt width
2Adaptability or versatility
If several single-line scanners are arranged one behind the other to cover different belt widths, then the scanner can adapt to varying product belt widths, but the alignment of their pixel lines to each other must be very precise
Solution Approach 1:
The patent assigns each line scanner in the series to cover a specific local region of the product belt width. Each scanner is optimized for its local coverage area with relaxed alignment requirements, while the series collectively provides adaptability to different belt widths. This local quality approach resolves the contradiction by allowing each component to have simpler requirements while the system as a whole achieves versatility
3Measurement precision
If light field technique with multiple cameras is used, then depth information can be determined, but the device complexity and calibration effort increase
Solution Approach 1:
The patent extracts only the essential depth-determining function from the full light field technique, using multiple cameras but focusing specifically on capturing images at different focal distances rather than processing complete light field data. This extraction maintains depth determination capability while significantly reducing device complexity and calibration requirements by eliminating unnecessary light field processing components
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 cost-effective, low-computational, and simplified setup for position and shape determination of products, reducing assembly and calibration efforts while maintaining high accuracy across varying product shapes and conveyor belt widths.
Implementation Method 1
Such scanners emit electromagnetic radiation which is reflected by the product, whereby the reflected radiation is detected by a detector on its one-dimensional or two-dimensional detector surface.
Data Source
Figure 1a~1b
Figure 2a~2b
Figure 3a~3c
AI summary
To scan the position, orientation, and especially the three-dimensional shape of products (P) on a product conveyor belt (101) before they enter the transfer area, several commercially available optical cameras (51.1, 51.2...) or other detectors for electromagnetic radiation with a wavelength outside the visible light spectrum are combined with a planar optical sensor (52.1, 52.2...) such as a CCD sensor along the scanning line (50') to form a scanner (50) or camera module (55.1, 55.2), so that their recording areas (53.1, 53.2...) overlap in the direction of the scanning line (50'). Then, from the different positioning of the images of a distinctive scanning point on the product (P) on the individual sensor areas (52.1, 52.2...), the following information can be obtained:) by arranging a virtual, as narrow as possible, image channel (56) across the individual images, the height of the considered distinctive point above the product conveyor belt (101) can be determined very easily and virtually without computing power, and thus the shape of the product (P) can be determined from a sequence of several scans carried out one after the other in the transport direction (10).