Conveyor Sensor Calibration Using a Moving Cuboid Test Object
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Solution Overview
Problem
Conventional manual calibration of sensor systems in conveying devices is time-consuming and prone to errors, especially for spatial and speed sensors, leading to inaccurate calibration results.
Innovation Solution
A method involving automated data recording and mathematical optimization to determine the position and orientation of spatial sensors and correspondence factor for speed sensors using a cuboid test object in multiple positions and orientations, reducing manual intervention and enhancing accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual calibration is performed for each sensor individually in a static state, then the calibration process is simple to implement, but it is very time-consuming and prone to errors
Solution Approach 1:
The patent combines the calibration of multiple sensors (spatial sensors and speed sensor) into a single dynamic process. Instead of calibrating each sensor separately as in conventional methods, the system performs simultaneous calibration of all sensors by recording measurement data from a test object moving through the detection zone, thereby reducing total calibration time while maintaining accuracy
Solution Approach 2:
The patent transitions from static calibration to dynamic calibration. The conveying device is operated during calibration to move a test object through the detection zone, allowing sensors to be calibrated in their actual operating state. This dynamic approach enables simultaneous calibration of multiple sensors and reduces time loss compared to static manual calibration
2Ease of operation
If manual calibration is performed for each sensor individually, then the calibration process is straightforward, but the different sensors can only be set up individually and not together
Solution Approach 1:
The system merges the calibration of spatial sensors and speed sensor into a unified process. A single test object moving through the detection zone provides measurement data for calibrating all sensors simultaneously, eliminating the need for separate calibration procedures for each sensor type and significantly improving calibration productivity
Solution Approach 2:
The test object serves multiple calibration functions simultaneously. As it moves through the detection zone, it enables calibration of spatial sensor positions and orientations, speed sensor correspondence factors, and the relationships between all sensors, making the calibration process universally applicable to the entire sensor system rather than requiring separate procedures for each sensor
3Ease of operation
If manual calibration of spatial sensors is performed, then individual sensor setup is possible, but errors in spatial sensor calibration lead to errors in speed sensor calibration requiring multiple corrections
Solution Approach 1:
The system uses feedback from the measurement data recorded during dynamic operation to calculate and correct calibration parameters for all sensors simultaneously. The evaluation unit processes the measurement data to determine correspondence factors and spatial relationships, providing feedback that ensures consistent and accurate calibration across all sensors, eliminating error propagation between sensors
Solution Approach 2:
The patent replaces manual mechanical calibration procedures with an automated computational system. Instead of manually adjusting each sensor based on coordinate measurements, the system uses recording units to capture measurement data and evaluation units to automatically calculate calibration parameters through mathematical optimization, thereby improving reliability by eliminating human error while maintaining individual sensor adjustability
Data Source
AI summary
The present invention relates to a method for calibrating a sensor system comprising at least one spatial sensor and at least one speed sensor, in particular for calibrating a volume measurement system, for conveying devices. According to the invention, a corresponding method comprises at least the following steps: recording reference data with an empty detection zone of the at least one spatial sensor by means of the at least one spatial sensor; conveying a cuboid test object in two different relative positions and orientations through the detection zone of the at least one spatial sensor and recording corresponding measurement data; determining an absolute orientation of the at least one spatial sensor and/or a correspondence factor for the speed sensor based on the determined reference data and measurement data using a mathematical optimization algorithm. Furthermore, the present invention also relates to sensor systems and conveying systems configured to carry out this method and to a computer-readable storage medium on which corresponding instructions are stored.