Conveyor SKU Validation Using Imaging for Continuous Pallet Loading
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Solution Overview
Problem
Existing pallet loading systems face inefficiencies due to frequent stoppages caused by package height discrepancies, limited ability to handle multiple pickers, and inadequate SKU identification accuracy, leading to errors in pallet loading processes.
Innovation Solution
A computer-based system utilizing machine learning models and imaging technology to identify SKUs by analyzing package images, comparing them to desired SKUs, and directing packages to appropriate pallets, with features like indistinguishable SKU handling and OCR for enhanced accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If package height is used for rough SKU verification on the conveyor, then error detection is facilitated, but the system experiences frequent stoppages
Solution Approach 1:
The patent replaces the mechanical height-based verification system with an optical imaging system. Cameras capture images of packages on the conveyor, and image processing algorithms determine SKU identification. This substitution eliminates the need for physical height measurements that cause stoppages, allowing continuous conveyor operation while maintaining or improving verification accuracy through visual recognition.
2Measurement precision
If light beam sensors are used to detect package location, then slot position verification is enabled, but the system prohibits multiple pickers from working on the first conveyor
Solution Approach 1:
The imaging system serves multiple functions simultaneously: it identifies SKUs, verifies package locations in slots, and tracks multiple packages from multiple pickers. The system processes images to extract various pieces of information (SKU, position, quantity) from the same visual data, making the system universally applicable to multiple pickers working in parallel without requiring additional sensors or restricting picker numbers.
3Reliability
If sequential picks of different SKUs are performed, then height-based error detection is facilitated, but picking efficiency is reduced
Solution Approach 1:
The imaging system operates continuously as packages move along the conveyor, capturing images without interrupting the picking flow. Multiple pickers can place packages sequentially or simultaneously, and the imaging system continuously verifies each package's SKU and position. This eliminates the need to pause for verification and allows error detection to occur continuously during normal picking operations, maintaining high productivity while ensuring reliability.
Data Source
AI summary
A pallet loading and validation system provides several features that are particularly beneficial in the context of a conveyor product distribution system, such as a pallet loading system, although some features are not exclusive to a conveyor system. In some aspects, the techniques described herein relate to a method for identifying a SKU of a package using a computer system having at least one processor, the method including: (a) taking at least one image of a package on a conveyor; (b) receiving the at least one image in the computer system; and (c) based upon the at least one image, the computer system determining a SKU associated with the package.