Dual Laser Detection for Loop Sorter Article Tracking
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Solution Overview
Problem
Current methods for detecting articles on tilt-tray and cross belt carriers in loop sortation systems are inefficient, often requiring costly maintenance and can miss small or offset items, leading to double inducts, recirculations, and decreased throughput.
Innovation Solution
A dual laser detection system that directs two laser traces laterally across the top surface of a loop sorter from acute angles, combined with a camera imaging system and image processing, to detect the presence and features of articles on the carriers, eliminating the need for reflective tape and photo eyes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If reflective tape and photo eyes are used for article detection, then detection capability is provided, but maintenance cost and labor increase
Solution Approach 1:
The patent replaces the mechanical/optical system of reflective tape and photo eyes with a laser-based detection system. The laser projector emits laser lines that are captured by cameras, eliminating the need for reflective tape while providing more reliable and maintenance-free detection capability.
2Device complexity
If reflective tape is placed centrally on trays, then detection is simplified, but small or offset articles go undetected
Solution Approach 1:
The patent transitions from single-point detection (photo eyes at tray center) to line-based detection (laser traces across the tray surface). By projecting laser lines laterally across the tray and capturing them with cameras positioned above, the system detects articles anywhere on the tray surface, including small or offset items, significantly improving detection accuracy without complicating the system.
3Device complexity
If traditional photo eye detection is used, then system simplicity is maintained, but throughput decreases due to double inducts and recirculations
Solution Approach 1:
The patent replaces the simple but unreliable photo eye system with a laser projection and camera capture system. This substitution enables more accurate article detection, eliminating false negatives that cause double inducts and recirculations, thereby increasing throughput while maintaining reasonable system complexity.
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
This solution increases detection accuracy and reliability, reduces maintenance costs, and allows for diverse product sizes, while minimizing false reads and exceptions, thereby enhancing system throughput and tray utilization.
Implementation Method 1
directing a first laser trace laterally across a top surface of a loop sorter from an acute angle to horizontal above and to a first lateral side
Implementation Method 2
imaging from above a field of view that encompasses at least a portion of the first and second laser traces
Data Source
AI summary
A detection system has a first laser that directs a first laser trace laterally across a surface of a conveyor from an acute angle. A second laser directs a second laser trace laterally across the surface of the conveyor, in spaced apart alignment with the first laser trace, from an acute angle. A camera images from above a field of view that encompasses at least a portion of the first and second laser traces. An image processing system detects a presence or absence of portions of the first and second laser traces, and determines a feature of one of the conveyor and an article inducted onto the conveyor based upon the detecting of the presence or absence.