Dual-Mode Camera System for Package Dimensioning and Collision Detection
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Solution Overview
Problem
Current systems for automatically measuring package dimensions are prone to errors, especially when packages are in motion or have dark surfaces, and require manual intervention, which is time-consuming and risky due to potential interference with moving equipment.
Innovation Solution
A dual-mode data capture system comprising cameras, a motion sensor, and a point cloud generator that switches between collision detection and dimensioning modes to accurately capture synchronous images of packages, generating point cloud data for precise dimensioning while ensuring safety by minimizing equipment interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual measurement is used to obtain package dimensions, then measurement accuracy can be maintained, but time consumption increases and worker safety risks arise due to interference with moving equipment
Solution Approach 1:
The patent replaces manual mechanical measurement with an automated optical measurement system using cameras and image processing. The system captures images of packages on conveyors and automatically calculates dimensions through coordinate mapping, eliminating the need for workers to physically measure moving packages while maintaining high accuracy.
Solution Approach 2:
The patent introduces an intermediary reference object with known dimensions placed on the conveyor alongside packages. This reference object serves as a mediator to establish coordinate transformations between the camera view and real-world dimensions, enabling accurate automated measurement without direct physical contact with moving packages.
2Productivity
If automated measurement systems are used to reduce time consumption, then productivity increases, but measurement accuracy deteriorates when packages are in motion or have dark surfaces
Solution Approach 1:
The patent performs preliminary calibration by capturing images of reference objects with known dimensions before measuring packages. This preliminary action establishes the coordinate transformation matrix and camera parameters, ensuring accurate measurements are ready when packages pass through the measurement zone, maintaining both speed and accuracy.
Solution Approach 2:
The patent changes measurement parameters dynamically by adjusting exposure settings, illumination intensity, and coordinate transformation based on detected package characteristics. When dark surfaces are detected, the system increases illumination intensity; when packages are moving, it adjusts the coordinate mapping parameters to account for motion, maintaining accuracy across varying conditions.
3Measurement precision
If multiple cameras are used to improve measurement accuracy of packages in motion, then dimensional precision increases, but device complexity and potential equipment interference increase
Solution Approach 1:
The patent segments the measurement task by assigning different cameras to capture specific views or aspects of packages. Multiple cameras are positioned at different angles, each capturing images of packages from its perspective. The system then integrates these segmented views through coordinate transformation to reconstruct complete package dimensions, improving accuracy while managing complexity through modular camera placement.
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
The system provides accurate and efficient measurement of package dimensions with reduced risk of interference, enhancing operational safety and efficiency in logistics and transportation settings.
Implementation Method 1
a motion sensor configured to generate a detection signal responsive to detecting an object at a capture position within the capture volume
Implementation Method 2
a plurality of cameras disposed to view a capture volume
Implementation Method 3
a point cloud generator connected to each of the plurality of cameras and configured to receive the synchronous set of images from the cameras and generate a point cloud representing the object based on the synchronous set of images
Data Source
AI summary
A dual-mode data capture system includes a capture controller, a point cloud generator, a collision detector, a plurality of cameras viewing a capture volume, and a motion sensor to generate a detection signal when an object arrives at a capture position within the volume. The controller: activates a subset of cameras in a collision detection mode to capture sequences of images of the volume; responsive to receiving the detection signal, activates the cameras in a dimensioning mode to capture a synchronous set of images of the capture position. The collision detector: determines whether the sequences of images indicate a potential collision; and responsive to detection of a potential collision, generates a warning. The point cloud generator: receives the synchronous set of images and generates a point cloud representing the object based on the synchronous set of images, for use in determining dimensions of the object.