Dual-Technology Dimensioning System for Irregular Packages
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Solution Overview
Problem
There is a need for a quick and accurate method to determine the dimensions and spatial volume of packages of varying sizes and irregular shapes in commercial and industrial settings, as existing methods are inadequate for measuring both small and large, irregularly configured packages simultaneously.
Innovation Solution
A dimensioning system employing two different technologies, including orthogonally oriented distance sensors and a gate with cooperative beam emitters and receivers, which measure dimensions by detecting beam interference and calculating dimensions from multiple positions, allowing for the measurement of small and large objects with high and low resolution respectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single dimensioning device is used, then device complexity is reduced, but measurement precision and accuracy deteriorate for packages of varying sizes and irregular shapes
Solution Approach 1:
The patent combines two different dimensioning technologies (laser triangulation and optical beam interruption) into a single integrated dimensioning system. The first dimensioning device uses laser triangulation with orthogonal sensors, while the second uses cooperative beam emitters and receivers. By merging these complementary technologies, the system achieves high measurement precision for both small and large irregular packages without requiring multiple separate devices.
Solution Approach 2:
The dimensioning system is designed with universal capability to measure packages of all sizes and shapes using a single apparatus. The first dimensioning device with orthogonal laser sensors handles small to medium packages, while the second dimensioning device with movable gate and cooperative beams handles large and irregularly shaped packages. This multi-functional design eliminates the need for different devices for different package types.
2Measurement precision
If high resolution measurement is used for all packages, then measurement precision is improved, but productivity decreases due to extended measurement time
Solution Approach 1:
The patent applies different measurement resolutions and technologies locally based on package characteristics. The first dimensioning device provides high-resolution measurements for small packages using laser triangulation, while the second dimensioning device provides appropriate resolution for large packages using cooperative beam interruption. This local quality approach ensures high precision where needed while maintaining efficient throughput for larger items.
Solution Approach 2:
The second dimensioning device incorporates dynamic elements including a movable gate that can be positioned along the conveyor belt and cooperative beam emitters and receivers that adjust to package size and shape. This dynamic adaptability allows the system to optimize measurement resolution and speed based on real-time package characteristics, balancing precision and productivity.
3Reliability
If multiple dimensioning devices are used, then measurement accuracy and redundancy are improved, but device complexity increases
Solution Approach 1:
The patent merges two different dimensioning technologies into a single integrated system with shared components such as the conveyor belt, control unit, and processing system. The first dimensioning device (laser triangulation) and second dimensioning device (cooperative beams) are combined in one apparatus, reducing overall system complexity while providing redundant measurements for improved accuracy and reliability.
Solution Approach 2:
The control unit serves as an intermediary that coordinates between the two dimensioning devices, processes data from both systems, and resolves measurements to determine final package dimensions. This centralized mediation simplifies the system architecture by providing a single point of integration rather than requiring separate independent systems.
4Ease of operation
If traditional single technology dimensioning is used, then ease of operation is maintained, but adaptability to various package types deteriorates
Solution Approach 1:
The dimensioning system is designed with universal capability to automatically adapt to various package types including small boxes, large packages, and irregularly shaped items. The dual-technology approach with orthogonal laser sensors and cooperative beam emitters provides versatility across all package categories while maintaining ease of operation through automated detection and measurement processes.
Solution Approach 2:
The system incorporates automatic package detection and classification capabilities where the control unit receives signals from both dimensioning devices, determines the appropriate measurement technology to use, and processes measurements without operator intervention. This self-service functionality maintains ease of operation while providing adaptability to diverse package types.
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 accurate measurement of dimensions and spatial volume of various package sizes, including irregularly shaped objects, improving efficiency in shipping, storage, and packing processes by providing redundant measurements for increased accuracy.
Implementation Method 1
detecting interference of emitted beams by the object for a plurality of positions of the first array and second array
Data Source
AI summary
A method and apparatus for dimensioning and, optionally, weighing an object. A platform with a surface is used for supporting an object. A user selects between two different dimensioning devices of the apparatus. The first device employs three distance sensors to determine a distance between each of the distance sensors and a side of an object. The second device includes a movable gate that is passed over and about an object or objects on the platform. Sensor arrays, such as paired, aligned light emitter and receiver arrays, are used in combination with a plurality of sensed gate positions to determine the dimensions of the objects(s) as the gate passes around the object(s) based on whether or not light from an emitter on one side of the gate reaches a light receiver on another, opposing side of the gate.