Guided Alignment for Range Sensor Dimensioning
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Solution Overview
Problem
Freight carriers face inaccuracies in calculating shipping costs due to manual measurements of package size and weight, leading to potential financial losses and customer dissatisfaction, as automated dimensioning systems require precise alignment of range sensors which can be challenging for users to achieve.
Innovation Solution
A package dimensioning system that includes a range sensor supported by an adjustable mount and a computing device executing adjustment software, which processes range images to provide guidance messages for aligning the sensor with a target pose, ensuring accurate dimensioning by facilitating the selection of a reference plane and positioning of the range sensor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If automated dimensioning systems use range sensors to measure package size, then measurement accuracy is improved, but the difficulty of aligning the range sensor to the correct pose increases
Solution Approach 1:
The system captures range images of the installation environment, processes them to detect the reference plane and calculate the current pose of the range sensor, then provides feedback messages to the user indicating the deviation from the target pose. This closed-loop feedback enables users to iteratively adjust the sensor position until alignment is achieved, resolving the contradiction between measurement precision and ease of operation.
Solution Approach 2:
The system introduces a computing device as an intermediary that processes range images and generates alignment guidance messages. This intermediary translates complex sensor pose calculations into user-friendly instructions, making the alignment process accessible to typical users without requiring expert knowledge of sensor positioning, thus improving ease of operation while maintaining measurement precision.
2Ease of manufacture
If the range sensor is manually positioned during installation, then the system can be set up, but positioning errors lead to dimensioning inaccuracies
Solution Approach 1:
The system performs self-calibration by automatically capturing range images of the installation environment, processing these images to detect the reference plane, and calculating the optimal target pose for the range sensor. This self-service capability eliminates the need for expert manual positioning while ensuring high positioning accuracy, resolving the contradiction between installation simplicity and positioning precision.
Solution Approach 2:
The system performs preliminary actions by capturing range images and calculating the target pose before the user finalizes the sensor installation. By pre-computing the correct positioning based on the detected reference plane, the system guides users to achieve accurate positioning without requiring expert knowledge, thus improving both installation simplicity and positioning accuracy.
Data Source
AI summary
A dimensioning system including a computing device running an alignment software program is disclosed. The alignment software uses range information from a range sensor in order to generate alignment messages. The alignment messages may help a user define a frame of reference and align the dimensioning system's range sensor for improved dimensioning performance.