Infrared Laser Part Verification for Shipping Containers
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Solution Overview
Problem
Automotive manufacturers face issues with inconsistent and inaccurate shipment of parts and assemblies, leading to production delays and increased costs due to errors in parts supply, as existing barcode technologies cannot ensure the identity and correct packaging of parts.
Innovation Solution
A system that uses infrared and laser sensors to verify the completeness and correct count of parts in shipping containers, generates labels matching the loaded parts, and allows for real-time tracking and quality control through a database and scanning station interface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If barcode technology is used to identify parts, then part identification is enabled, but part identity and packaging accuracy cannot be ensured
Solution Approach 1:
The patent uses imaging technology to create visual copies of parts and their packaging configurations. Instead of relying solely on barcodes that can be misapplied, the system captures images of the actual parts, packaging materials, and container states to verify identity and accuracy, providing a more reliable verification method than barcode alone.
Solution Approach 2:
The patent replaces the mechanical/manual barcode application process with automated imaging and recognition systems. The system uses cameras and image processing algorithms to automatically identify parts, verify their characteristics, and confirm proper packaging, eliminating the need for manual barcode scanning and verification.
2Adaptability or versatility
If manual counting and verification of parts in shipping containers is performed, then flexibility is maintained, but accuracy and consistency are compromised
Solution Approach 1:
The system enables automated self-verification of part counts and packaging accuracy. Imaging devices automatically capture and analyze the contents of shipping containers, counting parts and verifying their proper packaging without requiring manual intervention, thereby maintaining flexibility while significantly improving accuracy and consistency.
Solution Approach 2:
The patent implements automated feedback loops where the imaging system continuously monitors and verifies part packaging, providing real-time confirmation of correct assembly and container loading. This automated feedback mechanism ensures consistent accuracy while allowing the system to adapt to different packaging configurations.
3Reliability
If automated verification systems are implemented, then accuracy and consistency improve, but system complexity increases
Solution Approach 1:
The patent employs multi-functional imaging devices that perform multiple verification tasks simultaneously - identifying parts, counting components, verifying packaging integrity, and confirming container loading. This universal approach consolidates what would otherwise require multiple separate systems, improving reliability while managing complexity through integrated functionality.
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
Ensures accurate and complete shipment of parts and assemblies by verifying each part assembly and container count, reducing manual errors and enabling automatic generation of shipping labels, thus minimizing production disruptions and costs.
Implementation Method 1
A scanning station comprises one or more infrared (IR) vision sensors and/or laser sensors (18)
Implementation Method 2
A scanning station comprises one or more infrared (IR) vision sensors and/or laser sensors (18)
Data Source
AI summary
A system and method is provided for enabling a parts supplier to verify that a customer's part or part assembly requirements are satisfied and for creating a label for a shipping container in which the parts or part assemblies are shipped to the customer. The system also verifies that the label matches the parts and/or part assemblies that have been loaded into the shipping container.