Adaptive Laser Imaging Focus for Variable Container Fill Levels
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Solution Overview
Problem
Traditional imaging systems fail to adapt camera settings to the individual characteristics of objects being imaged, leading to variations in image quality, particularly in conveyance lines where the distance between the imaging system and the object is object-dependent.
Innovation Solution
Incorporating height detection sensors to receive sensor data reflective of object attributes, allowing the imaging system to adaptively calibrate the focus level of the imaging device based on these characteristics, thereby enhancing image quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional imaging systems use fixed camera settings, then the system structure remains simple, but image quality varies due to object distance differences
Solution Approach 1:
The system performs preliminary measurement of object distance using a laser distance sensor before imaging. Based on the measured distance, the system pre-selects the appropriate focus level from multiple calibrated focus levels. This preliminary action ensures that the imaging device is properly configured before capturing the image, thereby maintaining consistent image quality without requiring complex real-time adjustment mechanisms.
Solution Approach 2:
The imaging system transitions from a static fixed-focus design to a dynamic multi-focus capability. The system now includes multiple calibrated focus levels that can be selectively activated based on the measured object distance. This dynamic adaptation allows the system to maintain optimal image quality across varying object distances while keeping the physical structure relatively simple.
2Adaptability or versatility
If the imaging system adapts camera settings to object characteristics, then image quality consistency improves, but the device complexity increases due to additional sensors and control mechanisms
Solution Approach 1:
The laser distance sensor serves multiple functions: it measures object distance for focus level selection and can potentially be used for other measurement tasks in the system. The imaging device itself can operate at multiple focus levels, making it a multi-functional component that adapts to different object distances. This multi-functionality reduces the need for separate dedicated components for each function.
Solution Approach 2:
The laser distance sensor acts as an intermediary between the object and the imaging device. It provides distance information that mediates the selection of appropriate focus levels. This intermediary approach allows the system to adapt to object characteristics without requiring direct complex interaction between the imaging device and object, thereby managing system complexity.
3Manufacturing precision
If multiple calibrated focus levels are implemented, then image quality across varying distances improves, but the calibration process and system complexity increase
Solution Approach 1:
The focus adjustment range is segmented into multiple discrete calibrated focus levels rather than requiring continuous adjustment. Each focus level corresponds to a specific object distance range. This segmentation simplifies the calibration process by breaking it down into manageable discrete steps, making the system easier to manufacture and calibrate compared to a continuous adjustment system.
Solution Approach 2:
The system changes the focus parameter discretely by selecting from multiple pre-calibrated focus levels based on measured object distance. Instead of requiring complex continuous parameter adjustment, the system transitions between discrete focus states. This approach simplifies both the calibration process and the control mechanism while maintaining accurate focus for varying object distances.
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
Improves the consistency of image quality by dynamically adjusting focus levels according to object-specific attributes, ensuring high-quality imaging across varying conditions.
Implementation Method 1
mounted sensing devices, such as height detection sensors, that receive sensor data reflective of the attributes of an object
Implementation Method 2
receive sensor data reflective of the attributes of an object
Implementation Method 3
capture images of objects using camera settings that establish a focus level of an imaging device
Implementation Method 4
adaptively calibrate the focus level of an imaging device to the individual characteristics of an object
Data Source
AI summary
Various embodiments of the present disclosure provide an adaptive imaging process that includes receiving a measured fill level for a container based on a distance reading measurement, selecting a focus level from a plurality of calibrated focus levels based on the measured fill level, providing, to an imaging device, one or more imaging instructions to trigger a validation image at the focus level, receiving, from the imaging device, an imaging response to the one or more imaging instructions that comprises an image classification for the validation image, generating a verification event based on the image classification, and storing the verification event in association with the container.