3D Laser Scanner Volume Measurement for Unknown Containers
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Solution Overview
Problem
Current systems lack a cost-effective and accurate method for monitoring the volume of liquid in containers of unknown dimensions, leading to inefficiencies and potential errors in additive dosing.
Innovation Solution
A system comprising a sensor and a processor that determines the surface area of matter in a container and calculates the change in volume based on this surface area and measured distances, allowing for automatic dosing of additives without requiring container dimension input.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional volume monitoring devices are used for containers of unknown dimensions, then volume measurement can be achieved, but the system requires costly calibration processes and strapping tables
Solution Approach 1:
The system performs self-calibration by automatically scanning the container interior with a 3D laser scanner to generate point cloud data, which is then processed to create a digital twin model of the container. This eliminates the need for manual strapping tables or filling tables, as the system autonomously characterizes the container geometry and uses it for volume calculations.
Solution Approach 2:
The patent replaces traditional mechanical calibration methods (physical strapping tables, manual measurements) with optical scanning technology. The 3D laser scanner captures the container geometry optically, and digital processing algorithms compute volume measurements, substituting mechanical calibration procedures with automated optical-digital systems.
2Productivity
If flow meters are used to determine liquid volume, then volume can be calculated, but the accuracy drifts over time as the system falls out of calibration
Solution Approach 1:
The system performs preliminary characterization of the container geometry using 3D laser scanning to create a digital twin model before dosing operations begin. This pre-established geometric model serves as a reliable reference for volume calculations throughout operation, eliminating the need for continuous flow meter calibration and preventing accuracy drift.
Solution Approach 2:
The system incorporates continuous feedback through the sensor that monitors liquid level and provides real-time data to the processor. This feedback loop allows the system to continuously update volume calculations based on the pre-established digital twin model, maintaining measurement accuracy without relying on flow meters that drift over time.
3Measurement precision
If a 3D laser scanner is used to scan the shape of an empty container, then accurate volume readings can be obtained, but the process is costly and disruptive to production
Solution Approach 1:
The system performs the container scanning and digital twin creation as a preliminary setup operation before production begins. Once the digital model is established, the system can continuously monitor volume without requiring the container to be emptied or production to stop, as the pre-established model enables ongoing measurements during normal operation.
Solution Approach 2:
The patent creates a digital copy (digital twin) of the physical container's geometry through 3D laser scanning. This digital replica can be stored and reused for multiple dosing operations without requiring repeated physical scanning, eliminating the need to empty the container or disrupt production for each measurement while maintaining accurate volume readings.
4Adaptability or versatility
If manual calculation of additive dosage is performed, then flexibility is maintained, but human error increases and dosing accuracy decreases
Solution Approach 1:
The system automatically calculates the required additive dosage based on real-time volume measurements from the sensor and the pre-established digital twin model. The processor autonomously determines the correct amount of additive to add, eliminating manual calculations and reducing human error while maintaining flexibility through programmable dosing parameters.
Solution Approach 2:
The system uses feedback from the sensor's continuous monitoring of liquid volume to automatically adjust and control additive dosing. The processor receives real-time volume data, calculates the required additive amount based on predetermined ratios, and controls the additive injection, creating a closed-loop system that maintains dosing accuracy without manual intervention.
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 and automatic volume measurement and additive dosing for containers of any shape, reducing human error and operational costs, while allowing for seamless movement between different containers.
Implementation Method 1
The sensor may be a laser sensor or other type of electromagnetic radiation sensor. The sensor will usually be focused at a point on the surface of the matter in the container which is vertically below the sensor.
Data Source
Figure 1
Figure 2A~2B
Figure 2C~2D
AI summary
The present disclosure is directed towards a system and method for determining a change of volume within a container based on the surface area of material in the container.