Multi-Plane Laser Stripe Analysis for Object Dimension Measurement
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Solution Overview
Problem
Automated data readers face challenges in accurately measuring and identifying objects, particularly when objects are stacked or positioned closely, leading to errors in optical code reading due to shadowing or blocking, which affects the proper functioning of the system and can result in unscanned items in retail POS environments.
Innovation Solution
An automated optical code reading system that includes a lateral height sensor using a range finder and a light plane generator with a camera, which captures image data of objects passing through a laser plane to determine object dimensions and position, enabling accurate measurement and identification of stacked or closely positioned objects by analyzing the offset of the laser stripe within the camera's field of view.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single light plane generator is used for object measurement, then the device complexity is reduced, but the measurement precision for thin or short objects deteriorates
Solution Approach 1:
The measurement system is segmented into multiple light plane generators, each responsible for measuring specific height ranges. The first light plane generator measures objects in a first height range while the second light plane generator measures objects in a second height range, allowing each component to be optimized for its specific measurement task thereby improving overall measurement precision without requiring one complex device to handle all measurement scenarios
Solution Approach 2:
The patent introduces a vertical dimension to the measurement system by stacking light plane generators at different heights. The first light plane generator is positioned at a first height and the second light plane generator is positioned at a second height, creating a multi-level measurement architecture that improves precision for objects of varying heights by measuring them from different vertical perspectives
2Measurement precision
If multiple light plane generators are used to improve measurement precision, then the measurement precision for thin or short objects is improved, but the device complexity increases
Solution Approach 1:
Multiple light plane generators are designed with universal functionality to measure different types of objects (thin, short, tall, wide) across various height ranges. Each light plane generator can serve multiple measurement purposes, reducing the need for specialized equipment for each object type thereby managing device complexity while maintaining high measurement precision across diverse measurement scenarios
Solution Approach 2:
The patent introduces a controller as an intermediary that coordinates multiple light plane generators and cameras. The controller receives image data from multiple cameras, determines which light plane generator should be active based on object characteristics, and processes measurements from the appropriate sensors, thereby managing the complexity of multiple components through centralized coordination
3Productivity
If objects are stacked or positioned closely to increase productivity, then the productivity of the system is improved, but the reliability of optical code reading deteriorates due to shadowing or blocking
Solution Approach 1:
The patent transitions from a single-plane measurement approach to a multi-dimensional measurement system with light plane generators positioned at different heights. This vertical dimensionality allows the system to measure stacked objects by capturing their profiles from multiple height levels, enabling the system to distinguish between closely positioned or stacked objects thereby maintaining reliability in optical code reading while supporting high-productivity stacked configurations
Solution Approach 2:
The system uses feedback from multiple cameras capturing image data at different heights to detect and correct measurement errors. When objects are stacked or closely positioned, the feedback mechanism allows the controller to analyze measurements from multiple perspectives, identify shadowing or blocking issues, and adjust the measurement approach to ensure accurate optical code reading thereby maintaining reliability while supporting high-density object arrangements
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
The system effectively measures object dimensions and identifies errors, ensuring all items are scanned, thereby preventing unscanned items and improving the accuracy and efficiency of the automated data reading process.
Implementation Method 1
a light plane generator with a camera, which captures image data of objects passing through a laser plane
Implementation Method 2
measuring an object height by measuring a distance of light traveled from a source by known laser radar (ladar) distance measurement techniques
Data Source
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Figure 3A
AI summary
Systems and methods of determining object dimensions of objects passed through a read zone of an automated data reader are disclosed. A system can include a data reader to read an optical code disposed on the objects, a transport mechanism, an object measurement system to measure dimensions of objects that are transported by the transport mechanism, a light plane generator to project a light plane that produces a light stripe on an object, and a camera to capture image data of objects and a light stripe thereon that can be processed to determine a deviation of a light stripe relative to an optical center within the image data. A deviation from the optical center is used to determine one or more dimensions of the object.