LiDAR Cargo Contour Detection for Container Configuration Checks
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Solution Overview
Problem
Existing container handling systems, such as STS and RTG cranes, struggle to reliably distinguish between single 40-foot containers and two 20-foot containers due to limited visibility, leading to potential jamming or falling containers and safety hazards during lifting, especially when sensors can only detect gaps in a specific position and lose accuracy with slight shifts.
Innovation Solution
A device and method using LiDAR sensors to detect spatial coordinates of cargo contours, comparing them with predefined contours to determine the number and configuration of containers, providing real-time feedback to operators or control systems to adjust the spreader securely.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If photoelectric sensors are used to detect container gaps, then container configuration can be detected, but detection reliability deteriorates when the spreader shifts position even slightly
Solution Approach 1:
The patent transitions from 2D photoelectric sensor detection to 3D LiDAR scanning. The LiDAR sensor captures spatial coordinates of multiple points on the container surface, creating a three-dimensional point cloud that enables accurate contour detection regardless of the spreader's horizontal position. This dimensional upgrade allows the system to detect container configurations reliably even when the spreader shifts by several centimeters.
Solution Approach 2:
The system performs preliminary contour detection and analysis before the lifting operation begins. By capturing the container contour in advance and comparing it with stored reference contours for different container configurations, the system determines the correct number and arrangement of containers beforehand, ensuring safe operation from the start.
2Loss of information
If the spreader is positioned to detect container gaps, then container configuration can be identified, but operational flexibility deteriorates as the spreader must be precisely positioned
Solution Approach 1:
The LiDAR sensor's ability to capture three-dimensional spatial information allows contour detection without requiring precise horizontal positioning. The sensor can detect the container contour from various positions and angles, providing operators with flexibility in spreader positioning while still accurately identifying container configurations.
Solution Approach 2:
The LiDAR-based detection system serves multiple functions: it can detect container configurations, measure distances, and identify container positions regardless of the spreader's horizontal location. This multi-functionality eliminates the need for precise positioning requirements while maintaining comprehensive container information detection.
3Device complexity
If crane operators rely on visual inspection, then no additional equipment is needed, but safety deteriorates due to inability to reliably distinguish container types
Solution Approach 1:
The patent replaces the mechanical/visual inspection method with an optical LiDAR-based automated detection system. The LiDAR sensor automatically captures container contours and the evaluation unit automatically compares them with reference data, eliminating the need for manual visual inspection and providing reliable container type identification.
Solution Approach 2:
The system performs self-detection and self-evaluation of container configurations. The LiDAR sensor automatically scans the container, the evaluation unit automatically processes the spatial coordinates and compares contours, and the system automatically determines the container configuration without requiring operator intervention or interpretation.
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
Enhances safety and operational efficiency by accurately distinguishing container types and configurations, preventing accidents and optimizing loading processes through precise contour detection and adjustment.
Implementation Method 1
at least one sensor (24) is provided, in particular a LiDAR sensor, for detecting at least one set of spatial coordinates of measuring points (28)
Data Source
Figure 1
Figure 2
Figure 3a~3d
AI summary
A device for monitoring cargo (12) to be loaded comprises at least one sensor (24) configured to detect at least one set of spatial coordinates of measuring points (28) (42), wherein the measuring points (28) are located in a spatial region encompassing the cargo (12). An evaluation unit (32) is configured to determine at least a part of a contour of the cargo (12) from the set of spatial coordinates of the measuring points (28) (44) and to perform a comparison (46) between the determined contour of the cargo (12) and at least one predetermined contour. An output unit (34) is configured to output a signal based on the result of the comparison.