LIDAR Freight Contour Detection for Container Locking Safety

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Solution Overview

Problem

Existing container handling systems struggle to accurately distinguish between single and multiple containers during loading, leading to potential tilting or crashing due to incorrect locking, especially when visibility is limited, and current sensor systems are ineffective when the spreader is not centrally positioned.

Innovation Solution

A device comprising a LIDAR sensor to detect spatial coordinates of a freight's contour, an evaluation unit to compare with predefined contours, and an output unit to signal the results, allowing for reliable identification of container configurations, including single or multiple containers, and ensuring correct locking and positioning.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If photoelectronic sensors are used to detect container gaps, then container configuration can be identified, but detection fails when the spreader is not centrally positioned

Engineering Contradiction:

Improvecontainer configuration detection accuracyVSAvoiddetection reliability under positional variations

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The patent transitions from 2D photoelectronic sensor detection to 3D LIDAR-based spatial coordinate detection. By capturing measurement points in three-dimensional space and processing them into contour data, the system achieves reliable container configuration identification regardless of spreader positioning, resolving the limitation of central-position-only detection

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

Solution Approach 2:

The system changes the detection parameter from simple gap presence/absence detection to comprehensive spatial coordinate measurement. By measuring multiple points in 3D space and analyzing contour characteristics, the system can accurately distinguish between single and multiple containers even when the spreader is offset from the center position

Inventive Principle:

Principle #35Parameter changes

2Productivity

If the spreader is positioned to grip containers, then loading operation can proceed, but incorrect container configuration leads to tilting or crashing

Engineering Contradiction:

Improveloading operation efficiencyVSAvoidcontainer gripping safety

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The system performs preliminary detection of container configuration using LIDAR before the spreader engages the containers. By identifying whether one or multiple containers are present in advance, the system enables the operator to adjust the spreader positioning and locking strategy accordingly, preventing tilting or crashing during the lifting operation

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system provides real-time feedback about container configuration to the crane operator or control system. This feedback loop allows dynamic adjustment of the spreading and locking operations based on the detected container arrangement, ensuring safe and reliable handling while maintaining operational efficiency

Inventive Principle:

Principle #23Feedback

3Ease of operation

If the operator relies on visibility from the cab, then operation is simple, but container configuration cannot be reliably distinguished

Engineering Contradiction:

Improveoperator control simplicityVSAvoidcontainer configuration information

Core Design Contradiction:

Ease of operationVSLoss of information

Solution Approach 1:

The patent replaces the operator's visual inspection from the cab with an automated LIDAR sensing and evaluation system. The LIDAR device captures spatial coordinates and the evaluation unit automatically determines container configuration, providing objective and reliable information that complements or replaces the operator's visual assessment without adding operational complexity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 operational efficiency and safety by simplifying data acquisition and analysis, enabling accurate container handling and preventing accidents through precise contour detection and adaptive crane operations.

Implementation Method 1

The sensor is configured to detect at least one set of spatial coordinates of measurement points

Methodology Applied

Scientific EffectTime of flight: Time of Flight

Implementation Method 2

A device comprising a LIDAR sensor to detect spatial coordinates of a freight's contour

Methodology Applied

Scientific EffectLIDAR: LIDAR

Data Source

PatentUS20250376357A1Device and method for monitoring freight to be loaded

Publication Date: 2025.12.11 SICK AG

AI summary

A device for monitoring freight to be loaded has at least one sensor that is configured to detect at least one set of spatial coordinates of measurement points, wherein the measurement points lie in a spatial zone that comprises the freight. An evaluation unit is configured to determine at least a part of a contour of the freight from the set of spatial coordinates of the measurement points and to carry out a comparison between the determined contour of the freight and at least one predefined contour. An output unit is configured to output a signal based on a result of the comparison.