Light-Guided Parcel Singulation for Orientation Defect Correction
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Solution Overview
Problem
Existing singulation systems struggle with handling parcels of varying shapes, sizes, and orientations at high speeds, leading to inefficiencies and defects such as misorientation, stacking, and gaps, which are challenging for human workers and robotic mechanisms to correct effectively.
Innovation Solution
Implementing a light-assisted singulation quality control system that uses cameras, computer vision, and AI to identify defects, and projectors to indicate corrective actions to human workers or robots, ensuring proper parcel orientation and spacing through color-coded instructions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If mechanical singulation devices are used to separate parcels at high speed, then productivity increases, but manufacturing precision deteriorates due to misorientation, stacking, and gaps
Solution Approach 1:
The system uses cameras to capture images of parcels on the conveyor, processes these images to detect orientation defects, and provides real-time feedback through light indicators to workers about which parcels need correction. This closed-loop feedback mechanism enables high-speed processing while maintaining precision through continuous monitoring and immediate corrective action.
Solution Approach 2:
The patent replaces purely mechanical singulation systems with a hybrid system that incorporates optical detection (cameras), computational processing (AI/ML algorithms), and visual indication (light projectors). This substitution of mechanical systems with optical and informational systems enables more precise control over parcel orientation while maintaining high processing speeds.
2Manufacturing precision
If human workers manually correct parcel defects, then manufacturing precision improves, but productivity decreases due to human fatigue and error
Solution Approach 1:
The system introduces an intermediary information layer between the mechanical singulation system and human workers. Cameras and image processing act as intermediaries that detect defects, while light indicators serve as intermediaries that communicate defect locations and required corrections to workers. This intermediary system reduces the cognitive load on workers and enables them to maintain high precision without sacrificing productivity.
Solution Approach 2:
The system enables workers to quickly self-correct parcel defects by providing them with clear, real-time visual guidance about which parcels need correction and what correction is needed. This self-service approach with guided feedback reduces errors and maintains high processing speeds by empowering workers to make rapid, accurate corrections without extensive training or supervision.
3Manufacturing precision
If complex robotic mechanisms are deployed to correct parcel defects, then manufacturing precision improves, but device complexity increases
Solution Approach 1:
The patent extracts the defect detection and indication functions from complex robotic correction mechanisms and separates them into independent components: cameras for detection, AI/ML processors for analysis, and light indicators for communication. This extraction allows the system to achieve high precision through a simpler, more modular architecture rather than relying on complex robotic manipulation systems.
Solution Approach 2:
The system creates an informational copy of the parcel orientation state through camera imaging and digital processing. Instead of directly manipulating parcels with complex robots, the system creates a digital representation, analyzes it for defects, and provides guidance based on this copy. This copying approach simplifies the physical system while maintaining high precision through computational analysis.
Data Source
AI summary
The present disclosure provides techniques for singulating parcels. In certain aspects, a method for singulating parcels includes obtaining one or more images of a first portion of a conveyor conveying one or more parcels, detecting at least one parcel being conveyed along the conveyor based on the one or more images, determining a defect associated with the at least one parcel, generating a corrective action for addressing the defect associated with the at least one parcel, and causing a visual indication device to provide a visual indication of the corrective action for addressing the defect.