Industrial Line Camera Calibration on Running Transport

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Solution Overview

Problem

Conventional calibration methods for industrial line scan cameras in transportation and logistics applications are time-consuming and require skilled technicians, introducing errors due to manual measurements and complex programming routines.

Innovation Solution

A dynamic calibration system that includes a camera, range finder, and tachometer networked together, allowing for automatic calibration without static calibration, using pre-defined user inputs and refinement routines to generate accurate calibration parameters.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If conventional calibration methods using manual positioning devices and extensive programming routines are used, then calibration can be performed, but the process is time-consuming and requires skilled technicians

Engineering Contradiction:

Improvecamera calibration accuracyVSAvoidcalibration time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

The system performs automatic calibration without requiring skilled technician intervention. The computer executes calibration routines autonomously, capturing images of calibration targets and computing calibration parameters automatically, eliminating the need for manual positioning and extensive programming by technicians.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical positioning devices (levels, angles) are replaced with an automated computer-controlled system that uses image capture and digital processing to achieve precise camera calibration, substituting mechanical adjustment with computational methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Measurement precision

If manual positioning devices and extensive programming routines are used for calibration, then camera calibration can be achieved, but skilled technician participation is required making the process expensive

Engineering Contradiction:

Improvecamera calibration accuracyVSAvoidcalibration complexity

Core Design Contradiction:

Measurement precisionVSEase of manufacture

Solution Approach 1:

The calibration system operates autonomously without requiring skilled technician expertise. The computer automatically executes calibration routines, processes images of calibration targets, and computes calibration parameters, making the complex calibration process accessible to operators without specialized skills.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Complex manual positioning and programming procedures are replaced with automated computer-controlled image capture and digital processing, simplifying the calibration process while maintaining or improving accuracy.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If static calibration routines with manual measurements are performed, then operating region of interest can be established, but manual measurements are time-consuming and introduce errors

Engineering Contradiction:

Improvecalibration accuracyVSAvoidstatic calibration time

Core Design Contradiction:

Measurement precisionVSLoss of time

Solution Approach 1:

Manual measurement procedures during static calibration are replaced with automated image capture and digital processing. The computer automatically measures distances and positions by analyzing images of calibration targets, eliminating manual measurement errors and reducing calibration time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Physical manual measurements are replaced by creating digital copies through image capture. The system captures images of calibration targets and uses digital image processing to extract measurement data, replacing physical measurement tools with optical and computational methods.

Inventive Principle:

Principle #26Copying

4Measurement precision

If individual camera calibration is performed through extensive programming routines, then each camera can be calibrated, but the process must be repeated for each camera making it inefficient

Engineering Contradiction:

Improveindividual camera calibration accuracyVSAvoidcalibration throughput

Core Design Contradiction:

Measurement precisionVSProductivity

Solution Approach 1:

The system merges multiple camera calibrations into a single unified process. By capturing images that contain calibration targets visible to multiple cameras simultaneously and processing them together, the system calibrates multiple cameras in parallel rather than sequentially, significantly improving throughput.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The calibration system is designed to handle multiple cameras with a single calibration routine. The computer executes a universal calibration process that can calibrate any number of cameras using the same methodology, eliminating the need for separate programming routines for each camera.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS12469171B2Dynamically calibrating one or more industrial line cameras simultaneously with a calibration target, packages, and running transport

Publication Date: 2025.11.11 DATALOGIC USA INC

AI summary

A dynamic dimensioning system includes at least one camera, a range finder, and a tachometer. A computer may be used to perform a dynamic calibration operation for the cameras coupled over a communications network. The dynamic calibration operation includes a calibration estimate routine configured to generate default configuration parameters selected by a user from among a plurality of pre-defined user inputs via a graphical user interface, and a calibration refinement routine configured to refine the default configuration parameters to generate a completed set of calibration parameters that are set for the at least one camera. The dynamic calibration operation may be performed without first performing any static calibration operation.