Line Sensor Uniform Resolution via Geometry Detection
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Solution Overview
Problem
Existing image capture systems using line cameras for object sorting on conveyor belts often produce distorted images due to varying object positions and angles, leading to poor code recognition and text recognition, especially when objects are not perpendicular to the camera, resulting in lower resolution and incorrect readings.
Innovation Solution
An apparatus with a geometry detection sensor and line sensor that adjusts the zoom factor and taking frequency to ensure uniform high-resolution images across all lines, preventing distortion by setting the hardware parameters to capture images with optimal information density and resolution directly, without the need for postprocessing correction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a line camera is used to capture images of moving objects, then the system can achieve automated code reading, but the images become distorted when objects are not perpendicular to the camera
Solution Approach 1:
The patent changes the temporal parameter of image capture by using multiple line cameras at different positions along the conveyor direction, capturing images at different times as objects move past. This temporal parameter change allows the system to capture complete object information without requiring objects to be perpendicular to a single camera, thereby resolving the distortion problem while maintaining automated code reading capability
Solution Approach 2:
The patent adds the conveyor direction dimension to the traditional single-line-camera setup. By arranging multiple line cameras along the conveyor direction rather than just perpendicular to it, the system captures object information from multiple spatial positions and combines them temporally, transforming a 2D spatial problem into a 3D spatio-temporal solution that eliminates perspective distortion
2Adaptability or versatility
If multiple line cameras are mounted above and beside the conveyor belt to achieve omnidirectional reading, then code recognition on all object sides is possible, but the total image becomes too distorted to be reliably evaluated
Solution Approach 1:
The patent segments the omnidirectional imaging task into multiple specialized line cameras positioned at different locations along the conveyor. Each camera captures a specific portion of the object at a specific moment, and the system combines these segmented captures into a complete, non-distorted total image through temporal synchronization, thereby maintaining both omnidirectional coverage and evaluation reliability
Solution Approach 2:
The system performs preliminary actions by capturing multiple partial images at different positions along the conveyor before combining them into the final total image. This preliminary segmentation and capture approach allows the system to assemble a complete, undistorted image that maintains reliability for evaluation while achieving omnidirectional reading capability
3Manufacturing precision
If image processing software is used to equalize the image by rescaling every line, then uniform resolution can be achieved, but image quality deteriorates and computer-intensive postprocessing is required
Solution Approach 1:
The patent performs the equalization action preliminarily during the image capture phase rather than as a postprocessing step. By using multiple line cameras positioned at different distances from the object, the system captures lines that are naturally at uniform resolution from the start, eliminating the need for later rescaling operations that would degrade image quality or require intensive computation
Data Source
AI summary
An apparatus (10), in particular a code reader, for the taking of undistorted images of a surface of objects (14) moved on a conveying device (12) is set forth, wherein the apparatus (10) has a geometry detection sensor (18) which is made for the detection of the geometry of the objects (14) with reference to spacing data and/or to the remission behavior of the objects (14) as well as a line sensor (20), in particular a line camera, which can scan the objects (14) linewise for the generation of image data of the surface in a linear reading window (22) which forms an angle with the conveying direction. In this connection, a control (24) is provided which is made to generate, on the basis of geometrical data of the geometry detection sensor (18), a respective spacing profile of the surface over the reading window (22) from the perspective of the line sensor (20) and to generate an associated zoom factor and/or a taking frequency for the line sensor (20) from each spacing profile; to set the line sensor (20) to the associated zoom factor and/or to the taking frequency for the respective line of the objects (14) to be scanned; and to compose the image data thus taken linewise in an undistorted manner to form a uniformly resolved total image of the surface.