Modular Camera Code Reader Using Segmented Image Sensors
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Solution Overview
Problem
Existing camera-based code readers with high-resolution receiver lines are complex, expensive, and inflexible, making them difficult to adapt to varying applications and requiring extensive mechanical adjustments, which limits their usability and increases system weight.
Innovation Solution
A modular camera-based code reader system using multiple simpler image sensors with smaller detection areas, allowing for a scalable and flexible design, where individual image sensors can be adjusted electronically and combined to form a high-resolution image line, reducing the need for mechanical adjustments and optimizing lighting and focusing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If a single high-resolution image sensor with a long receiver line is used to cover the entire conveyor belt width, then the reading field coverage is improved, but the cost and complexity increase significantly
Solution Approach 1:
The patent divides the single long receiver line into multiple shorter receiver lines by using multiple individual image sensors. Each sensor covers a portion of the conveyor belt width, and their combined fields create the complete reading area. This segmentation reduces the complexity of individual sensors while maintaining overall coverage.
Solution Approach 2:
The patent combines multiple individual image sensors and their respective reading fields to form a complete reading field that covers the entire conveyor belt width. The evaluation unit merges the image data from all sensors to create a unified view, achieving full coverage without requiring a single complex high-resolution sensor.
2Area of stationary object
If a single high-resolution image sensor is used, then the reading field coverage is improved, but the manufacturing cost increases
Solution Approach 1:
The patent segments the expensive high-resolution sensor into multiple lower-resolution individual sensors. Each sensor is cheaper to manufacture, and their collective coverage matches that of a single high-resolution sensor, thereby reducing the overall manufacturing cost.
Solution Approach 2:
The patent replaces expensive high-resolution sensors with multiple cheaper individual sensors. While individual sensors have smaller detection areas, their lower cost allows for multiple units to be used, achieving the same overall coverage at reduced total cost.
3Adaptability or versatility
If mechanical adjustments are made to adapt the reading field to different applications, then the adaptability is improved, but the adjustment complexity and time increase
Solution Approach 1:
The patent enables dynamic adaptability by allowing the evaluation unit to electronically select and activate individual image sensors based on application requirements. Instead of mechanical adjustments, the system can dynamically configure which sensors are active and how their data is combined, providing flexibility without physical reconfiguration.
Solution Approach 2:
The patent changes the operational parameters of the image sensor system by allowing the evaluation unit to selectively activate different sensors and adjust their individual settings. This enables adaptation to different applications through parameter changes rather than mechanical adjustments, reducing complexity while maintaining versatility.
4Area of stationary object
If a single centralized camera system is used, then the reading field is unified, but the system weight increases
Solution Approach 1:
The patent segments the single centralized camera system into multiple smaller individual image sensors distributed across the reading field. Each sensor is lightweight, and their distributed arrangement reduces the need for heavy centralized support structures while maintaining unified reading field coverage.
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
The modular design enhances flexibility, reduces costs, improves image quality by minimizing shading, and allows for efficient adjustment and use in various applications, including those with varying object orientations and heights, while simplifying the production and assembly process.
Implementation Method 1
a light receiver (36) with a linear reading field for recording an image line
Implementation Method 2
an optical element (42) on a rocker (40), wherein the image focal length or focal length can be changed by pivoting the rocker (40)
Data Source
Figure 1~2
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AI summary
A camera-based code reader (10) is described, comprising an image sensor with a line-shaped reading field (18) for capturing an image line, an illumination unit (28, 30) for illuminating the reading field (18), an evaluation unit (46) configured to combine successively captured image lines into an image, and a decoding unit (48) for locating and decoding code information in the image. An elongated base body (26) is provided with several individual image sensors (32) mounted on it, each having a line-shaped individual reading field (18a-d), which together form the image sensor by being oriented and arranged relative to each other such that the individual reading fields (18a-d) overlap to form the line-shaped reading field (18), the evaluation unit (46) further being configured to combine image data from the individual image sensors (32) into an image line.