Multiline Scanner Sensor Array for Variable Package Imaging
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Solution Overview
Problem
Conventional scanners require a moving mechanical focus mechanism, which is slow and expensive, and have a limited depth of field, making it difficult to capture sharp images of packages of varying sizes on a conveyor belt, leading to inefficiencies and the need for manual processing.
Innovation Solution
A multiline scanner with a sensor array and shared lens system, where multiple rows of sensors are activated as objects pass on a conveyor belt, allowing for simultaneous imaging of objects with different sizes and orientations without the need for mechanical focusing, using CCD or CMOS sensors with off-axis configurations to capture focused images.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a fixed focal length lens is used in conventional scanners, then the device complexity is reduced, but the measurement precision deteriorates due to limited depth of field
Solution Approach 1:
The sensor array is divided into multiple rows, each row dedicated to capturing images of packages at specific depth ranges. This segmentation allows the fixed lens to maintain sharp focus for different package sizes simultaneously by assigning different sensor rows to different focal planes, resolving the contradiction between fixed lens simplicity and image quality.
2Measurement precision
If a moving mechanical focus mechanism is used, then the measurement precision is improved, but the productivity deteriorates due to slow focusing speed
Solution Approach 1:
The mechanical focus mechanism is replaced with an electronic solution using multiple sensor rows that can be electronically activated. Instead of physically moving lens elements to adjust focus, the system electronically switches between sensor rows to capture images at different depths, eliminating mechanical complexity and improving processing speed while maintaining image sharpness.
3Measurement precision
If a moving mechanical focus mechanism is used, then the measurement precision is improved, but the device complexity increases
Solution Approach 1:
The mechanical focus adjustment system is replaced with an electronic sensor array configuration. Multiple sensor rows are positioned at different depths, and electronic control activates the appropriate row based on package size, eliminating the need for mechanical lens movement while achieving the same focus adjustment effect.
4Measurement precision
If pre-sorting is employed to handle different package sizes, then the measurement precision is improved, but the productivity deteriorates due to additional processing steps
Solution Approach 1:
The scanner is designed with universal capability to handle multiple package sizes simultaneously using a fixed lens and multi-row sensor array. Each sensor row is configured to capture images of specific package depth ranges, allowing the single scanner to universally process letters, boxes, and other package types without requiring pre-sorting or separate scanning operations.
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
Enables efficient, automated processing of objects on a conveyor belt by eliminating the need for mechanical focusing, allowing for simultaneous imaging of objects of varying sizes and orientations, improving processing efficiency and reducing manual intervention.
Implementation Method 1
A portion of the light which is reflected from the package is detected by the image sensor and converted into an electrical signal
Data Source
AI summary
Scanners, methods, and computer storage media having computer-executable instructions embodied thereon that process variable sized objects with high package pitch on a moving conveyor belt are provided. The scanners include a substrate and a plurality of sensors attached to the substrate. The plurality of sensors forms an array of sensors having at least two or more rows of off-axis sensors. The sensors may include a one or more area array sensors. The arrays of sensors captures moving objects row by row and are optimized reduce object spacing on the conveyor belt. Additionally, the scanner having the array of sensor may process different objects having different heights at the same time. Accordingly, object throughput on the conveyor belt is increased by reducing minimum object gap (e.g., processing of “no gap” or non-singulated objects).