Onboard Weight Sensor Calibration Using Cargo Bed Imaging
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Solution Overview
Problem
Onboard scales in vehicles, such as pickup trucks, can become inaccurate over time due to mechanical wear, leading to overreporting of cargo weight and customer dissatisfaction. Additionally, manual zeroing of scales is prone to human error, especially on uneven or soft surfaces.
Innovation Solution
The implementation of intelligent onboard scale calibration systems that utilize a cargo camera as a surrogate sensor to diagnose accuracy and adjust for offsets. This system ensures the scale is calibrated by determining when the cargo bed is empty, using image processing techniques like image subtraction and pixel contrast analysis, and adjusting the scale readings accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual zeroing of the scale is performed, then the scale can be calibrated, but human errors occur when cargo items are forgotten or the truck is parked on soft terrain or inclined surfaces
Solution Approach 1:
The patent replaces the manual mechanical zeroing process with an automated optical detection system. A camera captures images of the cargo bed, and image processing algorithms automatically detect whether objects are present, eliminating the need for manual intervention and reducing human error in the calibration process.
Solution Approach 2:
The system performs self-calibration by automatically detecting the presence or absence of objects in the cargo bed through image processing. The scale zeros itself without requiring user action, making the calibration process autonomous and consistent regardless of external conditions.
2Measurement precision
If onboard scales are used to measure cargo weight, then weight measurement capability is provided, but mechanical parts wear over time causing the scale to overreport or underreport true weight
Solution Approach 1:
The system implements a feedback mechanism where the camera continuously monitors the cargo bed, and the processed image data feeds back to the control unit to automatically adjust and zero the scale. This closed-loop feedback system compensates for mechanical wear and drift by continuously verifying the empty bed state and correcting offsets.
Solution Approach 2:
The patent substitutes the purely mechanical scale measurement system with a hybrid system that incorporates optical sensing and image processing. The camera-based object detection provides a non-mechanical reference for verifying the empty bed state, compensating for mechanical wear in the scale components.
3Extent of automation
If intelligent calibration system with cargo camera is implemented, then automation and accuracy are improved, but device complexity increases
Solution Approach 1:
The cargo camera serves multiple functions: it monitors cargo items for safety and security purposes, and simultaneously enables automatic scale calibration by detecting the presence or absence of objects in the cargo bed. This multi-functionality reduces the need for separate dedicated calibration hardware, thereby limiting the increase in overall system complexity.
Data Source
AI summary
Theft deterrent systems and methods using onboard weight sensors are disclosed herein. An example method can include obtaining an image of a location where a scale is located in a vehicle, the scale being used for cargo weight measurement, determining from the image, when the location of the scale is located is empty, determining a weight value output by the scale, determining an offset for the scale when the weight value is greater than a weight threshold, and adjusting the scale using the offset to zero the scale.