Handheld Optical Dimensioning Device for Planar Surfaces

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Solution Overview

Problem

Existing methods for dimensioning planar surfaces, such as packages and room walls, are costly and time-consuming due to the use of overhead laser scanners and associated processing equipment.

Innovation Solution

A mobile, handheld device with a light pattern assembly, rangefinder, and imaging assembly that projects light spots and a range light spot onto the surface, captures images with a CCD or CMOS imager, and uses a controller to determine angular and scale relationships to calculate dimensions accurately and efficiently.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If overhead laser scanners with rangefinders are used to dimension freight, then measurement precision is improved, but device complexity and cost increase

Engineering Contradiction:
Improvedimensional accuracyVSAvoidscanner and processing equipment complexity
Core Design Contradiction:
Measurement precisionVSDevice complexity

Solution Approach 1:

The patent divides the dimensioning task into multiple independent measurements. Instead of using a complex overhead scanner that captures everything at once, the system uses multiple simple rangefinders positioned at different locations to measure specific points on the target surface independently. Each rangefinder measures the distance to a specific point, and these individual measurements are then combined to determine overall dimensions.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The patent introduces a coordinate transformation matrix as an intermediary element. This matrix serves as a mediator that converts the simple distance measurements from multiple rangefinders into accurate dimensional information about the target surface. The matrix handles the complex geometric relationships and coordinate transformations, allowing simple measurement devices to achieve precise dimensioning results.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Measurement precision

If overhead laser scanners with rangefinders are used to dimension freight, then measurement precision is improved, but processing time increases

Engineering Contradiction:
Improvedimensional accuracyVSAvoidscanning time
Core Design Contradiction:
Measurement precisionVSLoss of time

Solution Approach 1:

The patent performs preliminary positioning of rangefinders at known locations before actual measurement. By pre-establishing the positions and orientations of multiple rangefinders, the system eliminates the need for time-consuming real-time calibration and alignment during the dimensioning process. The pre-configured system can immediately begin taking measurements once activated.

Inventive Principle:
Principle #10Preliminary action

Solution Approach 2:

The system uses the target surface itself as a reference for measurement. By projecting light patterns or using the target's own geometric features as reference points, the system eliminates the need for external reference objects or complex calibration procedures. The target surface serves its dual purpose as both the object being measured and the reference framework for the measurements.

Inventive Principle:
Principle #25Self-service

3Measurement precision

If traditional dimensioning methods are used for room walls, then measurement precision is improved, but ease of operation deteriorates

Engineering Contradiction:
Improvedimensional accuracyVSAvoidoperational simplicity
Core Design Contradiction:
Measurement precisionVSEase of operation

Solution Approach 1:

The patent creates a virtual copy or digital model of the target surface through multiple distance measurements. Instead of requiring the operator to physically measure and calculate dimensions manually, the system captures the geometric information and creates a digital representation that can be processed automatically. This digital copy preserves all dimensional information while eliminating the complexity of manual measurement procedures.

Inventive Principle:
Principle #26Copying

Solution Approach 2:

The patent replaces manual mechanical measurement procedures with optical and electronic systems. Instead of requiring physical tape measures, rulers, or manual calculations, the system uses rangefinders, light sources, and computational algorithms to automatically determine dimensions. This substitution eliminates the physical labor and complexity of traditional measurement methods while maintaining or improving precision.

Inventive Principle:
Principle #28Mechanics substitution (Replace mechanical system)

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 cost-effective, rapid, and accurate dimensioning of planar surfaces, allowing for efficient handling and material estimation, such as paint or wallpaper needs, without the high costs and lengthy processing times of traditional methods.

Implementation Method 1

the light pattern assembly includes a laser source for emitting a main laser beam along a laser axis

Methodology Applied
Scientific EffectLaser: Laser

Implementation Method 2

a beam splitter, such as a diffractive optical element (DOE) or a refractive optical element (ROE), for splitting the main laser beam into a plurality of split laser beams

Methodology Applied
Scientific EffectDiffraction: Diffraction

Implementation Method 3

the rangefinder assembly includes a ranging laser for emitting a ranging laser beam along a ranging axis to form the range spot on the target surface

Methodology Applied
Scientific EffectLaser: Laser

Implementation Method 4

an imaging assembly for capturing an image of the target surface, the light pattern, and the range spot

Methodology Applied
Scientific EffectReflection: Reflection

Data Source

PatentUS10317194B2Arrangement for, and method of, remotely dimensioning generally planar, target surfaces of objects
Publication Date: 2019.06.11 SYMBOL TECHNOLOGIES LLC
  • US10317194B2 patent drawing
  • US10317194B2 patent drawing
  • US10317194B2 patent drawing

AI summary

Spaced-apart light spots are projected in a light pattern on a target surface lying in a target plane. A range spot is projected at a position on the target surface to find a target distance to the target surface. An image of the target surface, light pattern, and range spot is captured along an imaging axis that is perpendicular to an imager plane of an imager. A controller determines an angular relationship between the imager and target planes based on the light pattern in the captured image, determines a scale relationship between the target surface and the imager based on the position of the range spot in the captured image, displays a compensated image of the target surface that is corrected in tilt by the angular relationship and in scale by the scale relationship, and determines dimensions of the target surface based on dimensions of the displayed compensated image.