Overhead Imaging System for Package Identification and Pallet Placement
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Solution Overview
Problem
The challenge in online retail logistics is the accuracy and efficiency of moving products from conveyor systems to pallets, where human factors lead to errors due to physical demands and time constraints, necessitating improved identification and placement methods.
Innovation Solution
An overhead imaging system using 2D and potentially 3D cameras to read machine-readable indicia on packages, providing real-time feedback through visual, audible, and tactile signals to ensure correct pallet placement, reducing the need for manual barcode scanning and minimizing errors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual barcode scanning is used by workers, then the system is simple and easy to operate, but accuracy decreases due to human factors and physical demands
Solution Approach 1:
The patent replaces manual mechanical barcode scanning with an automated overhead imaging system using cameras and image processing algorithms. The system captures images of packages on the conveyor belt and automatically identifies them through computer vision, eliminating the need for workers to manually scan barcodes and reducing human error in package identification and placement.
Solution Approach 2:
The imaging system enables packages to be automatically identified and tracked without requiring active participation from workers. The system self-monitors package movement, reads identifiers, and provides feedback, allowing the logistics process to operate with minimal human intervention while maintaining high accuracy.
2Productivity
If workers manually carry packages from conveyor to pallets, then flexibility is maintained, but errors increase due to time constraints and physical demands
Solution Approach 1:
The overhead imaging system provides real-time feedback to workers by displaying package identifiers and placement status on screens or mobile devices. This immediate feedback allows workers to verify correct package-pallet matching while maintaining manual handling flexibility, thereby increasing both speed and accuracy of package placement.
Solution Approach 2:
The system performs preliminary identification and verification of packages before they reach the worker. By pre-processing image recognition and determining correct pallet destinations in advance, the system prepares information that guides workers' actions, reducing decision-making time and minimizing errors during the actual placement process.
3Ease of operation
If handheld barcode scanners are used, then equipment simplicity is maintained, but operational efficiency decreases due to alignment requirements
Solution Approach 1:
The patent transitions from handheld scanning in three-dimensional space (requiring alignment) to overhead imaging in a top-down two-dimensional view. The cameras capture images from above, automatically framing the entire conveyor belt area, which eliminates the alignment problem inherent in handheld scanning and allows simultaneous processing of multiple packages.
Solution Approach 2:
The overhead imaging system serves multiple functions simultaneously: it identifies packages, tracks their movement, determines correct destinations, and provides feedback to workers. This multi-functional system replaces the single-function handheld scanner, significantly improving operational efficiency while maintaining ease of use through automated processes.
Data Source
AI summary
A system and method for managing packages may include determining an identifier on a package. A determination as to whether the package is to be positioned on a pallet based on the identifier may be made. In response to determining that the package is not to be positioned on the pallet, a first feedback signal (e.g., red light) indicative to the operator that the package is not to be placed on the pallet may be generated. In response to determining that the package is to be positioned on the pallet, a second feedback signal (e.g., green light) that is indicative to the operator that the package is to be on the pallet may be generated or no signal may be generated. Additionally, if an identifier cannot be read from the package, then a third feedback signal (e.g., yellow light) may be generated and illuminated on the package or elsewhere.