Packaging Plant Layout Capture Using Mobile 3D Imaging
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Solution Overview
Problem
Existing methods for designing packaging plants require extensive manual effort, involving up to 200 manual positions with 3D laser scanners, which is time-consuming and prone to errors due to forgotten measurement points.
Innovation Solution
A method utilizing a measuring vehicle equipped with image capturing devices and sensors to record data and images from multiple positions within the plant area, reducing the number of necessary recording points and enabling the creation of complete three-dimensional design models.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual 3D laser scanning is used to create plant design models, then complete and accurate plant images can be obtained, but the time required increases significantly (up to 200 positions must be taken manually)
Solution Approach 1:
The patent replaces manual mechanical 3D laser scanning with an automated system using drones equipped with cameras and 3D sensors. The drone automatically flies through the plant area capturing images and data, eliminating the need for manual positioning of heavy laser scanning equipment at 200 different locations. This substitution of mechanical manual operations with automated aerial photography and sensing dramatically reduces the time required while maintaining measurement completeness.
Solution Approach 2:
The patent introduces aerial photography from above as a new dimensional approach to plant documentation. Instead of ground-level manual scanning, the drone captures images from the air, providing a bird's-eye view that covers the entire plant area in fewer positions. This dimensional change allows for more efficient data collection by overlooking the plant from multiple aerial angles rather than ground-level points.
2Manufacturing precision
If manual 3D laser scanning and software modeling are used, then detailed plant models can be created, but the process becomes complex and error-prone (problems arise if measurement points are forgotten)
Solution Approach 1:
The patent implements self-service through automated drone navigation and data processing. The drone autonomously flies predetermined routes through the plant area, automatically capturing images and 3D data without human intervention. The system self-manages the measurement process, eliminating human errors such as forgetting measurement points. The automated flight paths and systematic data collection ensure consistent and reliable documentation of the entire plant area.
Solution Approach 2:
The patent incorporates feedback mechanisms through the automated processing of captured images and 3D data. The system processes the collected data to generate design models, and this automated feedback loop ensures that all measurement points are systematically covered and verified. The predetermined flight routes and automated data processing provide built-in checks that prevent measurement omissions and ensure model accuracy.
3Extent of automation
If drones with GPS are used for plant measurement, then automated data collection is possible, but GPS reception may not be available in buildings causing collisions
Solution Approach 1:
The patent uses visual markers placed throughout the plant area as intermediaries to enable automated navigation. Instead of relying on GPS signals that may be blocked by buildings, the system employs visual markers that the drone's camera can detect and use for positioning. These markers serve as intermediaries between the drone's navigation system and the physical environment, providing reliable reference points for automated flight paths even in GPS-denied indoor environments.
Data Source
AI summary
Disclosed is a method for designing a packaging plant, wherein a measuring vehicle is moved within an area in which the production plant is to be erected or modified, and a position of the measuring vehicle relative to the area is detected. The measuring vehicle is positioned at a plurality of positions within this area and at this position records respective images and/or data of the area with a first image capturing device, wherein at least one geometric property of the area and/or the packaging plant is detected.