Pallet Barcode Reading via Image Capture
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Solution Overview
Problem
Existing pallet loading and unloading control systems face issues with unreliable barcode reading, lack of proof of loading/unloading, and the need for manual identification, particularly with laser beam bar code readers and portable terminal solutions.
Innovation Solution
A system comprising a terminal with a camera, flash, microcontroller, and diffusion/reflective sensors that automatically identifies pallets by taking photos and processing barcodes, ensuring continuous reading without machine interruption, and providing proof of movement through a database.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a laser beam barcode reader is used, then the reading area can be limited, but the barcode reading reliability is poor (approximately 30% of barcodes are not read)
Solution Approach 1:
The system uses a camera to capture an image of the barcode and creates a digital copy of it. This image is then processed and analyzed to extract the barcode information, replacing the direct optical reading method with an image-based copying approach that improves reliability.
Solution Approach 2:
The patent replaces the mechanical/optical laser beam reading system with an image capture and processing system. Instead of using a laser beam to directly read the barcode, the system captures an image and uses image processing algorithms to extract the barcode information, substituting a more reliable method.
2Ease of operation
If a handheld terminal with barcode scanner is used, then portable identification is possible, but the pallet identification before loading is not guaranteed and requires a pause
Solution Approach 1:
The system enables automatic identification of pallets as they pass through the detection zone. The terminal autonomously captures images, processes barcodes, and records information without requiring manual intervention or pausing the loading/unloading operation, making the system self-sufficient and continuous.
Solution Approach 2:
The patent implements continuous automatic identification during the loading and unloading processes. The system operates continuously without requiring pauses or manual intervention, maintaining the flow of operations while automatically capturing and processing barcode information for each pallet.
3Reliability
If automatic photo capture is implemented, then proof of loading/unloading is provided, but the system complexity increases with multiple sensors and processing units
Solution Approach 1:
The patent combines multiple functions into a single integrated terminal unit. The terminal integrates the camera, flash, barcode processing unit, and database communication capabilities into one device, reducing overall system complexity while maintaining the ability to capture proof of loading and unloading 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
Ensures reliable automatic identification of pallets during loading, unloading, and transit, with continuous reading and photo capture, providing proof of operations and accurate volume measurement without stopping handling machines.
Implementation Method 1
a first pallet detection cell, the first detection cell comprising a first diffusion sensor and a second diffusion sensor indicating a passage in front of the terminal
Implementation Method 2
a second detection cell, the second detection cell having a first reflection sensor and a second reflection sensor, cooperating with a reflector positioned on a pallet handling device indicating the presence of a pallet at the terminal
Implementation Method 3
a camera-type image capture device configured to take a picture when a pallet passes in front of said terminal
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention relates to a pallet loading and unloading control system comprising a terminal (20) positioned near the pallet passage point, each pallet having a barcode. The terminal (20) comprises: - a camera (21), configured to take a picture when a pallet passes in front of said terminal (20), - a flash (22) connected to the camera (21) which is triggered when the picture is taken; - a control unit, comprising a microcontroller controlling the system and said database, a photo processing unit to identify the barcode of the photographed pallet, and a unit for triggering the photo capture based on at least one first pallet detection cell indicating passage in front of the terminal.