Robot Lidar Package Scanning for Dense Warehouse Storage
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Solution Overview
Problem
Existing methods for scanning and measuring packages in warehouses are slow and inefficient, leading to backlogs and suboptimal use of storage space, which increases costs and environmental impact due to inefficient shipping and handling.
Innovation Solution
A robot with a distance measuring device located above the floor surface autonomously scans packages from multiple angles, generating volumetric dimensions without requiring access to all sides, and optimizes storage by determining the best location based on package dimensions and storage duration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a static camera with sensors is used to scan packages in a 3D scanning bay, then package volume measurements can be obtained, but the scanning process becomes slow and cumbersome requiring manual package manipulation
Solution Approach 1:
The patent replaces manual mechanical manipulation of packages with an autonomous mobile robot equipped with a laser distance measuring device. The robot autonomously navigates around packages, automatically capturing distance data at multiple heights and positions, eliminating the need for workers to manually move packages while maintaining measurement accuracy.
Solution Approach 2:
The system transitions from a static camera setup to a dynamic mobile robot that can move freely around packages. The robot's ability to change position and height dynamically allows it to collect comprehensive measurement data from multiple angles without requiring package manipulation, thereby improving both productivity and measurement completeness.
2Productivity
If multiple packages are unloaded and placed on the floor for scanning, then scanning can begin, but access to all sides of packages becomes difficult when packages are adjacent to one another
Solution Approach 1:
The patent elevates the measurement device to a height of at least 0.5 meters above the floor surface. This vertical dimension change allows the robot to scan the top surfaces of packages and adjacent sides without requiring lateral access to all sides of each package, enabling efficient scanning of densely arranged packages while maintaining measurement accuracy.
Solution Approach 2:
The mobile robot acts as an intermediary between the measurement device and the packages. By positioning the robot at elevated height and moving it around packages, it mediates the measurement process, capturing data from multiple angles and heights without requiring direct human intervention or complete accessibility to all package sides.
3Ease of manufacture
If packages are stacked in shipping containers without knowing their volume or shapes, then loading is simplified, but space utilization becomes inefficient leading to revenue loss and increased environmental impact
Solution Approach 1:
The system performs preliminary measurement and analysis of package dimensions and shapes before loading into containers. The mobile robot scans packages early in the process, generating accurate volumetric data that is stored and used for optimization. This preliminary action enables subsequent efficient space planning and container loading strategies, maximizing space utilization while maintaining loading simplicity.
Solution Approach 2:
The system implements a feedback loop where measurement data from the mobile robot is processed to generate optimized stacking arrangements. This feedback information is used to plan container loading sequences and configurations, ensuring that packages are stacked in the most space-efficient manner based on their actual dimensions and shapes, thereby eliminating wasted space and reducing the number of journeys required.
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
This method reduces scanning time, maximizes warehouse capacity, decreases shipping resources, and minimizes environmental impact by improving the efficiency of package handling and storage allocation.
Implementation Method 1
using a distance measuring device to gather data of distance from said robot to the first package at a plurality of heights
Data Source
AI summary
A method for measuring and analysing packages particularly for optimising storage in a warehouse or for packing for transporting. The method follows the steps of placing packages on a floor surface moving a robot to adjacent one of the packages. Lidar or similar is used to measuring distance data from the robot to the package at a multiple heights from at least 0.5 m above the floor surface. The robot then follows a path around all or part of the packages gathering further distance data as it travels. The distance data is then used to determine or infer the shape of the sides of the package and from their estimate volumetric dimensions of the package. The volumetric dimensions are then used to optimise storage of the package with other packages.