Roller Conveyor Scanning Layout for Accurate Pallet Detection
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Solution Overview
Problem
Existing conveyor systems face challenges in accurately scanning and detecting objects, particularly pallets, due to limited scan areas and reflective surfaces, which can distort results and fail to reliably detect pallet positions, especially when pallets have cracks or gaps.
Innovation Solution
The conveyor arrangement employs scanners oriented parallel to the rollers' axis and angled to the horizontal plane, providing an expanded view to detect pallet surfaces and positions accurately, using LIDAR technology to create a digital point cloud and align it with a simplified digital surface model, and adjusts drive speeds based on scanner feedback to maintain alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If scanners are oriented vertically from below the rollers to detect pallets, then the scanning setup is simple, but the scan area is limited and reflective surfaces cause detection errors
Solution Approach 1:
The patent changes the scanning dimension from vertical (below rollers) to horizontal (parallel to roller axis), allowing scanners to view pallet surfaces through gaps between rollers without direct line-of-sight obstruction. This dimensional shift enables detection of pallet cracks and gaps that vertical scanners miss, while avoiding reflective surface interference.
Solution Approach 2:
The patent positions multiple scanners at different locations along the conveyor, each with fields of view oriented parallel to the roller axis but at different angles to the horizontal plane. This creates localized scanning zones that collectively cover the entire pallet surface, with each scanner optimized for its specific viewing angle and position.
2Ease of manufacture
If scanners are positioned below rollers scanning through gaps, then installation is straightforward, but the field of view is severely limited when rollers are close together
Solution Approach 1:
The patent reorients scanner fields of view to be parallel to the roller axis rather than perpendicular to it. This allows scanners to scan along the length of the rollers, utilizing the gaps between rollers more effectively and dramatically expanding the scan area without requiring scanners to be positioned farther from the rollers.
3Measurement precision
If the conveyor system uses complex wiring for stationary drives, then precise control is achievable, but installation complexity and modification difficulty increase
Solution Approach 1:
The patent replaces complex wired electrical connections with wireless communication technology. The mobile drive unit communicates with the control system via wireless signals, eliminating the need for complex wiring along the entire roller conveyor while maintaining precise control capabilities through digital communication protocols.
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 solution enables precise detection and positioning of heavy objects like pallets and containers, even with varying positions and reflective surfaces, ensuring accurate conveyance without complex wiring, and allows easy installation and modification.
Implementation Method 1
using LIDAR technology to create a digital point cloud
Data Source
AI summary
Conveyor arrangement (1), comprising a conveying section (11) having a plurality of rollers (22) on which a conveyable object (9), in particular a pallet, can be conveyed, a mobile drive (30), wherein the mobile drive is movable along different positions along the conveying section (11) and the mobile drive is adapted to temporarily provide a drive power to a selected roller (22) depending on the position of the mobile drive (30) in particular by immediate contact between the mobile drive and the roller (22); wherein that the mobile drive (30) comprises scanners (40) to detect a presence of an conveyable object (9) located above the rollers (22).