Single Camera Irregular Object Dimensioning via Shadow Analysis
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Solution Overview
Problem
Current methods for determining the dimensions and volume of irregularly shaped objects for shipping are inaccurate, time-consuming, and fail to account for the object's size effectively, leading to inefficient space utilization and charging practices in transportation.
Innovation Solution
An optical system using a dimensioning station with collimated light sources and cameras to measure the shadows cast on walls, allowing for accurate determination of an object's dimensions and volume, even for complex shapes, by analyzing the size attributes of shadows formed by the light sources.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional tape measures or physical measuring devices are used to obtain object dimensions, then the measurement process is simple and low-cost, but the measurement accuracy is insufficient for complex-shaped objects and the process is time-consuming
Solution Approach 1:
The patent replaces manual mechanical measurement tools (tape measures, templates) with an automated optical measurement system. The system uses a camera to capture images of objects positioned on a turntable, processes these images computationally to extract dimensional data, and eliminates the need for manual measurement operations. This substitution achieves both high measurement precision for complex shapes and rapid automated processing.
Solution Approach 2:
The patent creates a digital copy of the object through image capture and processing. Instead of physically measuring the object with tools, the system captures visual information via camera, processes the images to generate dimensional data, and uses this digital representation for measurement purposes. This copying approach enables accurate measurement of complex geometries without physical contact or manual intervention.
2Measurement precision
If rough approximation methods like template enclosures are used to determine object size, then the measurement process is fast and simple, but the measurement precision is insufficient for accurate shipping cost calculation
Solution Approach 1:
The patent replaces manual approximation methods (template enclosures, visual estimation) with an automated optical measurement system. The camera captures precise images of objects, and computational algorithms automatically extract accurate dimensional data including length, width, height, and volume. This eliminates the need for manual template placement and visual approximation while maintaining high measurement efficiency through automation.
Solution Approach 2:
The system creates accurate digital representations of objects through image capture and processing. Instead of using physical templates for approximation, the camera captures the actual object geometry, and software processes these images to generate precise dimensional measurements. This digital copying approach provides both accuracy for cost calculation and efficiency through automated processing.
3Measurement precision
If multiple cameras are used to capture complete object dimensions from all angles, then the measurement completeness is improved, but the system complexity and cost increase significantly
Solution Approach 1:
The patent uses a dynamic measurement approach where a single camera is combined with a rotating turntable. The turntable rotates the object through multiple angles, allowing the stationary camera to capture complete three-dimensional information by processing images taken at different orientations. This dynamic system achieves the same measurement completeness as multiple fixed cameras but with significantly reduced system complexity and cost.
Solution Approach 2:
The patent adds temporal and rotational dimensions to a single-camera system. Instead of using multiple cameras simultaneously, the system captures images over time as the object rotates on the turntable. This transforms a single spatial viewpoint into multiple viewing angles through rotational movement, achieving complete dimensional measurement with a single camera position.
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
Enables fast and accurate measurement of objects, allowing carriers to efficiently fill containers and charge consumers based on the true space required, maintaining profitability amidst rising energy and labor costs.
Implementation Method 1
A first collimated light passes from the first collimated light source generally parallel to the base, illuminating the first wall, and defining a shadow
Data Source
AI summary
An optical system for measuring an irregularly shaped object includes a dimensioning station having a base, a first wall extending from the base, and a second wall extending from the base. A collimated light is passed from each of first and second collimated light sources arranged generally parallel to the base, illuminating the first and second walls and defining first and second shadows, respectively. A camera is arranged to obtain image data representing each of the first and second shadows. The system is configured to collect the image data for determining at least one dimension of an object from each of the first and second shadows. Each of the first and second collimated light sources may be a light with a collimating lens arranged between the light and the respective wall. The light source may be an LED and the collimating lens may be a collimating Fresnel lens.