Single-Scanner 3D Parcel Measurement Using Label Reference Scaling
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Solution Overview
Problem
Existing systems for determining the three-dimensional size of items, such as mail packages, are inefficient, often requiring multiple scanners and relying on manual or inaccurate dimension estimation, which is time-consuming and cumbersome.
Innovation Solution
A system using a single optical scanner to determine the three-dimensional size of items based on known dimensions of a standard size element, such as a label, by calculating pixel ratios and conveyor distances to derive item dimensions and height.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If multiple scanners are used to determine three-dimensional size of items, then measurement precision is improved, but device complexity increases
Solution Approach 1:
The patent uses a single optical scanner positioned at an angle to capture two-dimensional images that contain depth information. By utilizing the angular perspective and mathematical projection relationships, the system derives three-dimensional dimensions (length, width, height) from two-dimensional image data, eliminating the need for multiple scanners while maintaining measurement accuracy.
Solution Approach 2:
The patent introduces a known reference object (item with standard label) as an intermediary to establish scale and geometric relationships. The scanner captures images of both the reference object and the target item, allowing the system to calculate dimensional proportions through comparative analysis. This intermediary approach enables accurate three-dimensional measurement using a single scanner.
2Productivity
If manual dimension estimation is used, then device complexity is reduced, but productivity decreases
Solution Approach 1:
The system automatically captures images of items on the conveyor belt and performs dimension calculations without human intervention. The optical scanner continuously scans passing items, the processor automatically analyzes the image data to determine three-dimensional dimensions, and the results are immediately available for sorting or routing decisions. This self-service automation eliminates manual measurement while maintaining high processing speeds.
Solution Approach 2:
The patent replaces manual mechanical measurement methods with optical scanning and digital image processing. Instead of physical contact measurement or visual estimation by operators, the system uses non-contact optical sensors and computational algorithms to automatically determine item dimensions, significantly increasing processing speed and consistency.
3Measurement precision
If multiple scanners are deployed, then measurement precision is improved, but loss of time increases
Solution Approach 1:
The optical scanner is positioned to continuously scan items as they move along the conveyor belt without interruption. The system captures images of multiple items in sequence, processing each image to determine three-dimensional dimensions in real-time. This continuous scanning approach maintains measurement accuracy while minimizing processing time, as items are measured during their natural transit through the system without requiring stopping or repositioning.
Data Source
AI summary
The present disclosure relates to a system and method for automatically determining a three dimensional size of an item. The system may include an optical sensor scanning a surface of the item being transported on a conveyor spaced apart from the optical sensor by a conveyor distance, the surface including a standard size element having a first dimension. The system may also include a memory storing the first dimension and the conveyor distance. The system may also include a processor configured to calculate a second dimension of the surface based on a scanned image of the surface and a scanned image of the standard size element and the stored first dimension. The processor may obtain an item distance between the optical sensor and the surface and determine a height of the item based on the obtained item distance and the stored conveyor distance.