Synchronized Ranged Imaging for Measuring Moving Vehicle Dimensions
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Solution Overview
Problem
Current measurement systems using industrial robots with short-range laser triangulation sensors for tracking vehicle features on an assembly line are inefficient due to the need for physical translation and rotation of sensors, limited measurement points per cycle, potential damage from robot failures, and fragility to varying paint colors and vehicle position variations.
Innovation Solution
A system and method employing a position encoding unit, a controller, and a ranged imaging unit fixed to a stage that moves synchronously with a device, allowing non-contact measurement of dimensional characteristics by scanning with a ranged imaging unit between predefined zones, and adjusting speed to match the device's motion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If industrial robots physically translate and rotate short-range laser sensors to measure vehicle features, then measurement capability is achieved, but measurement speed decreases and time is wasted on mechanical movement
Solution Approach 1:
The patent replaces the mechanical robot system with an optical/ranged imaging system that can measure vehicle features without physical contact or mechanical movement. The ranged imaging unit captures dimensional data of multiple features simultaneously in a single field of view, eliminating the need for mechanical translation and rotation of sensors.
Solution Approach 2:
The patent transitions from point-by-point measurement in one dimension to simultaneous multi-point measurement across two or three dimensions. The ranged imaging unit captures the entire vehicle or large portions of it in a single snapshot, measuring multiple features across the vehicle's surface simultaneously rather than sequentially.
2Measurement precision
If robots reach into the path of moving vehicles for close-proximity measurements, then measurement accuracy is improved, but system fragility increases due to robot faults causing impacts
Solution Approach 1:
The patent replaces the mechanical robot system that physically reaches into the vehicle path with a stationary ranged imaging system positioned at a safe distance. The imaging unit remains fixed in a predetermined location and uses optical/ranged measurement techniques to capture vehicle features without mechanical contact or proximity to the moving vehicle.
Solution Approach 2:
The patent introduces a stationary platform and predetermined position as an intermediary between the measurement system and the moving vehicle. The ranged imaging unit is mounted on a fixed structure at a location that allows measurement without being in the vehicle's path, eliminating the risk of impact while maintaining measurement capability.
3Productivity
If robots are programmed to operate at the extents of their reach and joint limits to measure more points, then the number of measurable points increases, but system fragility to position and timing errors increases
Solution Approach 1:
The patent enables measurement of a much larger number of points simultaneously by capturing the entire vehicle or large portions of it in a single field of view. The ranged imaging unit measures multiple features across the vehicle's surface in parallel rather than sequentially, dramatically increasing the number of measurable points without requiring the system to operate at mechanical limits.
Solution Approach 2:
The patent creates a comprehensive digital copy or map of the vehicle's features through single-shot or multi-shot ranged imaging. By capturing the entire vehicle geometry in one or a few snapshots, the system obtains a complete set of measurement data without needing to physically traverse or reach extreme positions to access different measurement points.
4Productivity
If more robots are added to increase the number of measurement points per cycle, then measurement coverage improves, but system complexity and operational difficulty increase
Solution Approach 1:
The patent segments the measurement task by dividing the vehicle into multiple fields of view or measurement zones that can be captured in sequence or simultaneously. The ranged imaging unit may take multiple shots from different angles or positions, but these are coordinated by a single controller rather than requiring multiple independent robot systems.
Solution Approach 2:
The patent creates a universal measurement system where a single ranged imaging unit can measure all vehicle features by capturing the entire vehicle or large portions of it. The system is designed to be multi-functional, handling various measurement tasks with one imaging unit rather than requiring specialized robots for different measurement zones.
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 approach enhances measurement accuracy and speed, reduces the risk of system failure and damage, and improves robustness against paint color variations and position errors, enabling efficient tracking of moving vehicles without mechanical proximity.
Implementation Method 1
ranged imaging unit with a laser and an array of photosensors
Implementation Method 2
The respective receiver may be configured to sense a respective beam state of the respective beam and transmit the respective beam state to the controller
Data Source
AI summary
System and method for tracking at least one device in real-time. A position encoding unit is configured to detect a position of the device, which is configured to move in a first direction. A stage is configured to selectively move with a forward axis of travel and a reverse axis of travel substantially parallel to the first direction and having a stage speed controllable by a controller. A ranged imaging unit is fixedly mounted to the stage and may selectively scan the device upon command. The controller is configured to obtain a speed of the device. When the device reaches a pre-programmed position, the stage is selectively moved at the stage speed synchronized to the speed of the device to within a predefined match value. The ranged imaging unit is employed to determine dimensional characteristics of the device.