Load Handling Device Using ToF Cameras for Container Positioning
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Solution Overview
Problem
Current container handling systems face challenges in accurately gripping and stacking containers due to limitations in existing camera-based systems, particularly in varying weather conditions and dark gaps between containers, which require high precision and accuracy from operators, and are not suitable for automated operations.
Innovation Solution
The implementation of a method and apparatus using Time-of-Flight (ToF) cameras or other 3D cameras to create distance maps, enabling accurate monitoring and control of container positions and alignments by determining distance values and image points, allowing for improved handling and stacking accuracy both manually and automatically.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional camera-based systems are used for container handling, then the system structure is simple, but the measurement precision and reliability deteriorate in varying weather conditions and dark gaps between containers
Solution Approach 1:
The patent replaces conventional optical camera-based detection systems with a laser-based distance measurement system. The laser distance measuring device emits laser beams to actively measure distances to container corner castings, providing precise positional data independent of ambient lighting and weather conditions. This substitution of measurement mechanism resolves the contradiction by maintaining high measurement precision and reliability in environments where conventional cameras fail.
Solution Approach 2:
The invention changes the measurement parameter from passive optical image capture to active laser time-of-flight or phase-shift distance measurement. By measuring the time for laser light to travel to and from the target or the phase difference between emitted and received laser waves, the system obtains accurate distance measurements that are not affected by darkness or adverse weather, thereby improving both measurement precision and reliability.
2Manufacturing precision
If high precision container alignment is required for stacking, then the stacking accuracy improves, but the operational complexity and time consumption increase
Solution Approach 1:
The system enables automatic alignment by having the load handling device equip itself with laser distance measuring capabilities. The device autonomously measures distances to multiple corner castings of the lower container, calculates the required alignment adjustments, and executes the positioning without requiring manual measurement or complex operator intervention, thereby achieving high stacking accuracy efficiently.
Solution Approach 2:
The invention implements a feedback control system where laser distance measurements to container corner castings provide real-time positional information. The control system processes these measurements to determine alignment deviations and automatically adjusts the spreader and container position to achieve precise stacking alignment, reducing both time and operational complexity.
3Measurement precision
If manual operation with high operator accuracy is required, then the handling precision improves, but the productivity and automation level remain limited
Solution Approach 1:
The patent replaces manual visual estimation and manual alignment operations with an automated laser-based measurement and control system. The laser distance measuring device objectively and precisely measures container positions, eliminating human error while the automated control system rapidly processes measurements and executes positioning commands, thereby simultaneously achieving high precision and improved productivity through automation.
Solution Approach 2:
The invention introduces a laser distance measuring device as an intermediary between the operator/load handling device and the container. This intermediary automatically performs the measurement and alignment functions that previously required skilled manual operation, providing precise digital measurements to the control system and enabling automated decision-making, thus bridging the gap between manual precision and automated productivity.
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 enhances the accuracy and ease of container handling by providing clear visual feedback of container positions and alignments, even in challenging conditions, facilitating both driver-assisted and fully automated operations, thereby improving handling efficiency and reducing errors.
Implementation Method 1
The implementation of a method and apparatus using Time-of-Flight (ToF) cameras or other 3D cameras to create distance maps
Data Source
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AI summary
A load is handled by a load handling device comprising gripping means for gripping at least one fastening point of the load, comprising determining, in the gripping means, a distance map within the area of which are described a part of the area of the load to which the gripping means attach and/or on which another load is stacked, as well as surroundings of the load.