Shelving structure and validation apparatus for improved image processing of codes on storage bins
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Solution Overview
Problem
Existing imaging-based Kanban systems face issues with optical code visibility due to improper camera alignment, bin arrangement, lighting, and image cropping, leading to ineffective inventory management.
Innovation Solution
A top shelf structure with enhanced optical code visibility and a validation apparatus to ensure proper camera alignment and installation, using QR codes or barcodes, and a challenge board to validate camera setup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If bins are stacked on top of each other or placed in front of another to maximize storage space, then the quantity of bins that can be stored increases, but the optical code visibility deteriorates because codes become hidden
Solution Approach 1:
The patent introduces a vertical dimension to code visibility by placing optical codes at multiple height levels on the bin front surfaces. Codes are positioned at different vertical positions so that at least one code remains visible regardless of how bins are stacked or arranged, transforming a two-dimensional placement problem into a three-dimensional solution space.
2Device complexity
If the camera field of view angle is not properly aligned with the bin angle, then the device complexity is reduced, but the optical code detection precision deteriorates
Solution Approach 1:
The patent changes the parameter of code position from a single fixed location to multiple locations at different angles and heights. By distributing codes across multiple angular positions on the bin surface, the system becomes tolerant to camera angle variations, allowing detection even when the camera is not perfectly aligned with any single code.
3Productivity
If bins are arranged to maximize storage density, then the storage efficiency increases, but the image processing reliability deteriorates due to hidden codes and improper positioning
Solution Approach 1:
The patent applies preliminary action by pre-positioning multiple optical codes on each bin at carefully calculated locations before the bins are ever stored. This advance preparation ensures that regardless of how the bins are subsequently arranged in the storage system, at least one code will remain accessible and visible to the camera, guaranteeing reliable detection.
Data Source
AI summary
In an optical imaging based Kanban inventory replenishment system, a top shelf structure is configured to enhance the visibility of optical codes on empty bins that are placed on the top shelf of a shelving unit, and a validation apparatus placed on top of the top shelf structure is configured for use in validation procedure that confirms a proper installation and alignment of cameras used in capturing images of the optical codes on the empty bins.