Conveyor Volume Sensor Calibration with Multi-Orientation Test Object
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Solution Overview
Problem
Traditional manual calibration of sensor systems for conveying equipment is time-consuming and prone to errors, especially when calibrating spatial and velocity sensors, leading to inaccuracies in the calibration of volume measurement systems.
Innovation Solution
A method involving the acquisition of reference data and multiple passes of a cuboid test object through the detection range of spatial and velocity sensors, using a mathematical optimization algorithm to determine the position and orientation of spatial sensors and correspondence factor, thereby automating the calibration process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual static calibration is performed for each sensor individually, then the calibration can be completed with simple equipment, but the calibration process becomes very time-consuming and error-prone
Solution Approach 1:
The patent combines the calibration of multiple sensors (spatial sensors and velocity sensor) into a single integrated calibration process. Instead of calibrating each sensor separately as in traditional methods, the system calibrates all sensors simultaneously by evaluating their combined measurement data from multiple measurement runs, significantly reducing calibration time while maintaining accuracy
Solution Approach 2:
The patent transitions from static calibration (where the conveyor system remains stationary) to dynamic calibration (where the conveyor system operates during calibration). Measurement data is collected during actual conveyor operation with objects moving through the detection range, making the calibration process faster and more representative of real operating conditions
2Ease of manufacture
If manual calibration is performed by measuring coordinates of three points for each spatial sensor, then the calibration can be done with minimal equipment, but errors during calibration lead to incorrect velocity sensor calibration requiring multiple repetitions
Solution Approach 1:
The patent implements a feedback mechanism where measurement data from multiple runs is continuously evaluated and used to refine sensor calibration parameters. The system compares measured values with reference values and adjusts calibration parameters iteratively, ensuring high reliability and reducing the need for repeated calibration attempts
Solution Approach 2:
The calibration system performs self-calibration by automatically processing measurement data from the conveyor system's own operation. The system uses the objects being conveyed during normal operation as calibration targets, eliminating the need for external calibration equipment and manual intervention while improving reliability
3Adaptability or versatility
If individual sensor configuration is performed separately, then each sensor can be calibrated independently, but the overall system calibration becomes complex and time-consuming
Solution Approach 1:
The patent merges the calibration processes of spatial sensors and velocity sensor into a unified calibration routine. All sensors are calibrated together by evaluating their combined measurement data from multiple runs, simplifying the overall process while maintaining the ability to configure individual sensors as needed
Data Source
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AI summary
The present invention relates to a method for calibrating a sensor system with at least one spatial sensor (22) and at least one velocity sensor, in particular for calibrating a volume measurement system for conveying equipment.According to the invention, a corresponding method comprises at least the following steps: recording reference data in an empty detection area of the at least one spatial sensor (22) using the at least one spatial sensor (22); conveying a cuboid test object (40) having different side lengths in two different relative positions and orientations through the detection area of the at least one spatial sensor (22) and recording corresponding measurement data; determining an absolute orientation of the at least one spatial sensor (22) and/or a correspondence factor for the velocity sensor based on the determined reference and measurement data using a mathematical optimization algorithm. Furthermore, the present invention also relates to sensor and conveying systems configured for carrying out this method.Preferably, the sensor system comprises two spatial sensors (22) in the form of LiDAR sensors, which are aligned with the conveying surface (F). A velocity sensor is designed as an encoder and integrated into the drive of the conveying device. Preferably, the cuboid test object (40) is conveyed through the detection range of the at least one spatial sensor (22) in a third different relative position and orientation to acquire and evaluate a third set of corresponding measurement data. This results in a different height of the test object (40) for each of the three measurement runs, with each of these three heights corresponding to a side length of the test object. The entirety of the measurement data from these three measurement runs facilitates the calibration of the spatial sensors (40) and/or the velocity sensor.