WO2003025498A1 - System and method for measuring the dimensions of moving packages - Google Patents

System and method for measuring the dimensions of moving packages Download PDF

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Publication number
WO2003025498A1
WO2003025498A1 PCT/US2002/030018 US0230018W WO03025498A1 WO 2003025498 A1 WO2003025498 A1 WO 2003025498A1 US 0230018 W US0230018 W US 0230018W WO 03025498 A1 WO03025498 A1 WO 03025498A1
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WIPO (PCT)
Prior art keywords
ught
portions
light
reflected
mirror
Prior art date
Application number
PCT/US2002/030018
Other languages
French (fr)
Inventor
Richard L. Hartman
Original Assignee
Advanced Optical Systems, Inc.
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from US09/957,172 external-priority patent/US6798528B1/en
Application filed by Advanced Optical Systems, Inc. filed Critical Advanced Optical Systems, Inc.
Publication of WO2003025498A1 publication Critical patent/WO2003025498A1/en

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Classifications

    • GPHYSICS
    • G01MEASURING; TESTING
    • G01BMEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
    • G01B11/00Measuring arrangements characterised by the use of optical techniques
    • G01B11/02Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness
    • G01B11/04Measuring arrangements characterised by the use of optical techniques for measuring length, width or thickness specially adapted for measuring length or width of objects while moving

Definitions

  • the present invention relates generally to systems and methods for measuring the dimensions of packages. More particularly, this invention pertains to a system and method for measuring the dimensions of packages being moved by material handling equipment.
  • Package shipping companies such as FedEx, have a need for measuring the dimensions, i.e., the height, width, and length, of the packages they ship. This information is used for a variety of purposes, including calculating the volume occupied by the package and using this volume information to load the packages as efficiently as possible or to bill customers by volume rather than weight.
  • one object of the present invention is to provide a system and method for measuring the dimensions of packages being moved by material handling equipment.
  • Another object is to provide a system and method for measuring the dimensions of packages having a wide range of shapes and sizes. Still another object is to provide a system and method for measuring packages being moved by material handling equipment at different heights relative to the material handling equipment.
  • a system and method for measuring the dimensions of packages that includes a computer system connected to a position tracking system and a slice measurement system.
  • the computer system uses the position tracking system to generate a series of position measurements of the packages as they move through the slice measurement system and uses the slice measurement system to generate a cross sectional slice of the packages at each measured position.
  • the computer system then uses the cross sectional slice information to determine the height and width of the packages and uses the position measurements to determine the length of the packages.
  • Fig. 1 is a block diagram of one embodiment of the present invention.
  • Fig. 2 is a side view of one embodiment of the present invention showing a forklift moving packages through the system.
  • Fig. 3 is a side view of one embodiment of the beacon system and slice measurement system of the present invention.
  • Fig. 4 is an enlarged side view of the beacon system shown in Fig. 3.
  • Fig. 5 is a side view of one embodiment of the reflector system of the present invention.
  • Fig. 6 is the output of the position-tracking detector of the present invention when the material handling unit enters the slice measurement system travehng in a direction perpendicular to the slice measurement system.
  • Fig. 7 is an image output by the position-tracking detector of the present invention when the material handling unit enters the slice measurement system travehng in a direction that is not perpendicular to the slice measurement system.
  • Fig. 8 is a side view of one embodiment of the slice measurement system of the present invention.
  • Fig. 9 is a side view of one embodiment of a slice detector used in the present invention.
  • Fig. 10 is a side view of portion of the slice measurement system shown in Fig. 8.
  • Fig. 11 is a side view of one alternative embodiment of the present invention.
  • Fig. 12 is a side view of another alternative embodiment of the present invention.
  • Fig. 13 is a perspective view of one embodiment of a parabolic mirror used with the present invention.
  • Fig. 14 is a flowchart showing an overview of the steps performed by the computer system of the present invention.
  • Fig. 15 is a flowchart showing the steps performed by the computer system to calculate position and orientation of packages.
  • Fig. 16 is a flowchart showing the steps performed by the computer system to generate cross sectional slices of the packages.
  • Fig 17 is a flowchart showing the conversion of the data set for geometrical corrections.
  • Fig 18 is a flowchart showing a typical algorithm for translating each slice into a common frame of reference by equations of translation and the Euler equations of rotation.
  • Fig. 19 is a flowchart showing the steps for calculating a parallelpiped based on the measured dimensions of the packages.
  • one embodiment of the present invention of a system 10 for measuring the dimensions of moving packages includes a computer system 12 connected to a position tracking system 14 and a slice measurement system 16.
  • the computer system 12 uses the position tracking system 14 to detect the arrival and to measure the position and orientation of packages 18 as they are moved through the slice measurement system 16 using material handling equipment 20, i.e., a forklift, and uses the slice measurement system 16 to measure cross sectional slices 22 of the packages 18 as they pass through the slice measurement system 16.
  • the number of position measurements and corresponding cross sectional slices required to accurately determine the dimensions of the packages 18 is dependent upon the speed at which the packages 18 are passing through the slice measurement system 16. If the packages are moving at a slow speed and the packages form a relatively uniform shape, then a smaller number of position measurements is required. On the other hand, if the packages are moving very rapidly and the packages are not relatively uniformly shaped, then a larger number of position measurements are required.
  • the number of position measurements is also dependent upon the required accuracy of the measurements of the dimensions and the size of the packages 18. For example, if the dimensions of the packages must be measured to within V* inch, then the cross sectional slices must be taken every A inch along the length of the packages 18. If, on the other hand, the required accuracy is Yt inch, the cross sectional slice can be measured every V2 inch.
  • the computer system 12 detects the arrival and measures the position and orientation of the packages 18 by illuminating an area 24 in front of the slice measurement system 16 and measure Ught reflected off of the material handling unit 18 as it passes through this area using the position tracking system 14.
  • the position tracking system 14 includes a beacon system 26 that includes a light source 28, a beam splitter 30, a lens 32, and a position detector 34.
  • the light source 28 generates a beam of Ught 36 that is reflected by the beam spUtter 30 toward the lens 32, the lens 32 spreads the beam of Ught 36 so that it covers area 24, and the position detector 34 records any Ught reflected back through lens 32.
  • the Ught source 28 is a conventional infrared LED and the detector 34 is a conventional rectangular array.
  • the detector 34 can be a convention video camera, such as a CMOS PC-51 video camera, or some other type of recording device.
  • the position tracking system 14 includes a reflector system 38 that includes a mounting plate 40 and two retroreflectors, 42 and 44, separated by a known distance.
  • the mounting plate 40 is used to connect the reflector system 38 to material handhng unit 20, and retroreflectors, 42 and 44, which are known in the art, are used to reflect Ught striking the reflectors back toward the source of the Ught. Because the retroreflectors, 42 and 44, have a highly selective return, the image recorded by the detector 34 includes two spots of Ught, 46 and 48 (see Fig. 6), one from each retroreflector.
  • the location of these spots on the detector 34 is proportional to the position of the material handling unit 20, and indirectly a measure of the position of the packages 18, with respect to the slice measurement system 16 and is used by the computer system 12 to calculate the position of the packages 18 as they move through the slice measurement system 16.
  • the computer system 12 also uses the location of the spots on the detector 34 to calculate the orientation of the material handling unit 20, which is also an indirect measurement of the orientation of the packages 18, as weU.
  • the system 10 is designed to receive packages 18 that are travehng in a direction that is perpendicular to the sUce measurement system 16. If the material handling unit 20 is not traveUng in a direction that is perpendicular to the sUce measurement system 16, the computer system 12 must compensate for this difference in order to accurately calculate the dimensions of the packages 18.
  • the computer system 12 calculates an angle 50 formed by the two spots, 46 and 48, on the detector 34 (see Fig. 7).
  • the angle 50 is a measure of the orientation of the material handhng unit 20, and indirectly the packages 18, with respect to the sUce measurement system 16 and is used by the computer system 12, along with conventional coordinate transformation equations, to compensate for this difference.
  • One technique for transforming coordinate systems used with the present invention is described in Herbert Goldstein's book entitled “Classical Mechanics,” pubhshed in 1959 and hereby incorporated by reference.
  • the computer system 12 must compensate for these changes with regard to each cross- sectional slice of the packages 18.
  • the sUce measurement system 16 will generate one cross-sectional sUce when the material handhng unit has one orientation and another cross-sectional sUce when the material handling unit 20 has a different orientation, and the computer system 12 must compensate for this change in order to accurately combine the slices to calculate the height and width of the packages 18.
  • the reflector system 38 can be reduced to a single retroreflector and the mounting plate 40 and the computer system 12 does not perform this compensation step.
  • the reflector system 38 may be replaced with some sort of active beacon (not shown).
  • the beacon system 26 would include the lens 32 and detector 34, and would be designed to record light emitted by the active beacon.
  • the slice measurement system 16 includes a frame 51, a horizontal measurement system 52, and a vertical measurement system 54.
  • the measurements systems, 52 and 54 are identical and are used to measure the width 56 and height 58 of the packages 18, respectively. More specificaUy, the horizontal measurement system 52 is used by the computer system 12 to measure the width 56 of the packages 18 and includes two paraboUc mirrors, 60 and 62, a light source 64, and two shce detectors, 66 and 68.
  • the vertical measurement system 54 is used by the computer system 12 to measure the height 58 of the packages 18 and also includes two paraboUc mirrors, 70 and 72, a light source 74, and two slice detectors, 76 and 78.
  • the light sources, 64 and 74 are side emitting fiber optic filaments known in the art, with hght source 74 embedded in the frame 51 and light source 64 embedded in the ground under the frame 51.
  • the computer system 12 also uses the cross-sectional slices to compensate for tilt in the material handling unit 20.
  • the system 10 is designed to receive packages that are level with the ground, i.e., the bottom of the packages is paraUel with the ground. If the material handhng unit 20 is tilted up or down, the computer system 12 must compensate for this difference in order to accurately calculate the dimensions of the packages 18.
  • the computer system 12 measures the height of the packages 18 using one cross sectional shce and measures the height of the packages 18 using a second cross-sectional slice. If the measured heights are the same, then the computer system 12 determines that there is no tilt. If the heights are different, the computer system 12 determines that there is tilt and, using the same conventional coordinate transformation equations referenced previously, compensates for the tilt.
  • the computer system 12 is further used to exclude any measurements of the forklift tines of the material handling unit 20. This is done by rejecting any cross sectional shce that has a height dimension equal to the thickness of the forklift tines or a width dimension equal to the width of the forklift tines.
  • the location of the forkUft tines is detected by knowing the location of the forklift, knowing the height and tilt of the forklift tines from the bottom measurement, and knowing the width between the forklift tines from the top measurement.
  • the computer system 12 measures the width and height of the packages 18 by using the shce detectors, 60, 62, 66, and 68, to record shadowed images, i.e., images that include a brightly Ut portion and a shadowed portion.
  • the amount of each image that is shadowed is a measure of the width 56 and height 58 of the packages 18.
  • the light sources generate and direct a beam of hght 80 toward the packages 18 and the mirrors, 60, 62, 70, and 72.
  • a portion of the hght 66 is blocked by the packages 18, casting a shadow on portions of the mirrors, 60, 62, 70, and 72, and the rest of the Ught 66 is reflected by the mirrors, 60, 62, 70, and 72, back to the slice detectors, 66, 68, 76, and 78, which record shadowed images.
  • the sUce detectors, 66, 68, 76, and 78 each include a cyhndrical lens 82, a slit 84, and a detector array 86.
  • the sUce detectors, 66 and 68 which are used to measure the height 56 of the packages 18, the sUts are positioned to cause the shts to pass only reflected horizontal rays of hght.
  • each slit in sUce detectors, 76 and 78 which are used to measure the width of the packages 18, are arranged to pass only reflected vertical rays of hght.
  • the size of each slit is determined by the pixel size of the detector array and the distance between the slit and the detector 66. In general, each slit is sized to constrain the field of view of each detector pixel to a beam the size of the required measurement accuracy.
  • a detector array is shown in Fig. 9, a video camera may be used in place of the detector array.
  • the use of a video camera increases the amount of processing (video images contain more data than images generated by detector arrays) required by the computer system 12 and slows the system 10.
  • the thickness of the paraboUc mirrors is dependent upon the desired accuracy of the system 10. For example, if the system 10 is designed to measure the dimensions of the packages 18 to an accuracy of a V * inch, the thickness of the paraboUc mirrors should be no larger than a V4 inch. If, on the other hand, the required accuracy is ⁇ inch, the thickness of the paraboUc mirrors can be no larger than % inch. In one embodiment designed to have an accuracy of inch, the thickness of the parabolic mirrors is V* inch.
  • the size of the parabohc mirrors is dependent upon the maximum size of the packages 18 to be measured by the system 10. For example, if the maximum height and width of the packages 18 to be measured is 10 feet, the parabolic mirrors must be 10 feet long. If the maximum height and width is less than 10 feet, the paraboUc mirrors may be shorter than 10 feet. In one embodiment designed to measure packages as large as 12 feet, the parabolic mirrors are aU 6 feet long. Because two mirrors are used as shown in Fig. 8, the system 10 can measure packages having a maximum size of 12 feet. Two parabolic mirrors are used with the horizontal measurement system and the vertical measurement system because, in some cases, the packages 18 may block a portion of Ught reflected by the parabolic mirrors.
  • Fig. 10 shows light source 74, parabohc mirror 70, and shce detector 76.
  • Light ray “a” leaves the light source 74, travels horizontaUy, and is reflected by paraboUc mirror 70. The ray then travels to shce detector 76, iUuminating the bottom pixel. Ray “b” likewise uluminates another pixel.
  • Ray “c” is blocked by the packages 18 to be measured.
  • the location of the edge between illuminated pixels and nonilluminated pixels is a measurement of the location of the edge of the packages 18.
  • Ray “m” passes the bottom of the object, but after reflection by the mirror, is blocked by the object.
  • this configuration can be used to measure the upper edge of the packages 18 but can not be used to measure the lower edge of the packages 18. Accordingly, a second parabohc mirror, as shown in Fig. 10, is needed to measure the lower edge of the packages 18.
  • Alternative embodiments of the shce measurement system 16 can have several different configurations of parabolic mirrors.
  • one alternative embodiment shown in Fig. 11 includes only two parabolic mirrors, two Ught sources, and two slice detectors. This type of configuration may be used when the packages 18 do not block portions of reflected hght.
  • another alternative embodiment includes one large paraboUc mirror and one smaU paraboUc mirror for the vertical measurement system 54. This type of configuration may be used when the lower paraboUc mirror measures a smaller portion of the packages than the upper paraboUc mirror.
  • other alternative configurations may be used as weU. Although large conventional paraboUc mirrors could be used with the present invention, these mirrors are prohibitively expensive.
  • the apphcant of the present invention developed a method of manufacturing an inexpensive parabolic mirror that includes a thin flexible reflector 80 bonded to a substrate 82.
  • the substrate 82 is machined out of aluminum and the reflector, which is a piece of plexiglass coated with a reflective coating, is connected to the substrate using an adhesive (see Fig. 13).
  • the reflector which is a piece of plexiglass coated with a reflective coating
  • the substrate is machined out of aluminum and the reflector, which is a piece of plexiglass coated with a reflective coating
  • the substrate 82 is machined out of aluminum and the reflector, which is a piece of plexiglass coated with a reflective coating, is connected to the substrate using an adhesive (see Fig. 13).
  • other types of mirrors may be used as well.
  • the data from the position tracking system 14 and from the slice measurement system 16 are corrected and calibrated. Measurements on the various detectors need to be converted to engineering units, such as inches and feet. Depending on the dimensions of any specific
  • the track data of the location and orientation of the material handling equipment is used to convert the slice data to a common coordinate system, building up the data representative of the three dimensional extremes of the object, or packages, being measured.
  • the virtual box which contains all the data points is optimized.
  • Fig. 15 is a flow chart describing steps performed by the position tracking system 14.
  • the array data of position detector 34 is acquired, for example by a frame grabber, internal digitizing, or similar methods. If there is no signal in the frame, no data is acquired. The two brightest spots indicate the location of two retroreflectors, 42 and 44. The average of the two provides the location of the MHE. The arctangent of the ratio of the difference of x and y coordinates provides the orientation. If a variety of MHE are used, such that it is possible for retroreflectors, 42 and 44, to be at different heights, the height is determined from the square root of the sum of the squares of the differences, and used to calibrate the location of the MHE in engineering units.
  • Figure 16 is a flow chart describing steps performed by the slice measurement system 16. If the position-tracking algorithm above detects a reflection, a linear frame of data is acquired from each slice detector in the slice measurement system 16. The location of the transition between a bright and dark line defines the edge of the slice. After all four shadow sensors have been read, the size of the slice is determined. The measurement of left plus right is the width of the slice. The measurement of top minus bottom is the height of a slice.
  • Fig 17 is a flowchart showing the conversion of the data set for geometrical corrections.
  • Fig 18 shows a typical algorithm for translating each slice into a common frame of reference by equations of translation and the Euler equations of rotation. The resulting set of vectors or points delimit the size of the box.
  • the rotation to account for fork tilt is performed first, moving the slices to a common "floor" based at zero height. In this case, the remaining conversion involves only two angles instead of three, and the Euler equations reduce to correction cosines.
  • Fig. 19 shows one approach to calculating the size of a circumscribing parallelpiped, i.e., a box that can be used to enclose the measures height, width, and length of the packages 18.

Abstract

A system and method for measuring the dimensions of moving packages includes a computer system (12) connected to a position tracking system (14) and a slice measurement system (16). The computer system uses the position tracking system to generate a series of position measurements of the packages (18) as they move through the slice measurement system and uses the slice measurement system to generate a cross sectional slice (22) of the packages at each measured positioned. The computer system then uses the cross sectional slice information to determine the height and width of the packages and uses the position measurements to determine the length of the packages.

Description

DESCRIPTION SYSTEM AND METHOD FOR MEASURING THE DIMENSIONS OF
MOVING PACKAGES TECHNICAL FIELD The present invention relates generally to systems and methods for measuring the dimensions of packages. More particularly, this invention pertains to a system and method for measuring the dimensions of packages being moved by material handling equipment.
BACKGROUND ART
Package shipping companies, such as FedEx, have a need for measuring the dimensions, i.e., the height, width, and length, of the packages they ship. This information is used for a variety of purposes, including calculating the volume occupied by the package and using this volume information to load the packages as efficiently as possible or to bill customers by volume rather than weight.
More importantly, these companies have a need to measure the dimensions of these packages as quickly as possible. This is true because, in many cases, packages being shipped must arrive at a destination within a specific amount of time. As a result, the amount of time available for use in measuring the dimensions of packages is limited in these situations. One possible solution to these problems, as taught by the present invention, is to measure the dimensions of packages as they are moved around by material handling equipment, i.e., a forklift or some other type of similar equipment.
None of the prior art systems known in the art, however, teach a system for measuring packages as they are moved around by material handling equipment. For example, U.S. Patent No. 5,661,561, issued to Wurz et al. on August 26, 1997 and entitled "Dimensioning System," and U.S. Patent No. 4,929,843, issued to Chmielewski, Jr. et al. on May 29, 1990 and entitled "Apparatus and Method for Determining a Dimension of an Object," both teach systems for measuring the dimensions of a package being moved by a moving conveyor. U.S. Patent No. 5,416,591, issued to Yoshimura et al. on May 16, 1995 and entitled "Method of Determination of a Three-Dimensional Profile of an Object," U.S. Patent No. 5,193,120, issued to Gamache et al. on March 9, 1993 and entitled "Machine Nision Three Dimensional Profiling System," and U.S. Patent No. 4,939,379, issued to Horn on July 3, 1990 and entitled "Contour Measurement Using Time-Based Triangulation Methods," all teach systems for measuring the dimensions of a package by scanning the package with a beam of light while the package is stationary.
What is needed, then, is a system and method for measuring the dimensions of packages being moved by material handling equipment.
DISCLOSURE OF THE INVENTION Accordingly, one object of the present invention is to provide a system and method for measuring the dimensions of packages being moved by material handling equipment.
Another object is to provide a system and method for measuring the dimensions of packages having a wide range of shapes and sizes. Still another object is to provide a system and method for measuring packages being moved by material handling equipment at different heights relative to the material handling equipment.
These and other objects, which will become apparent to someone practicing the present invention, are satisfied by a system and method for measuring the dimensions of packages that includes a computer system connected to a position tracking system and a slice measurement system.
The computer system uses the position tracking system to generate a series of position measurements of the packages as they move through the slice measurement system and uses the slice measurement system to generate a cross sectional slice of the packages at each measured position. The computer system then uses the cross sectional slice information to determine the height and width of the packages and uses the position measurements to determine the length of the packages.
Fig. 1 is a block diagram of one embodiment of the present invention. Fig. 2 is a side view of one embodiment of the present invention showing a forklift moving packages through the system.
Fig. 3 is a side view of one embodiment of the beacon system and slice measurement system of the present invention.
Fig. 4 is an enlarged side view of the beacon system shown in Fig. 3. Fig. 5 is a side view of one embodiment of the reflector system of the present invention.
Fig. 6 is the output of the position-tracking detector of the present invention when the material handling unit enters the slice measurement system travehng in a direction perpendicular to the slice measurement system.
Fig. 7 is an image output by the position-tracking detector of the present invention when the material handling unit enters the slice measurement system travehng in a direction that is not perpendicular to the slice measurement system. Fig. 8 is a side view of one embodiment of the slice measurement system of the present invention.
Fig. 9 is a side view of one embodiment of a slice detector used in the present invention.
Fig. 10 is a side view of portion of the slice measurement system shown in Fig. 8.
Fig. 11 is a side view of one alternative embodiment of the present invention.
Fig. 12 is a side view of another alternative embodiment of the present invention. Fig. 13 is a perspective view of one embodiment of a parabolic mirror used with the present invention. Fig. 14 is a flowchart showing an overview of the steps performed by the computer system of the present invention.
Fig. 15 is a flowchart showing the steps performed by the computer system to calculate position and orientation of packages. Fig. 16 is a flowchart showing the steps performed by the computer system to generate cross sectional slices of the packages.
Fig 17 is a flowchart showing the conversion of the data set for geometrical corrections.
Fig 18 is a flowchart showing a typical algorithm for translating each slice into a common frame of reference by equations of translation and the Euler equations of rotation.
Fig. 19 is a flowchart showing the steps for calculating a parallelpiped based on the measured dimensions of the packages.
BEST MODE FOR CARRYING OUT THE INVENTION
Referring to Figs. 1 and 2, one embodiment of the present invention of a system 10 for measuring the dimensions of moving packages includes a computer system 12 connected to a position tracking system 14 and a slice measurement system 16. The computer system 12 uses the position tracking system 14 to detect the arrival and to measure the position and orientation of packages 18 as they are moved through the slice measurement system 16 using material handling equipment 20, i.e., a forklift, and uses the slice measurement system 16 to measure cross sectional slices 22 of the packages 18 as they pass through the slice measurement system 16.
The number of position measurements and corresponding cross sectional slices required to accurately determine the dimensions of the packages 18 is dependent upon the speed at which the packages 18 are passing through the slice measurement system 16. If the packages are moving at a slow speed and the packages form a relatively uniform shape, then a smaller number of position measurements is required. On the other hand, if the packages are moving very rapidly and the packages are not relatively uniformly shaped, then a larger number of position measurements are required.
The number of position measurements is also dependent upon the required accuracy of the measurements of the dimensions and the size of the packages 18. For example, if the dimensions of the packages must be measured to within V* inch, then the cross sectional slices must be taken every A inch along the length of the packages 18. If, on the other hand, the required accuracy is Yt inch, the cross sectional slice can be measured every V2 inch.
Referring to Figs. 3 and 4, the computer system 12 detects the arrival and measures the position and orientation of the packages 18 by illuminating an area 24 in front of the slice measurement system 16 and measure Ught reflected off of the material handling unit 18 as it passes through this area using the position tracking system 14. To illuminate area 24 and to measure reflected light, the position tracking system 14 includes a beacon system 26 that includes a light source 28, a beam splitter 30, a lens 32, and a position detector 34. The light source 28 generates a beam of Ught 36 that is reflected by the beam spUtter 30 toward the lens 32, the lens 32 spreads the beam of Ught 36 so that it covers area 24, and the position detector 34 records any Ught reflected back through lens 32. In one embodiment, the Ught source 28 is a conventional infrared LED and the detector 34 is a conventional rectangular array. In alternative embodiments, the detector 34 can be a convention video camera, such as a CMOS PC-51 video camera, or some other type of recording device.
Referring to Fig. 5, to reflect the beam of light 36 emitted by the beacon system 26, the position tracking system 14 includes a reflector system 38 that includes a mounting plate 40 and two retroreflectors, 42 and 44, separated by a known distance. The mounting plate 40 is used to connect the reflector system 38 to material handhng unit 20, and retroreflectors, 42 and 44, which are known in the art, are used to reflect Ught striking the reflectors back toward the source of the Ught. Because the retroreflectors, 42 and 44, have a highly selective return, the image recorded by the detector 34 includes two spots of Ught, 46 and 48 (see Fig. 6), one from each retroreflector. The location of these spots on the detector 34 is proportional to the position of the material handling unit 20, and indirectly a measure of the position of the packages 18, with respect to the slice measurement system 16 and is used by the computer system 12 to calculate the position of the packages 18 as they move through the slice measurement system 16. The computer system 12 also uses the location of the spots on the detector 34 to calculate the orientation of the material handling unit 20, which is also an indirect measurement of the orientation of the packages 18, as weU. The system 10 is designed to receive packages 18 that are travehng in a direction that is perpendicular to the sUce measurement system 16. If the material handling unit 20 is not traveUng in a direction that is perpendicular to the sUce measurement system 16, the computer system 12 must compensate for this difference in order to accurately calculate the dimensions of the packages 18.
To compensate, the computer system 12 calculates an angle 50 formed by the two spots, 46 and 48, on the detector 34 (see Fig. 7). The angle 50 is a measure of the orientation of the material handhng unit 20, and indirectly the packages 18, with respect to the sUce measurement system 16 and is used by the computer system 12, along with conventional coordinate transformation equations, to compensate for this difference. One technique for transforming coordinate systems used with the present invention is described in Herbert Goldstein's book entitled "Classical Mechanics," pubhshed in 1959 and hereby incorporated by reference.
In a similar manner, if the material handhng unit 20 enters the slice measurement system 16 with one orientation and changes orientation while passing through the slice measurement system 16, the computer system 12 must compensate for these changes with regard to each cross- sectional slice of the packages 18. In other words, the sUce measurement system 16 will generate one cross-sectional sUce when the material handhng unit has one orientation and another cross-sectional sUce when the material handling unit 20 has a different orientation, and the computer system 12 must compensate for this change in order to accurately combine the slices to calculate the height and width of the packages 18.
In alternative embodiments where the material handling unit 20 can only enter the sUce measurement system 16 traveUng in a direction perpendicular to the shce measurement system 16, the reflector system 38 can be reduced to a single retroreflector and the mounting plate 40 and the computer system 12 does not perform this compensation step. In addition, in other alternative embodiments, the reflector system 38 may be replaced with some sort of active beacon (not shown). In this case, the beacon system 26 would include the lens 32 and detector 34, and would be designed to record light emitted by the active beacon.
Referring to Fig. 8, the slice measurement system 16 includes a frame 51, a horizontal measurement system 52, and a vertical measurement system 54. The measurements systems, 52 and 54, are identical and are used to measure the width 56 and height 58 of the packages 18, respectively. More specificaUy, the horizontal measurement system 52 is used by the computer system 12 to measure the width 56 of the packages 18 and includes two paraboUc mirrors, 60 and 62, a light source 64, and two shce detectors, 66 and 68. In a similar manner, the vertical measurement system 54 is used by the computer system 12 to measure the height 58 of the packages 18 and also includes two paraboUc mirrors, 70 and 72, a light source 74, and two slice detectors, 76 and 78. In one embodiment, the light sources, 64 and 74, are side emitting fiber optic filaments known in the art, with hght source 74 embedded in the frame 51 and light source 64 embedded in the ground under the frame 51. The computer system 12 also uses the cross-sectional slices to compensate for tilt in the material handling unit 20. The system 10 is designed to receive packages that are level with the ground, i.e., the bottom of the packages is paraUel with the ground. If the material handhng unit 20 is tilted up or down, the computer system 12 must compensate for this difference in order to accurately calculate the dimensions of the packages 18.
To compensate, the computer system 12 measures the height of the packages 18 using one cross sectional shce and measures the height of the packages 18 using a second cross-sectional slice. If the measured heights are the same, then the computer system 12 determines that there is no tilt. If the heights are different, the computer system 12 determines that there is tilt and, using the same conventional coordinate transformation equations referenced previously, compensates for the tilt.
The computer system 12 is further used to exclude any measurements of the forklift tines of the material handling unit 20. This is done by rejecting any cross sectional shce that has a height dimension equal to the thickness of the forklift tines or a width dimension equal to the width of the forklift tines. In one embodiment, the location of the forkUft tines is detected by knowing the location of the forklift, knowing the height and tilt of the forklift tines from the bottom measurement, and knowing the width between the forklift tines from the top measurement.
The computer system 12 measures the width and height of the packages 18 by using the shce detectors, 60, 62, 66, and 68, to record shadowed images, i.e., images that include a brightly Ut portion and a shadowed portion. The amount of each image that is shadowed is a measure of the width 56 and height 58 of the packages 18.
To generate the shadowed image, the light sources generate and direct a beam of hght 80 toward the packages 18 and the mirrors, 60, 62, 70, and 72. A portion of the hght 66 is blocked by the packages 18, casting a shadow on portions of the mirrors, 60, 62, 70, and 72, and the rest of the Ught 66 is reflected by the mirrors, 60, 62, 70, and 72, back to the slice detectors, 66, 68, 76, and 78, which record shadowed images. Referring to Fig. 9, the sUce detectors, 66, 68, 76, and 78 each include a cyhndrical lens 82, a slit 84, and a detector array 86. Light 66 reflected by the parabolic mirrors, 60, 62, 70, and 72, is directed by the lenses 82 through the shts 84 and onto the detector arrays 86. For the sUce detectors, 66 and 68, which are used to measure the height 56 of the packages 18, the sUts are positioned to cause the shts to pass only reflected horizontal rays of hght. In a similar manner, the slits in sUce detectors, 76 and 78, which are used to measure the width of the packages 18, are arranged to pass only reflected vertical rays of hght. The size of each slit is determined by the pixel size of the detector array and the distance between the slit and the detector 66. In general, each slit is sized to constrain the field of view of each detector pixel to a beam the size of the required measurement accuracy.
Although a detector array is shown in Fig. 9, a video camera may be used in place of the detector array. The use of a video camera, however, increases the amount of processing (video images contain more data than images generated by detector arrays) required by the computer system 12 and slows the system 10.
The thickness of the paraboUc mirrors is dependent upon the desired accuracy of the system 10. For example, if the system 10 is designed to measure the dimensions of the packages 18 to an accuracy of a V* inch, the thickness of the paraboUc mirrors should be no larger than a V4 inch. If, on the other hand, the required accuracy is Λ inch, the thickness of the paraboUc mirrors can be no larger than % inch. In one embodiment designed to have an accuracy of inch, the thickness of the parabolic mirrors is V* inch.
The size of the parabohc mirrors is dependent upon the maximum size of the packages 18 to be measured by the system 10. For example, if the maximum height and width of the packages 18 to be measured is 10 feet, the parabolic mirrors must be 10 feet long. If the maximum height and width is less than 10 feet, the paraboUc mirrors may be shorter than 10 feet. In one embodiment designed to measure packages as large as 12 feet, the parabolic mirrors are aU 6 feet long. Because two mirrors are used as shown in Fig. 8, the system 10 can measure packages having a maximum size of 12 feet. Two parabolic mirrors are used with the horizontal measurement system and the vertical measurement system because, in some cases, the packages 18 may block a portion of Ught reflected by the parabolic mirrors. To iUustrate this problem, consider Fig. 10, which shows light source 74, parabohc mirror 70, and shce detector 76. Light ray "a" leaves the light source 74, travels horizontaUy, and is reflected by paraboUc mirror 70. The ray then travels to shce detector 76, iUuminating the bottom pixel. Ray "b" likewise uluminates another pixel. However, ray "c" is blocked by the packages 18 to be measured. The location of the edge between illuminated pixels and nonilluminated pixels is a measurement of the location of the edge of the packages 18. Ray "m" passes the bottom of the object, but after reflection by the mirror, is blocked by the object. Because ray "m" is blocked, this configuration can be used to measure the upper edge of the packages 18 but can not be used to measure the lower edge of the packages 18. Accordingly, a second parabohc mirror, as shown in Fig. 10, is needed to measure the lower edge of the packages 18.
Alternative embodiments of the shce measurement system 16 can have several different configurations of parabolic mirrors. For example, one alternative embodiment shown in Fig. 11 includes only two parabolic mirrors, two Ught sources, and two slice detectors. This type of configuration may be used when the packages 18 do not block portions of reflected hght. Referring to Fig. 12, another alternative embodiment includes one large paraboUc mirror and one smaU paraboUc mirror for the vertical measurement system 54. This type of configuration may be used when the lower paraboUc mirror measures a smaller portion of the packages than the upper paraboUc mirror. Depending on the application, other alternative configurations may be used as weU. Although large conventional paraboUc mirrors could be used with the present invention, these mirrors are prohibitively expensive. Accordingly, the apphcant of the present invention developed a method of manufacturing an inexpensive parabolic mirror that includes a thin flexible reflector 80 bonded to a substrate 82. In one embodiment, the substrate 82 is machined out of aluminum and the reflector, which is a piece of plexiglass coated with a reflective coating, is connected to the substrate using an adhesive (see Fig. 13). In other embodiments, other types of mirrors may be used as well. As shown in Fig. 14, the data from the position tracking system 14 and from the slice measurement system 16 are corrected and calibrated. Measurements on the various detectors need to be converted to engineering units, such as inches and feet. Depending on the dimensions of any specific instrument, data must be converted to linear coordinate systems. Then the track data of the location and orientation of the material handling equipment (MHE) is used to convert the slice data to a common coordinate system, building up the data representative of the three dimensional extremes of the object, or packages, being measured. In applications where the absolute volume is required, the virtual box which contains all the data points is optimized.
Fig. 15 is a flow chart describing steps performed by the position tracking system 14. In one embodiment, the array data of position detector 34 is acquired, for example by a frame grabber, internal digitizing, or similar methods. If there is no signal in the frame, no data is acquired. The two brightest spots indicate the location of two retroreflectors, 42 and 44. The average of the two provides the location of the MHE. The arctangent of the ratio of the difference of x and y coordinates provides the orientation. If a variety of MHE are used, such that it is possible for retroreflectors, 42 and 44, to be at different heights, the height is determined from the square root of the sum of the squares of the differences, and used to calibrate the location of the MHE in engineering units.
Figure 16 is a flow chart describing steps performed by the slice measurement system 16. If the position-tracking algorithm above detects a reflection, a linear frame of data is acquired from each slice detector in the slice measurement system 16. The location of the transition between a bright and dark line defines the edge of the slice. After all four shadow sensors have been read, the size of the slice is determined. The measurement of left plus right is the width of the slice. The measurement of top minus bottom is the height of a slice.
Fig 17 is a flowchart showing the conversion of the data set for geometrical corrections. Fig 18 shows a typical algorithm for translating each slice into a common frame of reference by equations of translation and the Euler equations of rotation. The resulting set of vectors or points delimit the size of the box. In the preferred embodiment of the conversion algorithm, the rotation to account for fork tilt is performed first, moving the slices to a common "floor" based at zero height. In this case, the remaining conversion involves only two angles instead of three, and the Euler equations reduce to correction cosines. Fig. 19 shows one approach to calculating the size of a circumscribing parallelpiped, i.e., a box that can be used to enclose the measures height, width, and length of the packages 18. In the preferred embodiment we take advantage of the fact that the bottom of the freight unit is flat. Thus the height is defined by the highest value of height. The maximum width is multiplied by the maximum length, giving a trial area. Then an additional rotation in the horizontal plane is used to determine if a different orientation of the virtual box would have a smaller area and thus a smaller volume. This process is repeated until a minimum is reached. Thus, although there have been described particular embodiments of the present invention of a new and useful Dimensioning System For Moving Objects, it is not intended that such references be construed as Umitations upon the scope of this invention except as set forth in the foUowing claims.

Claims

CLAIMS What is claimed is: 1. A method of measuring an object, comprising the steps of: iUuminating the object with a beam of Ught using a light source positioned on a first side of the object; reflecting portions of the beam of Ught traveUng past the object using a parabolic mirror positioned on a second side of the object; generating a recording of the portions of the beam of Ught reflected by the paraboUc mirror using a Ught detector positioned on the first side of the object; and wherein the recording of the portions of the Ught reflected by the parabohc mirror contains information indicative of one dimension of the object.
2. The method of claim 1, further comprising the steps of: iUuminating the object with a second beam of light using a second light source positioned on a third side of the object; reflecting portions of the second beam of Ught traveling past the object using a second parabolic mirror positioned on a fourth side of the object; generating a recording of the portions of the second beam of Ught reflected by the second paraboUc mirror using a second light detector positioned on the third side of the object; and wherein the recording of the portions of the second beam of Ught reflected by the second paraboUc mirror contains information indicative of a second dimension of the object.
3. The method of claim 2, further comprising the steps of: generating, at multiple positions along the object, recordings of the portions of the beam of Ught reflected by the parabolic mirror using the Ught detector positioned on the first side of the object; generating, at multiple positions along the object, recordings of the portions of the second beam of hght reflected by the second parabolic mirror using the second Ught detector positioned on the third side of the object; and wherein the multiple recordings of the portions of the Ught reflected by the paraboUc mirror contain information indicative of one dimension of the object at multiple positions along the object and the multiple recordings of the portions of the second beam of Ught reflected by the second paraboUc mirror contains information indicative of a second dimension of the object at multiple positions along the object.
4. The method of claim 3, further comprising the steps of: iUuminating the object with Ught emitted from a third Ught source positioned on a fifth side of the object; reflecting portions of light emitted by the third light source using a reflector system indirectly connected to the object; generating, at multiple positions along the object, recordings of the reflected portions of the light emitted by the third light source using a third light detector positioned on the fifth side of the object, each recording of the reflected portions of hght emitted by the third light source associated with one of the recordings of the reflected portions of the first beam of light and one of the recordings of the reflected portions of the second beam of Ught; and wherein the multiple recordings of the reflected portions of the Ught emitted by the third Ught source, in conjunction with the multiple recordings of reflected portions of the first and second beams of light, contain information indicative of a third dimension of the object.
5. The method of claim 4, wherein: the step of reflecting portions of the beam of light includes the step of reflecting portions of the beam of light using a pair of parabolic mirrors positioned on the second side of the object; and the step of generating, at multiple positions along the object, recordings of the portions of the beam of hght reflected by the parabolic mirror includes the step of generating, at multiple positions along the object, recordings of the portions of the beam of hght reflected by the pair of paraboUc mirrors using a pair of Ught detectors positioned on the first side of the object.
6. The method of claim 5, wherein: the step of reflecting portions of the second beam of light includes the step of reflecting portions of the second beam of light using a second pair of parabolic mirrors positioned on the fourth side of the object; the step of generating, at multiple positions along the object, recordings of the portions of the second beam of light reflected by the paraboUc mirror includes the step of generating, at multiple positions along the object, recordings of the portions of the second beam of light reflected by the second pair of parabolic mirrors using a second pair of light detectors positioned on the first side of the object.
7. A method of measuring an object, comprising the steps of: iUuminating the object with a beam of Ught using a light source positioned on a first side of the object; reflecting portions of the beam of hght traveling past the object using a parabolic mirror positioned on a second side of the object; generating, at multiple positions along the object, recordings of the portions of the beam of light reflected by the parabolic mirror using a light detector positioned on the first side of the object; illuminating the object with a second beam of light using a second light source positioned on a third side of the object; reflecting portions of the second beam of light traveling past the object using a second paraboUc mirror positioned on a fourth side of the object; generating, at multiple positions along the object, recordings of the portions of the second beam of light reflected by the second parabolic mirror using a second light detector positioned on the third side of the object; illuminating the object with hght from a third Ught source positioned on a fifth side of the object; reflecting portions of light emitted by the third light source using a reflector system indirectly connected to the object; generating, at multiple positions along the object, recordings of the reflected portions of the light emitted by the third light source using a third Ught detector positioned on the fifth side of the object; and wherein the multiple recordings of the portions of the Ught reflected by the paraboUc mirror contain information indicative of one dimension of the object at multiple positions along the object, the multiple recordings of the portions of the second beam of Ught reflected by the second parabohc mirror contain information indicative of a second dimension of the object at multiple positions along the object, and the multiple recordings of the reflected portions of the Ught emitted by the third Ught source, in conjunction with the multiple recordings of reflected portions of the first and second beams of Ught, contain information indicative of a third dimension of the object.
8. A system for measuring an object, comprising: a light source positioned on a first side of the object; a parabolic mirror positioned on a second side of the object; and a light detector positioned on the first side of the object.
9. The system of claim 8, further comprising: a second Ught source positioned on a third side of the object; a second paraboUc mirror positioned on a fourth side of the object; and a second Ught detector positioned on the third side of the object.
10. The system of claim 9, further comprising: a third Ught source positioned on a fifth side of the object; a reflector system indirectly connected to the object; and a third Ught detector positioned on the fifth side of the object.
11. The system of claim 10, wherein the system includes a pair of parabolic mirrors positioned on the second side of the object and a pair of hght detectors positioned on the first side of the object.
12. The system of claim 11, wherein the system includes a second pair of parabohc mirrors positioned on the fourth side of the object and a second pair of Ught detectors positioned on the third side of the object.
13. A system for measuring an object, comprising: a light source positioned on a first side of the object; a paraboUc mirror positioned on a second side of the object; a light detector positioned on the first side of the object; a second Ught source positioned on a third side of the object; a second paraboUc mirror positioned on a fourth side of the object; a second light detector positioned on the third side of the object; a third Ught source positioned on a fifth side of the object; a reflector system indirectly connected to the object; and a third light detector positioned on the fifth side of the object.
14. A parabolic mirror, comprising: a paraboUc-shaped substrate; and a reflector bonded to the substrate.
15. The paraboUc mirror of claim 14, wherein: the substrate includes aluminum; and the reflector includes a piece of thin, flexible material coated with a reflective coating.
16. The parabolic mirror claim 15, wherein the flexible material includes Plexiglas.
17. A method of manufacturing an inexpensive mirror, comprising the steps of: manufacturing a parabohc-shaped substrate; and bonding a reflector to the substrate using an adhesive.
18. The method of claim 17, wherein the step of bonding the reflector to the substrate includes the steps of: applying the adhesive to the substrate; and pressing the reflector against the substrate until the adhesive cures.
19. The method of claim 18, further comprising the step of coating a thin, flexible piece of material with a reflective coating to form the reflector.
PCT/US2002/030018 2001-09-20 2002-09-20 System and method for measuring the dimensions of moving packages WO2003025498A1 (en)

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CN102753934A (en) * 2010-05-31 2012-10-24 天际停车公司 Method and device for measuring the spatial extension of an object
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DE102015201317A1 (en) 2015-01-27 2016-07-28 Bayerische Motoren Werke Aktiengesellschaft Measuring a dimension on a surface
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